Works Approval

Transcription

Works Approval

Works Approval
EPA Works Approval Application
De Inking Pulp Plant
Maryvale PaperMill, Morwell Victoria
18 JUNE 2012
Prepared by
Paper Australia Pty Ltd
Works Approval - Australian Paper
Table of Contents
1 Introduction............................................................................................................. 1 1.1 Company Details ................................................................................................ 2 1.2 Contact Details ................................................................................................... 2 1.3 Premises Details ................................................................................................ 2 2 Proposal .................................................................................................................. 3 2.1 Project Description ............................................................................................ 3 2.1.1 Production ........................................................................................................................3 2.1.2 New and Upgraded Equipment and Facilities ...............................................................3 2.2 Cost of Works and Application Fee ................................................................. 4 2.3 Proposed Dates.................................................................................................. 4 3 Approvals ................................................................................................................ 5 3.1 Need for Works Approval .................................................................................. 5 3.2 Planning and Other Approvals ......................................................................... 5 3.3 Existing EPA Approvals .................................................................................... 6 4 Environment and Community ................................................................................ 7 4.1 Track Record ...................................................................................................... 7 4.1.1 Recent environmental performance ..............................................................................7 4.1.2 Relevant Offences............................................................................................................7 4.1.3 Enforcement Actions related to the site ........................................................................7 4.2 Key Environmental Considerations ................................................................. 8 4.2.1 Environmental considerations .......................................................................................8 4.2.2 Environmental benefits ...................................................................................................8 4.2.3 Social and economic benefits ........................................................................................8 4.3 Community Engagement ................................................................................... 8 4.3.1 Community Consultation Committee ............................................................................8 4.3.2 Government engagement meetings ...............................................................................9 4.3.3 Project Communication Plan ........................................................................................10 5 Process and Best Practice................................................................................... 11 5.1 Process and Technology ................................................................................ 11 5.2 Environmental Best Practice .......................................................................... 13 5.2.1 Steps taken to determine industry best practice .......................................................13 43283717/001/B
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5.2.2 Literature Review ...........................................................................................................13 5.2.3 Process Benchmarking .................................................................................................15 5.3 Integrated Environmental Assessment ......................................................... 16 5.4 Choice of Process and Technology ............................................................... 17 5.5 Choice of Location and Layout ...................................................................... 17 6 Resources ............................................................................................................. 19 6.1 Carbon .............................................................................................................. 19 6.2 Water Use ......................................................................................................... 19 6.3 Solid Waste....................................................................................................... 19 6.4 Prescribed Industrial Waste............................................................................ 20 7 Air Emissions........................................................................................................ 21 7.1 Air Emissions ................................................................................................... 21 7.1.1 Odour Assessment ........................................................................................................21 7.2 Discharge to Surface Water ............................................................................ 22 7.3 Discharge to Land............................................................................................ 22 7.4 Noise Emissions .............................................................................................. 22 8 Environmental Management ................................................................................ 25 8.1 Non-routine Operations................................................................................... 25 8.2 Separation Distances ...................................................................................... 25 8.3 Management System ....................................................................................... 25 8.3.1 Systems and certifications ...........................................................................................25 8.3.2 Major Hazard Facility .....................................................................................................26 8.4 Construction..................................................................................................... 26 8.5 Traffic ................................................................................................................ 28 9 A - Carbon ............................................................................................................. 29 9.1 Energy Use and Greenhouse Gas Emissions ............................................... 29 9.2 Best Practice Carbon Management ................................................................ 31 9.2.1 Best Practice ..................................................................................................................31 9.3 Benchmarking .................................................................................................. 32 10 B - Water .............................................................................................................. 33 10.1 Water Use ......................................................................................................... 33 ii
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10.2 Best Practice Water Management .................................................................. 33 11 C - Solid Waste ................................................................................................... 35 11.1 Solid Waste Generation................................................................................... 35 11.2 Best Practice Solid Waste Management ........................................................ 36 12 F - Water .............................................................................................................. 38 12.1 Water Discharges............................................................................................. 38 12.1.1 Licensed Discharges .....................................................................................................38 12.1.2 DIP Plant Wastewater Sources .....................................................................................39 12.1.3 Predicted Wastewater Quality ......................................................................................39 12.2 Best Practice Water Management .................................................................. 42 12.2.1 Maryvale wastewater treatment and disposal system ...............................................42 12.2.2 Wastewater Benchmarking Data ..................................................................................44 12.3 Impact on Waterway ........................................................................................ 44 13 G - Land and Groundwater ................................................................................ 49 13.1 Discharge or Deposit to Land ......................................................................... 49 13.2 Best Practise Land and Groundwater Management ..................................... 49 13.3 Impact on Land and Groundwater .................................................................. 49 14 I - Environmental Management .......................................................................... 50 14.1 Non-routine Operations................................................................................... 50 14.1.1 Steps taken to identify potential process upsets or failures ....................................50 14.1.2 Managing environmental risks .....................................................................................51 14.2 Monitoring ........................................................................................................ 53 15 Applicant Statement ........................................................................................... 55 43283717/001/B
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Table of Contents
Tables
Table 1-1 Company details ............................................................................................................... 2 Table 1-2 Contact details .................................................................................................................. 2 Table 1-3 Premises details ................................................................................................................ 2 Table 3-1 State and Commonwealth Approvals ............................................................................... 5 Table 5-1 Benchmarking data from Nippon (based on tonnes of product) ..................................... 15 Table 5-2 Integrated Environmental Assessment ........................................................................... 16 Table 5-3 Choice of Location .......................................................................................................... 17 Table 6-1 Energy and Greenhouse Gas Emissions........................................................................ 19 Table 6-2 Solid Waste Generated ................................................................................................... 20 Table 7-1 Types of Air emissions .................................................................................................... 21 Table 7-5 AP Ground Level Concentration (GLC) Assessment ..................................................... 21 Table 7-6 Summary of DIP Plant Installed Power Located Externally ............................................ 23 Table 8-1 Traffic Movement during Construction ............................................................................ 27 Table 9-1 Annual Energy Use 2011 ................................................................................................ 29 Table 9-2 Proposed works power usage ........................................................................................ 29 Table 10-1 Simplified Water Balance ................................................................................................ 33 Table 11-1 Summary of Solid Waste Generation from the DIP ........................................................ 35 Table 12-1 EPA draft Licence specifications .................................................................................... 38 Table 12-2 Simplified Water Balance ................................................................................................ 39 Table 12-3 Fairfield DIP production run conditions ........................................................................... 40 Table 12-4 Estimated Treated Water Quality for River Discharge based on 2011 ........................... 41 Table 12-5 Latrobe River Water Quality Indicators and Results ....................................................... 45 Table 14-1 Relevant HAZOP Recommendations ............................................................................. 51 Table 14-2 External chemical storage............................................................................................... 52 Table 14-3 Distance to surrounding land uses ................................................................................. 52 Figures
Figure A
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Process Block Diagram................................................................................................... 12
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Appendices
Appendix A Figures Appendix B Communication Plan Appendix C Process and Equipment Appendix D Best Practice Assessment Appendix E Waste Appendix F Wastewater Appendix G Chemicals Appendix H HAZOP Appendix I Confidential PFD Appendix J Confidential Odour Assessment 43283717/001/B
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Abbreviations
Abbreviation
Description
ADt
Air dried tonne of pulp (10% w/w moisture content)
AOX
Adsorbable Organic Halide
AP
Australian Paper
BAT
Best Available Technique
BLS
Black liquor solids
BOD
Biochemical oxygen demand
°C
Degrees Celsius
CCC
Community Consultative Committee
CEMP
Construction Environmental Management Plan
CNG
Non-Condensable Gas
DAF
Dissolved Air Flotation
DCS
Distributed Control System
DIP
Deinked Pulp
DS
Dissolved Solids
ECF
Elemental Chlorine Free
EIP
Environment Improvement Plan
EMP
Environmental Management Plan
EMS
Environmental Management System
EPA
Environment Protection Authority
ESR
Effluent Solids Residue
FSC
Forest Stewardship Council
FAS
Formamidine Sulfinic Acid
GJ
Gigajoule – a measure of energy use or content
GLC
Ground Level Concentration
HAZOP
Hazard Operability
H2S
Hydrogen Sulphide
IPPC
Integrated Pollution Prevention and Control
%ISO
Brightness according to ISO, the International Organisation for
Standardisation
kg
kilogram
kL
kilolitre
km
kilometre
kPa
kilopascal
kWh
Kilowatt Hour
MHF
Major Hazard Facility
3
m
Cubic metres
mg/L
Milligrams per litre
3
mg/nm
µg/m
3
Milligrams per cubic metre volume at standard conditions
Micrograms per cubic meter volume at standard conditions
ML/day
Mega litres per day
MWh
Megawatt Hour
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Abbreviations
Abbreviation
Description
NATA
National Association of Testing Authorities
NOx
Oxides of nitrogen,
NPI
Nippon Paper Industries
NSSC
Neutral sulphite semi chemical
OMS
Operations Management System
OU
Odour Units
PEFC
Programme for the Endorsement of Forest Certification
pH
The hydrogen-ion activity in a system
ROS
Regional Outfall Sewer
SEPP
State Environment Protection Policy
SS
Suspended Solids
SWMP
Solid Waste Management Plan
tCO2-e
Tonnes of carbon dioxide equivalent
t/d
Tonnes per day
t/yr
Tonnes per year
TJ
Tetra joules
TRS
Total reduced sulphur
TSS
Total Suspended Solids
WWTP
Wastewater treatment plant
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43283717/001/B
Introduction
1
1
This document is an Application to the Environment Protection Authority (EPA) Victoria for a Works
Approval for the installation of a De-Inking Plant at the Maryvale mill to process white waste paper into
De-Inked Pulp (DIP).
Australian Paper
Australian Paper (AP) is Australia's largest manufacturer of fine papers and supplies more than
625,000 tonnes per year of paper products within Australia and around the world.
AP has been under the ownership of Nippon Paper Group Inc. (Nippon) since 2009. Nippon consists
of approximately 180 affiliates and related companies, and is a world leader in pulp and paper
manufacture. It is the largest de-inking plant operator in the world, with 17 de-inking lines.
AP manufactures paper in Victoria (Maryvale) and New South Wales (Shoalhaven), producing and
marketing over 2000 grades of paper.
Maryvale
The Maryvale Mill is Australia's largest integrated fine paper-making and packaging papers complex,
producing more than 500,000 tonnes of paper every year. Construction commenced in 1937 and
pioneered the Kraft pulping process for eucalypt wood.
Today, Maryvale Mill is a large and complex pulp and paper-manufacturing site. The Maryvale Mill has
a state of the art wood yard, three pulp mills, five paper-making machines, an elemental chlorine free
(ECF) bleach plant, pulp lapping machine, finishing facility and a cardboard waste paper processing
plant. A large chemical recovery complex, steam and electrical power generation, and water and
effluent treatment systems support these papermaking activities.
The site’s principal products are papers for containers (e.g. boxes and sacks) and high quality office
and printing papers.
It has been upgraded periodically over the years to improve efficiency and environmental
performance. Significant changes at the mill over the last 30 years include:
 1983-1984 – the Kraft Continuous Mill, a new re-causticising plant, recovery boiler 6 and No 4
evaporator system were installed;
 1986-1987 – paper machine M3 was rebuilt;
 1988 – the Kraft Batch Mill was upgraded to include a new screen room and installation of a brown
stock washer;
 1991 – recovery boiler 5 was rebuilt;
 1996-1998 – paper machine M5 was constructed;
 1997 – the upgrade of the effluent treatment system occurred, which included the installation of a
secondary clarifier;
 1998 – the No 8 foul gas incinerator was installed;
 2003 – a major capital replacement of black liquor oxidation system occurred in addition to
installation of extensible sack unit on paper machine M1;
 2005 – paper machine M1 was upgraded and modernised; and
 2008 - elemental chlorine-free bleaching plant commissioned and upgrade to the Kraft pulping
operations (known as the Pulp Mill Project).
The site holds dual FSC® and PEFC forestry Chain of Custody certifications.
43283717/001/B
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1 Introduction
1.1
Company Details
Australian Paper’s company details are listed in Table 1-1.
Table 1-1
Company details
Company Details
Company Name
Paper Australia Pty Ltd (AP)
ACN
061 583 533
Registered Address
307 Ferntree Gully Road, Mount Waverley, Victoria 3149
1.2
Contact Details
Australian Paper’s contact details are listed in Table 1-2.
Table 1-2
Contact details
Contact Details
Name
Garry Jones
Position
Planning & Development Manager
Phone
+ 61 3 8540 2214
Email
[email protected]
1.3
Premises Details
This works approval relates to Australian Paper’s Maryvale mill. The premise details are listed in
Table 1-3.
Table 1-3
Premises details
Premises Details
Premises address
Maryvale Paper Mill,
Traralgon West Road, Morwell, Victoria
Municipality
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43283717/001/B
Latrobe City Council
2
Proposal
2
2.1
Project Description
The proposed works will result in the installation of a De-Inking Plant at the Maryvale Mill to enable
processing of white waste paper (from office & other commercial sources) into de-inked pulp (DIP)
for feedstock to existing white paper plant lines. The following maps and plans are provided in
Appendix A.
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Location Maps showing areas of interest (Figure 1);
Detailed location map (Figure 2);
Zoning Map (Figure 3);
Location Plan (Figure 4);
Site Plans (Figures 5-1, 5-2, 5-3);
Detailed DIP plant Layout (Figures 6-1 through to 6-6); and
DIP Plant Location Options (Figure 7).
Planned Truck Routes (Figure 8)
2.1.1
Production
The plant is expected to operate under the following conditions:
Operating conditions
Waste Paper Feed rate
(ADt/yr.)
(ADt/h)
89,495
10.65
Design
9.59
90% operating efficiency
6.50
Design
5.85
90% operating efficiency
24 hours per day
Assumes 2 weeks annual
7 days per week
maintenance shutdown
80,546
DIP Production rate
54,600
49,140
Operating times
2.1.2
Basis
350 d/yr
New and Upgraded Equipment and Facilities
Much of the new equipment will be sourced from the Fairfield Recycling Centre (Fairfield) plant, which
will be shut-down in late 2012. After this plant is shut-down there will be no local supply of DIP,
therefore DIP will be sourced from overseas. The waste paper currently processed at Fairfield will
most likely be diverted to export or landfill.
AP will also undertake upgrades to site infrastructure to support the DIP plant, including an upgrade to
the aeration pond and associated facilities at the existing site wastewater treatment plant, which treats
site effluent prior to discharge to the Latrobe River. The key changes are listed below, and shown on
Figures 5-1 to 5-3 and 6-1 to 6-6:
 DIP Plant equipment and process building of approximately 2,220m2, located on western side of
site, with:
— Chemical Make-down and Storage (walled and bunded) of approximately 580 m2
— Truck unloading sump of approximately 84m2
— 250m3 white water storage tank;
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2 Proposal
— Dissolved Air Flotation (DAF) units (for reuse of DIP Plant wastewater) of approximately 528m2;
and
— Transformer Bay of approximately 144m2.
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Pulping Plant of approximately 400m2;
De-baling plant of approximately 1056m2 with conveyor to the pulping plant;
Outdoor wastepaper storage yard (with storage capacity for six days of processing) 250m2
Concrete solid waste storage bay of approximately 48 m2;
New chemical supply pipework of about 500 meters for NaOH and about 400 meters for H2O2;
New wastewater discharge pipework of about 475 meters connecting into on-site wastewater
treatment plant;
New transfer pipework of about 500 meters for hot stock to Paper Machine M3 and M5;
New wetlap process equipment installed inside existing wetlap building in centre of site;
New transfer pipework of about 400 meters for DIP to existing wetlap building ;
New aerators and mixers in wastewater treatment plant (WWTP) pond;
Upgrading chemical flocculent and nutrient dosing controls;
Installation of in-line Dissolved O2 meter for aeration control in WWTP pond;
Connection to site electrical supply;
Connection to site steam supply;
Connection to site filtered water supply; and
Connection to site recycled water supply.
AP will also reuse structural steel presently in use at the Fairfield plant.
It is noted that the DIP process will not require any new cooling towers or amendments to existing
cooling towers.
2.2
Cost of Works and Application Fee
The cost of works is estimated to be no more than AUD $90 million.
This equates to a Works Approval application fee of $26,431.90.
2.3
Proposed Dates
The decision for construction will be made by Nippon in August 2012.
The detailed design and construction is expected to take 16-24 months from obtaining all approvals.
The target construction start date is January 2013, with a target date for commissioning of January
2014.
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Approvals
3
3.1
Need for Works Approval
Under Section 19A of the Environment Protection Act 1970 (‘the EP Act’), a Works Approval is
required to construct or install plant or equipment at a scheduled premise where such activity is likely
to cause an increase in the waste or noise emitted from the premise or potential danger to the
environment. “Scheduled premises” are listed in the Environment Protection (Scheduled Premises
and Exemptions) Regulations 2007. Under Schedule 1 of these regulations, the Maryvale Mill is
classified as a scheduled premise as it meets the following description.
FO3 premises - Paper pulp mills.
The sections of the Environmental Protection Act that potentially apply to this Works Approval are:
 19A (1)(a), pertaining to an increase or alteration in the waste discharged or emitted from,
deposited to, or produced at, the premises;
 19A (1)(b), pertaining to an increase or alteration in the waste which is, or substances which are a
danger or potential danger to the quality of the environment or any segment of the environment
which are, reprocessed, treated, stored, contained, disposed of or handled, at the premises; and
 19A (1)(c), pertaining to a change in any method or equipment used at the premises for the
reprocessing, treatment, storage, containment, disposal or handling of waste, or of substances
which are a danger or potential danger to the quality of the environment or any segment of the
environment.
Exemptions
The specific exemption provisions described in the Environment Protection (Scheduled Premises and
Exemptions) Regulations 2007 do not strictly apply to the proposed new works.
Potential exemption provisions under the Environment Protection Act 1970 which may apply to the
project include those listed under Clauses 19A (4), (5) and (6).
3.2
Planning and Other Approvals
Table 3-1 lists the approvals required for the DIP plant at the Local, State and Commonwealth levels
and the status of these approvals.
Table 3-1
State and Commonwealth Approvals
Planning Zone
Act
Type of Approval
Required
Approving Authority
Approval /
Decision received
or pending
Commonwealth
Environment
Protection and
Biodiversity
Conservation Act
1999
EPBC Referral – If
the project is
deemed to be a
controlled action, it
will require an
EPBC Act approval.
Otherwise, no
approval is required.
Commonwealth
Department of
Environment, Water,
Heritage and the
Arts / Minister for
Environment
A letter is to be
submitted justifying
applicant’s belief
that this is not a
controlled action.
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3 Approvals
Planning Zone
Act
Type of Approval
Required
Approving Authority
Approval /
Decision received
or pending
La Trobe Planning
Scheme
Planning and
Environment Act
1987
Planning Permit
required for
construction of new
buildings and
equipment.
Latrobe City Council
Planning permit
application
submitted in
conjunction with
the works approval
State
Environment Effects
Act 1978
EES Referral – If
the Minister for
Planning considers
the project will have
a significant effect
on the environment,
an EES may be
required
Minister for Planning
Letter sent to J.
Ginivan of DPCD
on 9 May 2012
advising of
applicants
understanding that
an EES is not
required.
State
Environment
Protection Act 1970
Works Approval
Application
EPA Victoria
Pending approval
Maryville Mill is
located within an
‘Industrial 2 Zone’.
The site zoning is
industrial for pulp
and paper
manufacturing.
3.3
Existing EPA Approvals
The Maryvale mill currently holds a number of approvals granted by the EPA as described below.
EPA licences
 EPA Waste Discharge Licence EM30021
 Salt Cake Landfill LS232
 AP is registered for and submits annual EREP reports for the Maryvale site
Previous Maryvale Works Approval
 Pulp Mill Upgrade Works Approval WA59441
 Eastern Extension Landfill Works Approval WA69184
 Centre West Landfill Works Approval WA58438
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Environment and Community
4
4
4.1
Track Record
4.1.1
Recent environmental performance
Australian Paper (AP) has been working with EPA and the local community to manage its
environmental performance. Odour and Noise from the Maryvale operations are ongoing community
issues, which are being actively managed.
In 2011, AP received 27 noise and 19 odour complaints. This proposal will have minimal impact on
noise and odour in the community.
The DIP plant will be located in a new bunded installation, approximately 2 stories tall, with two
operating levels. The wastepaper handling will be enclosed within the structure, as well as the
Formamidine Sulfinic Acid (FAS) chemical make-down and storage. The remainder of the equipment
will be installed within the installation’s bunded area. Dangerous goods chemical storages will have
independent bunds within the installation’s bund.
The plant is not expected to generate significant noise or odours. Noisy equipment located externally
will be in acoustic enclosures. Only minor fugitive air emissions are expected, with an on-site impact
only.
The Maryvale Mill proactively seeks opportunities to ensure the future sustainability of the mill. Integral
with the existing Mill are a number of recycling loops to minimise consumption of chemicals and raw
water, recover energy and to ensure waste streams are reused a number of times prior to ultimate
disposal.
The Maryvale Mill’s commitment to meet all environmental laws and regulations and set responsible
objectives and targets is dependent upon all operating units taking responsibility for the environment.
AP recognises that the future of the site is dependent upon continuous improvement in environmental
performance.
Some sustainability initiatives undertaken at the Maryvale Mill in the past five years include:
 Upgrading the bleaching plant to reduce the generation of Organochlorine (AOX) and implement
the best practice ‘Elemental Chlorine Free – Light’ bleaching process.
 Generating 8,235,640 GJ of renewable energy within the mill in 2011.
 Increased Dilute CNG gas collection for Batch Kraft Mill and Continuous Kraft Mills.
 Reduced trade waste temperature to suit requirements of Gippsland Water Factory, utilising more
waste heat within the mill.
 Replaced Rail Spur Bridge and increased rail volume from the Mill.
 Achievement of a 60% reduction in waste to landfill since 2008 through the implementation of a
Solid Waste Management Plan (SWMP).
4.1.2
Relevant Offences
Australian Paper has not been prosecuted for a “relevant offence”, as defined in Section 20C of the
Environment Protection Act 1970, in the past 10 years.
4.1.3
Enforcement Actions related to the site
AP was issued with a Clean Up Notice by EPA in October 2007 for the discharge of Black Liquor at its
Maryvale site.
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4 Environment and Community
An environmental audit was conducted by URS in accordance with Section 53V of the Environment
Protection Act 1970. All conditions of this Clean Up Notice have been met and AP is awaiting EPA’s
final site visit to close out this notice.
4.2
Key Environmental Considerations
4.2.1
Environmental considerations
The environmental considerations associated with the DIP plant are:
 increased fresh water and energy use, but with reduced energy intensity and reduced carbon
emissions compared to the Fairfield plant;
 increased wastewater & solid waste generation at Maryvale site;
 introduction of new chemicals e.g. FAS; and
 potential change in the wastewater discharges to surface water (current EPA licensed discharge to
La Trobe River).
4.2.2
Environmental benefits
The key environmental benefits associated with the DIP plant are:
 a seven fold increase in Australian-made printing and office papers with recycled fibre; and
 an increase in white waste paper recycling from 15,000 ADt/yr to nearly 50,000 ADt/yr in Australia,
by continuous operation of the plant;
 re-using approximately 81,000 tonnes of waste paper that would otherwise go to landfill;
 utilising some pre-existing plant will eliminated the imbedded GHG emissions from new equipment;
and
 replacement of 15,000 tonnes/year of imported DIP from Europe and North America.
4.2.3
Social and economic benefits
The key social and economic benefits associated with the DIP plant are:
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capital works of up to $90 million;
employment of up to sixty construction workers;
creation of twelve full time on-going jobs in regional Victoria;
securing up to one hundred existing jobs in waste paper collection, sorting, baling and transporting
waste paper; and
 on-going operational costs of the DIP facility of $42.8 million p.a.
4.3
Community Engagement
4.3.1
Community Consultation Committee
In 1994, the AP Maryvale Community Consultation Committee (CCC) was formed to provide a formal
mechanism through which the community and the Maryvale Mill could discuss concerns relating to the
environment.
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43283717/001/B
The CCC is made up of members from the general community and from key interested parties
including:
 Community representatives from surrounding communities including Morwell, Traralgon and
Churchill;
 Latrobe Shire Council;
 Latrobe Field Naturalists;
 Gippsland Water;
 Students; and
 EPA Victoria.
The objective of the CCC is to provide a forum for community feedback with respect to community
impacts, and to inform the community with respect to the ongoing operations and objectives of the
Maryvale Mill.
Specifically, the CCC shall:
 limit its consideration to the environmental, safety and social interactions of AP Maryvale Mill’s
operation in Gippsland and the associated forestry activities;
 assist AP with the annual update of the Environment Strategic Plan which address the
environmental consequences of present operations;
 act as a focus for the interchange of information between AP and the community, and endeavour to
accurately reflect community concerns; and
 have access to details of AP’s environmental monitoring results, site conformance to licences and
agreements and the site’s environmental aims and objectives.
The CCC is important to the Maryvale Mill and continues to review site performance and recommend
changes. The Environment Support Manager is the site’s representative on this Committee. The
General Manager Operations and the Environment Support Manager and SH&E Manager have the
overall responsibility for ensuring coordination between the CCC and management plans and activities
on the site.
A specific meeting was held with the CCC on the 16th May to discuss the proposal.
Overall, community representatives expressed their support for the proposed works. The main issue
raised in the meeting was the impact on the waste water system and in particular surfactants and
BOD.
4.3.2
Government engagement meetings
AP is committed to working with stakeholders that are relevant to the company's operations. In relation
to this project, the Department of Business and Innovation (DBI) Invest Assist facilitated a meeting
with government and other key stakeholders at the site on 19 April, 2012, with a follow-up meeting on
the 23 May 2012. A further meeting is planned for late June, following the submissions to the EPA and
Latrobe City Council. The meetings included representatives from the following organisations:
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AP Maryvale Community Consultative Committee;
DPCD (Environment and Planning);
Latrobe City Council;
WorkSafe;
EPA Victoria;
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 Gippsland Water; and
 CFA.
The meeting included a site tour in which 4 different locations for the DIP plant were discussed. A
project overview was provided and there was open discussion with each of the agencies and
representatives about potential issues.
Issues that were raised relating to approvals included:
 the need for a Bushfire Management Plan as part of the Planning Permit application;
 whether the new chemical (FAS) was a Major Hazard Facility- regulated chemical;
 environmental values (e.g.: Latrobe River habitat) that needed consideration as part of approvals
applications; and
 Approach to community liaison and communications for the proposed new DIP plant.
A second meeting was held on the 24th May 2012 at which the draft documentation relating to the
planning permit and works approval applications was discussed.
4.3.3
Project Communication Plan
An overarching communication plan has been developed by AP and is attached as Appendix B. As
well as the CCC and government stakeholder meetings described above; media and local community
events will be used to communicate information on the DIP plant project.
In conjunction with the CCC it is planned to hold several Project Open Houses at community
accessible locations in the vicinity of the Maryvale Mill. The objective of this activity will be to inform
the wider local community about the proposed project and give opportunity for feedback. The
approach will be to have a display area that includes details of the project, including handouts for
community members in the form of project and company information. In addition the community will be
able to register to receive further information on the project as well as Australian Paper’s activities
more generally. The Open House(s) will be promoted via local media through general interest pieces
and some advertising as appropriate. Target dates for the Open House(s) are weekends in late June
and early July 2012.
The onpaper.com.au website is the on line site used to provide information on Australian Paper’s
activities and in this case, information on the proposed DIP Plant.
10
43283717/001/B
Process and Best Practice
5
5
5.1
Process and Technology
The DIP plant and wetlap processes comprise a large number of process vessels, pumps, pipework
and controllers. The detailed process flow diagram is included in Appendix I (commercial in
confidence) and the Equipment List is included in Appendix C. In summary, there will be about 216
new motors totalling 10,964 kW of installed power, with 194 of these located at the new DIP plant, 22
in the existing Wetlap building and upgrades to the existing WWTP. Motor sizes range from 0.18 to
1100 kW.
AP will implement a number of changes to the process and equipment compared to the Fairfield Plant:









Replacement of Coarse Screening
Increase Rotary Screen Capacity
Replacement of Fine Screening
Relocate Oxidative Bleaching to before the 1st Flotation (De-inking Stage)
Replace Post-Flotation Stage
Replace significant quantity of fresh water with Paper Machine Backwater
Supply hot stock to paper machines
Upgrade of existing on-site WWTP
Improved Process Control derived from NPI de-inking experience
There will be 56 tanks installed in the DIP Plant of which 13 are new tanks. The remainder will be
relocated from Fairfield, with 2 from Maryvale also being reused. The tanks range in in size from 4 to
225 m3. Most of the tanks will be located at the DIP plant, while the Wetlap building will have 3 tanks
ranging from 11 to 120 m3.
A summary of the process steps including key inputs and outputs is included in Appendix C. Figure a
on the following page shows the overall process and effluent flows.
The chemicals that will be used in the proposed DIP plant will be subject to a tendering process.
However it is expected that they will be similar to the chemicals that are currently used at Fairfield and
are summarised in Appendix G – Table 1. Appendix G also contains a copy of all of the chemical
MSDSs.
43283717/001/B
11
5 Process and Best Practice
Figure A
12
Process Block Diagram
43283717/001/B
5.2
Environmental Best Practice
5.2.1
Steps taken to determine industry best practice
In assessing best practice for this proposed project, reference has been made to EPA policy and
guidelines, international publications and benchmarking data available from the existing Amcor
Fairfield site and Nippon Paper DIP plants. Literature reviewed was as follows:
 Integrated Pollution Prevention and Control (IPPC) - Reference Document on Best available
techniques in the Pulp and Paper Industry, European Commission (December 2001);
 Integrated Pollution Prevention and Control (IPPC) – Technical Guidance for the Pulp and Paper
Sector (IPPC S6.01), Environment Agency, Bristol (2000);
 Progress in Paper Recycling – Deinking Review (Volume 20 Number 1), TAPPI, USA (2011);
 Vahlroos, Sari, Comparison of DIP Bleachability between traditional soap and reduced alkaline
chemistries, Oulu (2005);
 Meersman, Tom, Improved contaminant removal in deinking systems, USA (1997); and
 Benchmarking Data from Nippon Japanese Mills (NPI).
It is noted that much of the published literature is 5-10 years old, reflecting the fact that there have
been minimal changes in DIP plant processes and few new plants commissioned worldwide since the
early 2000’s.
This section compares the proposed changes at the Maryvale Mill against best practice for the pulp
and paper manufacturing industry. It also provides benchmarking of the proposed DIP plant against
comparable DIP plants in Nippon Paper.
5.2.2
Literature Review
IPPC - Reference Document on best available techniques in the Pulp and Paper
Industry, European Commission (December 2001);
In December 2001, the European Commission published a very comprehensive reference document
relevant to this development – The ‘Integrated Pollution Prevention and Control (IPPC, December
2001) Reference Document on Best Available Techniques in the Pulp and Paper Industry’. This
document is recognised as a definitive documentation on best available techniques in the pulp and
paper industry worldwide.
As part of the application of best practice for the proposed DIP plant, the Best Available Techniques
(BAT) have been assessed against this document. Where technology suggested in the IPPC
reference document has not been applied, alternative technology has been selected, which is more
applicable to the mill, and provides equivalent or better environmental performance.
IPPC – Technical Guidance for the Pulp and Paper Sector (IPPC S6.01), Bristol (2000)
This UK Guidance is based on the IPPC document developed by the European Commission. It is
designed to complement the European Commission’s document and to set techniques and standards
that need to be addressed in the UK. A number of BAT and best practice techniques were sourced
from this document.
43283717/001/B
13
Key best practices (from the IPPC documents above) include:










Separation of less contaminated water from contaminated streams and recycling of process water;
Optimal water management using a water loop arrangement;
Aerated biological treatment of wastewater;
Continuous operation instead of batch;
Application of Dissolved Air Flotation (DAF) as in-line treatment of water loops to recover fibres and
fillers and to clarify process water;
New screen designs;
Cogeneration of heat and power;
Reject and sludge dewatering;
Reuse of solid waste (from WWTP clarifiers, De-Ink Cleaners & Centrifuge Sludge); and
Incineration of solid waste with energy recovery.
Progress in Paper Recycling – De-inking Review (2011)
This paper presents an overview of the types of ink present in recovered paper blends and their
compatibility with flotation de-inking. Recent trends in de-inking and flotation chemistries are analysed
as well as the basic principles underlying flotation. This report focused on de-inking grades for
newsprint manufacture and was of limited relevance.
Comparison of DIP Bleachability between traditional soap and reduced alkaline
chemistries (2005)
This study followed the development of brightness and residual ink through a pilot deinking process
including a post bleaching stage. Results obtained indicated that the reduced alkali pulp was more
responsive to the post bleaching chemicals than was the pulp processed under traditional alkaline deinking conditions, resulting in an equivalent outcome. This report was of limited relevance.
Improved contaminant removal in de-inking systems, (1997)
This report focused on new systems and equipment to remove difficult contaminants from mixed office
waste (including putrescibles) and the processing of that waste into a high quality pulp to compete with
bleached virgin pulps. As the report focused on mixed office waste, it was of limited relevance.
A table summarising techniques to consider in the determination of BAT and the expected effect on
consumption and emissions levels has been extracted from this document and included in Appendix
D, together with a summary of their relevance to the proposed works.
Key components of the DIP plant project that represent best practice include:
 Separation of less contaminated water from contaminated streams and recycling of process water
(water reuse and recycling);
 Optimal water management using a water loop arrangement (water reuse and recycling);
 Continuous operation instead of batch (reducing energy input and odour emissions);
 Application of DAF as in-line treatment of water loops to recover fibres and fillers and to clarify
process water (waste reduction, wastewater effluent quality);
 Reuse of solid waste (from WWTP clarifiers, De-Ink Cleaners & Centrifuge Sludge) to make soil
conditioning products and / or kitty litter (waste reuse);
14
43283717/001/B
 Provision of a bypass for off-spec pulp to be re-processed from the Dump Tanks; and
 NPI experience to minimise process upsets and optimise process stability.
5.2.3
Process Benchmarking
Nippon has 17 plants that manufacture DIP and among them, 9 plants produce high brightness DIP.
Among 9 high brightness DIP plants, only 2 plants produce above 80% brightness from office waste.
Generally speaking, the quality of office waste is better in Japan than in Australia. Table 5-1 contains
a comparison between the current Fairfield DIP and the Nippon DIP made from office waste
Table 5-1
Benchmarking data from Nippon (based on tonnes of product)
NPI mill A NPI mill B Fairfield Maryvale Waste source
Office
Office
Office
Office
Yield
60%
60%
61%
61%
Target Brightness
85
83
82
82
Power
Units kWH/t
660
540
825
814
Fresh Water
3
m /t
17
75〜80
18.0
12.0
Machine Water(recycled
water)
m3/t
nil
6〜7
nil
25.0
Liquid Effluent
m3/t
15
55〜70
16.5
16.5 (10.5
discharge)
River
Sea
Melbourne
Water Sewer
Latrobe River
0 (all to
Biomass)
0 (all to
Biomass)
0.08
0.08
Biomass
boiler
Biomass
boiler
Kitty Litter
Composting or
Kitty Litter
Flotation
Split
Split
Split
Split
Dispersing
Kneader
Kneader
2 Kneaders
2 Kneaders
Bleaching
P+FAS
P
P+FAS
P+FAS
Wet Lapping
0%
0%
100%
38%
Effluent Final Discharge
Solid waste - Landfill
Solid Waste - Beneficial Use
t/t
PROCESS
The key difference in energy use at Maryvale compared to the other NPI plants is the extra kneader
and the wetlap process.
43283717/001/B
15
5.3
Integrated Environmental Assessment
The identified direct environmental benefits and impacts are summarised below in Table 5-2.
Table 5-2
Integrated Environmental Assessment
Environmental Element
Amount
Impact
Substitution of virgin wood
chip
98,000
ADt/yr
+
Reduced demand on forest resources
Use of wastepaper
81,000 t/yr
+
Reduced waste to landfill
Fresh water use
590 ML/yr
-
Reduced due to recycling of wastewater
Power consumption
43,498
MWh / yr
(running
load)
-
Relatively more energy efficient than Fairfield
operations
Greenhouse Gas emissions
59,234
tCO2-e/yr
-
This represents an increase of 9% at the site.
Partially off-set by closure of Fairfield Mill, and
eliminating need to import DIP.
Wastewater discharge
516 ML/yr
-
Reduced due to recycling of wastewater
-
Minor increase in some parameters. Increased
aeration, mixing and other improvements to
the aeration pond at the WWTP to ensure
remain within EPA licence limits.
Wastewater quality
Comments
Process equipment reuse
-
+
Lower carbon footprint due to less imbedded
energy
Transport of wastepaper
81,000 t/yr
+
Transported as back-loading on existing
finished goods trucks
Eliminate transport of recycled
DIP from overseas
15,000 t/yr
+
Reduced carbon footprint
Whilst the DIP plant will result in an increase in energy and fresh water use at the Maryvale site and
an increase in wastewater discharges from the site, it will allow a reduction in use of virgin woodchip,
production of high recycled content paper products and ensure diversion of a waste stream from
landfill. When compared to the Fairfield plant it uses less power and less fresh water per tonne of
DIP.
The solid wastes produced by the DIP process are almost completely comprised of waste materials
and waste fibre present in the waste paper supply, which would have been landfilled unless another
reuse was found. Therefore the solid wastes produced by the proposed DIP plant at AP site have not
been considered as an environmental ‘impact’ in the above integrated assessment.
The DIP plant project also provides social and economic benefits, including 12 additional permanent
jobs at the site; 60 jobs during construction and securing of up to 100 existing jobs in the Melbourne
area relating to collection and transport of the waste paper supply.
The site at Maryvale is better suited to locating the DIP plant than the Amcor Fairfield site due to the
integrated nature of the site and the large buffer distances to the site boundary and sensitive
receptors.
16
43283717/001/B
Based on the above comparison, the installation of a DIP plant is considered to give a net
environmental benefit compared to the ‘do nothing’ approach in which local waste paper would be
disposed to landfill and alternate DIP supply would be sourced overseas.
5.4
Choice of Process and Technology
AP has selected to re-use a significant portion of the existing process equipment that is installed at
Fairfield. This equipment dates from 1996. Additional second hand equipment has been sourced from
Nippon Paper plants in Japan to improve the process performance. Thirteen new tanks will also be
fabricated to replace non-reusable items from Fairfield and ensure DIP quality.
Alternative options that were considered by AP during process selection included:
 Purchase recycled fibre from overseas;
 Develop a stand-alone DIP plant operation; or
 Do nothing, and reduce the recycled content of paper in the Australian market.
It was decided that the best environmental outcome was to integrate the DIP plant with the Maryvale
mill using redundant equipment from Amcor’s DIP plant in Fairfield.
The final process selection was made on the basis of DIP pulp quality, process reliability, ease of
maintenance, availability of spare parts, minimisation of fresh water and chemical use, and optimal
energy demand.
5.5
Choice of Location and Layout
The project area is within the developed area of the Maryvale mill site currently used for pulp and
paper manufacture. It is a car park. There are no buildings on the site location.
The project area is essentially flat and has been cleared of native vegetation for many years.
Four alternative locations within the mill developed area were considered and are shown in Appendix
A - Figure 7. The final location has been chosen on the basis of site transport flows, process
connections to the rest of the plant and ease of construction. A summary of the options is included
below in Table 5-3.
Table 5-3
Location
Option 1
Choice of Location
Advantages
Disadvantages
Close to outfall sewer
10m slope across site
Trucks away from busy areas
Remote from fibre lines management
Long distance for power, water and stock lines
Road intersection requires modification
Option 2
Close to the MHF Chemical area
Weighbridge is already a bottle neck
Close to the weighbridge
Requires demolition of the old wood yard
Issues with underground obstacles
Longest distance to pipe wastewater effluent
Option 3
Close to power supply and steam
Possibly requires a new weighbridge
Medium distance to sewer
Cost to build road to plant
Effluent line in the area
Option 4
43283717/001/B
Close to power supply and steam
Remote from fibre lines management
17
Location
Advantages
Disadvantages
Medium distance to sewer
Road intersection requires modification
Effluent line passes NW corner
The preferred location is option 3 as it is the most convenient with respect to access and proximity of
services.
18
43283717/001/B
6
Resources
6
This section provides an overview of the environmental impacts of the proposed works, and provides
direction to further detail on environmental impacts reported within this document.
6.1
Carbon
The following energy use and subsequent greenhouse gas emissions generated by the upgrade
(including DIP plant, ancillary equipment, WWTP aerators etc.) is described below in Table 6-1 and is
based on DIP production of approximately 49,140 t/yr.
Table 6-1
Energy and Greenhouse Gas Emissions
Amount of energy use
Type of energy use
Amount in or tCO2e
Comments
Installed load = 10.964 MW
Electrical power (sourced
from the Victorian grid)
59,234 t
CO2e/yr.(running)
The running load assumes
that 38% of the pulp will be
wet lapped.
Running load = 5.84 MW
(based on 1.21 kg
CO2e/kWh
AP generates approximately 50% of its own energy from the combustion of lignin which is a renewable
power source. Additional electrical power is sourced from the Victorian grid.
38% of the pulp is expected to be wetlapped. The wet lap machine is used to dewater the pulp and
then create bales. The bales can be stored for reuse, or loaded onto trucks and delivered to other
pulp users.
The most energy intensive parts of the DIP plant are the pulpers and the kneaders. The power input
is affected by the quality of recovered paper being processed and the quality of the DIP required. A
detailed equipment list is included as Appendix C, and shows the power rating of planned new motors
and drives.
The increase in total annual carbon dioxide emissions for the Maryvale site following installation of the
DIP plant and associated infrastructure upgrades is approximately 59 ktCO2e/yr, (see Section A –
Carbon in Chapter 9).
6.2
Water Use
The new DIP plant will require an additional 1.68 ML/day of fresh filtered water. Existing mill recycled
water will be used for the remainder of the water demand, comprising approximately 0.84 ML/day
supply. Water will be reused and recycled within the DIP process via water loops.
The total annual fresh water use for the DIP plant is approximately 590 ML (see Section B – Water
Use in Chapter 10).
6.3
Solid Waste
Solid wastes that will be produced directly from the DIP plant consist of two main streams, as detailed
in Table 6-2, and shown in the overview diagram in Appendix E. In addition, wastewater from the DIP
plant process will be directed to the existing on-site wastewater treatment plant (WWTP), and
additional solids are expected to be separated by the WWTP clarifiers. Currently WWTP clarifier solids
that are not able to be reused in process are sent for composting, and the additional solids load from
the DIP plant will join this waste stream. On this basis, as there are no prescribed industrial wastes,
section D was not completed.
43283717/001/B
19
6 Resources
Table 6-2
Solid Waste Generated
Type of solid waste
Amount t/yr
Destination
WWTP sludge
6,930 t/yr
(including Clarifier sludge from Primary
and Secondary clarifiers)
(approx. 8.5% of
feed)
Generated at on-site WWTP. Will be sent
along with current clarifier sludge to
Pinegro for composting.
 consists of fibres, minerals &
CaCO3, plus biological mass from
secondary clarifier
DIP plant sludge
(including De-Ink Cleaners, DAF &
Centrifuge Sludge)
21,168 t/yr
(approx. 26% of feed)
 consists of cellulose fibres, ink and
mineral fillers
Recycled into soil conditioning products
(e.g. to Pinegro for composting) or other
value added products in conjunction with
other Maryvale by-products (e.g. kitty litter).
(Tested and classified as Industrial
waste)
Detrasher waste
(including Coarse Rejects (Grit) and
3,434 t/yr
High Consistency Cleaner rejects
(Sands))
These three wastes are similar in nature
and will be combined and sent to landfill at
Bacchus Marsh as industrial waste
 consists of metal, plastic, glass, grit,
fibre
(Classified as Industrial waste)
The detrasher waste and DIP plant sludge will be collected and stored at a bunded concrete bunker
located adjacent to the DIP plant pulpers. The wastes will be collected from here by trucks and
transported directly to the disposal and reuse locations.
The WWTP clarifier sludge is collected in a skip and transported to Cleanaway’s on-site sludge
treatment plant for de-watering, prior to transport to Pinegro for reuse
The total annual solid waste production from the DIP plant is approximately 31,532 tonnes (see
Section C – Solid Waste in Chapter 11).
6.4
Prescribed Industrial Waste
The DIP plant is not expected to generate any routine prescribed industrial waste.
Empty chemical containers will be returned to the supplier.
Non-routine wastes may be generated during annual plant maintenance shut-down, or if there is a
need to drain a process tank due to blockages or other process upsets.
Tank drainage during maintenance or process upsets will be managed in accordance with existing site
procedures.
Annual maintenance wastes will be of the same nature as wastes generated at the rest of the site, and
will be managed using existing site procedures.
20
43283717/001/B
7
Air Emissions
7
7.1
Air Emissions
The types of air emissions expected from the proposed DIP plant are summarised below in Table 7-1.
Table 7-1
Types of Air emissions
Type of air emissions
Rate or scale of emissions
Any Class 3 indicators
Fugitive emissions from DIP plant
tanks (possibly from starches
released in the warm water), DAF
units and waste paper storages.
Minor. May result in localised
odour on-site.
None
Minor fugitive emissions may be expected from process tanks, waste paper storage and dissolved air
flotation tanks associated with the DIP plant. The odour from these emissions will be similar in
character to those from the paper making process on site and of a much lesser magnitude than those
from the pulping and chemical recovery processes operated on the site. The de-inking cells are
ventilated by blowers which will be directed to atmosphere via roof vents.
The entire DIP process is expected to have an on-site odour impact only. See below for a
conservative assessment of the likely odour impact from the deinking cell vents.
7.1.1
Odour Assessment
Amcor Fairfield Odour Assessment
Some of the key equipment items will be sourced from Amcor Fairfield and as such a comparison
between Fairfield’s DIP plant odour emissions and the likely odour emissions from the AP DIP plant
has been undertaken as part of this assessment. Due to the confidential nature of this data, the
assessment is included in Appendix
In 2011, GHD was commissioned by AP to undertake modelling of TRS for the Maryvale site, to
assess compliance with the SEPP Ground Level Concentration (GLC) requirements for various
licence limits. The results are summarised below in Table 7-5.
Table 7-2
AP Ground Level Concentration (GLC) Assessment
GLC µg/m3
SEPP GLC
26
GLC for 65.45g/min TRS
(as H2S equivalents) emission rate
12.8
When TRS emissions were modelled at the licence limit of 65.45 g/min, the estimated GLC was 12.8
µg/m3, which is below the SEPP GLC of 26 µg/m3. Based on the conservative combined estimated
emission rate for the site and the DIP plant of 25.64 g/min, the DIP plant would not result in SEPP
GLC non-compliance for TRS or result in odour complaints.
Actual odour emission rates from the DIP plant are likely to be much lower than 0.64 g/min as TRS, as
the nature of the DIP process and de-inking cells is different to the existing sources of TRS-equivalent
odour at Maryvale. On the basis of the predicted minimal additional odour emissions from the DIP
plant, Section E was not completed.
43283717/001/B
21
7 Air Emissions
7.2
Discharge to Surface Water
Wastewater generated from the DIP plant will be directed to the existing on-site WWTP prior to
disposal via the EPA-licenced discharge point to Latrobe River. Part of the DIP plant project proposal
includes an upgrade to the WWTP to ensure that final effluent quality will remain within existing EPA
Licence discharge limits. The upgrade is discussed further in the Wastewater Technical Assessment
in Appendix F and includes additional aerator capacity, improved mixing and chemical dosing
controls.
Discharge to surface water has been selected as the most practicable option as the Mill is currently at
the limit of agreed trade waste volume, COD, pH & temperature parameters. It would be necessary to
install significant additional wastewater treatment apparatus to enable the DIP plant effluent to be
directed to trade waste, along with re-negotiating trade waste acceptance criteria with Gippsland
Water.
The DIP plant will generate 2.32 ML/d of wastewater. This will result in an overall increase of 1.47
ML/d discharge to the Latrobe River as approximately 0.84 ML/d of paper machine backwater that
currently goes to effluent treatment will be reused in the DIP plant.
Emissions to water will undergo primary and secondary treatment on site in conjunction with other site
treated wastewaters in the existing extensive treatment system, prior to being detained for several
weeks in a lagoon system before discharge to the Latrobe River.
This is discussed in further detail in Section F – Water in Chapter 12.
7.3
Discharge to Land
There will be no direct discharges to land from the DIP plant project. Detrasher wastes will be
landfilled, as noted in Section 6.3 above. All wastewater generated by the plant will be discharged to
the existing on-site wastewater treatment plant, prior to final discharge to the Latrobe River.
The waste that will be landfilled comprises:
1. Detrasher waste, consisting of glass, sand, grit, plastic, metal and fibre, which is separated from
the incoming waste paper supply at the start of the DIP plant process. This waste is classed as
Industrial Waste and will be sent to Bacchus Marsh landfill, which is licensed by the EPA to accept
this class of waste. The expected waste quantity is 3,434 t/year. Refer to Appendix E for details
of waste classification testing (waste stream “Screw Press”).
As there will be discharge of solid waste to landfill, Section G Land and Groundwater has been
completed (see Chapter 13).
There will be no discharges to groundwater from the DIP plant project.
7.4
Noise Emissions
The DIP plant is expected to operate 24h / day, 7 days per week and 350 days per year. Routine
maintenance shuts will occur in line with other plant outages.
Information was provided by Amcor Fairfield on noise complaints received – typically complaints
related to reversing beepers and noise from the Power Plant. There was one confirmed noise issue
related to the DIP plant facility, which was attributed to a noisy bearing on the rejects screw conveyer.
The nearest neighbours to Amcor are located only 200 meters from the site boundary.
22
43283717/001/B
7 Air Emissions
The preferred plant location for Maryvale (Option 3) is located on the west of the site within the AP mill
operational area as shown in Appendix A – Figure 5-1 and 7. The nearest residence is located
approximately 2.5 km north of the proposed new process equipment and it is not expected that the
DIP plant equipment will be audible above the background noise of the site.
A list of noise sources, location and approximate division of installed power and motor capacities is
summarised below in Table 7-6.
Table 7-3
Summary of DIP Plant Installed Power Located Externally
Plant
Installed power (inside)
Installed power (outside)
kW
kW
DIP plant
6136
3170
Wet-lap
549
Hot Stock Distribution
Re-slushing wetlap
205
448
Additional WWTP Aeration
391
Additional Sludge Handling
65
TOTAL
7133
3831
The DIP Plant will be located in a new installation, approximately 2 stories tall, with two operating
levels. The wastepaper handling will be enclosed within the structure, as well as the FAS make down
and storage. The pulpers and remainder of the equipment will be installed within the installation’s
bunded area. Noisy equipment will be located within acoustic enclosures. The plant is not expected to
generate significant noise.
All external DIP plant equipment will be installed to operate at maximum noise level of 80 dBA at 1
metre.
On this basis Section H has not been completed.
43283717/001/B
23
Environmental Management
8
8
8.1
Non-routine Operations
The DIP plant building will be internally bunded with drainage to on-site WWTP. All bulk chemicals will
be located within bunds designed in accordance with relevant Australian Standards. Day-tanks and
other chemicals in use will be located on portable bunds inside the building. The solid waste collection
area will be of concrete construction with sloped drainage and bunding back to an effluent collection
pit. These measures will prevent accidental release of chemicals, wastes and process waters to the
site stormwater system.
A level 2 Hazard Operability (HAZOP) assessment was undertaken on May 24 2012 to identify
potential process upsets and non-routine operations that may occur during operation of the proposed
DIP plant. A copy of the report is attached in Appendix H, and is summarised in Section I. As part of
the detailed design process further HAZOP studies and an assessment as part of the MHF
requirements will be undertaken. Findings that relate to environmental impacts will be addressed in
accordance with AP’s EMS procedures e.g. updating the aspects and impacts register, environment
management plan and contingency plans.
8.2
Separation Distances
The nearest residence is located approximately 2.5 km north of the proposed new process equipment.
The townships of Traralgon and Morwell are located some 4km from the site.
EPA Publication AQ 2/86 recommends a buffer distance of 5 km for paper or pulp processes involving
combustion of sulphur. Therefore the existing site has residences located within the recommended
buffer zone, however both the mill and the residences pre-date AQ 2/86. Refer to Section I (Chapter
14) for further detail.
8.3
Management System
8.3.1
Systems and certifications
The Maryvale mill has an integrated Operations Management System (OMS) that includes all
operations relating to pulp and paper manufacture and associated processes at the Maryvale Mill. The
OMS integrates environment, quality, health & safety and major hazard facility (MHF) requirements.
In addition, the Maryvale Mill holds the following certifications:




Environmental Management System (EMS) certified to AS/NZS ISO 14001:2004
Quality System certification to AS/NZS ISO 9001:2000;
Safety System certification to AS/NZS 4801:2001; and
MHF licence under the Occupational Health and Safety (Major Hazard Facilities) Regulations 2000.
The scope of the EMS includes all operations relating to pulp and paper manufacture and waste
treatment and disposal, and is applicable to the proposed new DIP plant.
All subcontractors working within the mill are contractually bound to ensure that they apply best
practice according to the mill’s ISO 14001 approved EMS. This best practice requirement includes
emergency response, among a variety of subcontractor responsibilities for environmental
management.
43283717/001/B
25
8 Environmental Management
The Nippon Environmental Policy provides the overriding requirements for environmental
management at Maryvale Mill. The fundamental purpose of the Maryvale Mill EMS is to implement,
achieve, review and maintain the Nippon Environmental Policy.
The Maryvale Mill’s Environmental Management Program (EMP) lists activities to be undertaken so as
to deliver the Environmental Policy. The items in the EMP are obtained from consideration of the:





Maryvale Mill Objects and Targets;
Register of Significant Environmental Aspects;
The Greenhouse Gas Reduction Plan;
The Community Environment Improvement Plan (EIP); and
Audits.
8.3.2
Major Hazard Facility
If the proposal proceeds, the MHF safety case will require updating. At this stage of the feasibility
study, the indications are that there are no credible major hazard risks associated with the new plant.
The new plant would utilise existing bulk chemical storages for its chemicals other than for FAS, which
would be new to the site. FAS quantities stored on site would be minimised, (around 2-3 tonnes) to
minimise risk.
8.4
Construction
The site requires minimal preparation in relation to the project. Most facilities already exist and most
areas of new construction are flat and have vehicle access. The new equipment for the proposed
upgrade will be located as shown in Appendix A – Figures 6 and Figure 8 (location of access road
into DIP).
The major area of ground disruption will be associated with the construction of a new internal access
road into the DIP plant and storage area which will require new roads, equipment and building
foundations.
The new plant is located on the West side of the site. Noise emissions during construction are
expected to be minor. There will be additional truck movements on public roads during the transport of
equipment to Maryvale from Fairfield. There will be additional traffic on-site including contractor
vehicles and machinery. The area immediately to the West of the site is forested with the nearest
residents located more than 2.5 kilometres to the Northwest and Southwest of the site.
If the project is approved late August 2012, it is expected that the DIP will be commissioned in the first
quarter of 2014. The first construction activity will be dismantling the existing plant and relocating the
equipment to the Latrobe Valley. The transport of the equipment is likely to be in December 2012, with
60% being stored at the BMC Store in Firmins Lane. The rest will be stored on the proposed site at
Maryvale. This could be a total of 100 trucks over 20 days, roughly 5 trucks a day. Some of these may
be over-sized loads.
Construction activity of the new site will commence February 2013, with mobilisation & earthworks
taking around a month. This includes the delivery of backfill etc. Material excavated from the
site would be retained at Maryvale. Concrete delivery is expected over a week in early April 2013 –
100 trucks over 5 days. Erection of the new building will take around 2 months, over May & June
2013, with structural steel included in the equipment from Fairfield as well as some new.
26
43283717/001/B
Once this is complete, the equipment will be installed, involving transfer from the Firmin’s Lane Store
and equipment imported from Japan. The installation work will take place over 8 months with the
deliveries staggered over that time.
It is expected that up to 60 people will be working on the construction of the plant, with the peak
number during the installation of the equipment. Car parking for them will be provided on-site.
Commissioning is planned for February 2014, with wastepaper and chemical deliveries late January
2014. Table 8-1 summarises the peak traffic movements based on the above schedule.
Any new equipment and piping will be pre-fabricated off-site and transported to the mill for
construction.
Table 8-1
Traffic Movement during Construction
Activity
No. of days
No. of trucks
Relocation of equipment from Fairfield to Maryvale
20
40
Relocation of equipment from Fairfield to Firmins Land
20
60
Mobilisation of site at Maryvale
5
10
Excavation of site – material remains on-site
20
Delivery of backfill materials
15
50
Concrete delivery
5
100
New structural steel delivery
5
20
Equipment from Firmins Lane
40
60
Equipment from Japan
40
10
Waste paper and chemical delivery
5
60
Construction personnel
255
60
CEMP
Construction works will be undertaken in accordance with a Construction Environment Management
Plan (CEMP). The CEMP will include the following elements:






Roles and responsibilities;
Site Characterisation;
Construction Elements;
Regulatory Requirements;
Environmental Impacts and Aspects;
Control of Significant Environmental Aspects;
—
—
—
—
—
—
—
Sediment and Erosion control and monitoring
stormwater;
Spill Control;
Dust control;
Noise;
Waste Management;
Dangerous Goods Management;
43283717/001/B
27
— Flora and Fauna;
— Fire Control;




Monitoring, Audits and Surveillance;
Training and Induction;
Reporting and Community Liaison; and
Incident Response.
8.5
Traffic
Entry to the DIP Plant at Maryvale will be via the Morwell-Maryvale Road, shown on Figure 8. Current
arrangements will require delivery trucks to enter the existing plant weighbridge, exit the site and then
access the new plant. The trucks will then be required to be re-weighed.
Table 8-1 summarises the additional truck movements to site and the increased traffic on the MorwellMaryvale Road section between the two private roads.
Table 8-1
Traffic movement during normal operation
Category
Additional
trucks per
day
Movements on
MorwellMaryvale road
Wastepaper to site
7.0
14
Solid waste to landfill
1.0
2
Beneficial use waste
5.0
2
WWTP sludge
Current
trucks per
day
Rationale
4.59
1.5
Hydrogen peroxide
0.13
0.05
Extra 1.5 deliveries per month
Caustic soda
0.79
0.07
Extra half a delivery per week
CHEMICALS
Sodium silicate
0.03
0.03
1 delivery per month
FAS
0.14
0.14
1 delivery per week
Surfactant
0.03
0.03
1 delivery per month
Miscellaneous
0.14
0.14
Extra delivery per week
8.0
18.3
Total does not include the
waste paper delivery as it is
planned to backload trucks
used for finished paper
transport.
TOTAL TRUCKS
28
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9
A - Carbon
9
9.1
Energy Use and Greenhouse Gas Emissions
Current Site Usage
Table 9-1 below summarises the energy use for the entire Maryvale paper mill site during the 2011
calendar year.
Table 9-1
Annual Energy Use 2011
Fuel
GJ/year
tCO2-e / year
Petrol
3496
234
Diesel
16,939
1,184
Natural Gas
7,204,000
369,781
LPG
16,173
973
Imported Electricity
764,216
259,007
Black Liquor
8,235,640
5436
Total
638,058
The site supplies 50% of its energy requirements from the combustion of black liquor, which means
that approximately 50% of the energy required for the DIP plant will be supplied from renewable
sources. The greenhouse gas emission from the DIP plant (using combined Maryvale energy supply)
is estimated as 20 ktCO2-e/year.
However, the overall impact on Maryvale site power demand will require the equivalent additional
power for the DIP plant to be imported electricity. The net change to the site greenhouse gas
emissions is estimated to be an additional 59 ktCO2-e based on running load. This is equivalent to an
increase of 9% of the sites total GHG annual emissions.
The Equipment List in Appendix C shows the installed power for all the new equipment associated
with the DIP plant. Table 9-2 summarises the installed power and equivalent energy use for each key
process step.
Table 9-2
Proposed works power usage
Process step
Step 1 - Pulping
Step 2 - Detrashing
Step 3 - High Consistency Cleaning
Step 4 - Coarse Screening
Step 5 – Thickening
Step 6 – Oxidative Bleaching
1
2
3
kW1
MW-h / yr2
TJ/yr
tCO2-e / yr3
1125
9449
34
11434
356
2986
11
3613
75
630
2
762
360
3020
11
3654
19
160
1
193
1459
12257
44
14831
Based on installed power
Based on 350 operating days per year of installed power
Based on installed power
43283717/001/B
29
9 A - Carbon
Process step
kW1
MW-h / yr2
TJ/yr
tCO2-e / yr3
Step 7 – Flotation (1st round)
862
7241
26
8761
Step 8 – Fine Screening
487
4087
15
4945
Step 9 – Heavy Cleaning
92
773
3
935
1678
14092
51
17051
201
1688
6
2043
Step 12 – Washing
198
1664
6
2013
Step 13 – Dewatering
147
1235
4
1494
Step 14 – Reductive Bleaching
559
4699
17
5685
1136
9540
34
11543
328
2753
10
3331
74
624
2
755
Effluent to WWTP
152
1277
5
1545
DIP Plant TOTAL
9306
78,174
281
94,591
Step 15 – Wet Lap
549
1521
5
1840
205
1722
6
2084
Re-slushing Wet lap
448
3763
14
4553
391
3280
12
3969
65
546
2
661
1657
10832
39
13107
10,964
89,007
320
107,698
5,840
48,954
176
59,234
nd
Step 11 – Flotation (2
round)
DIP Plant Water Treatment
Rejects
Chemicals
Additional WWTP Sludge Handling
DIP Handling TOTAL
TOTAL (based on installed power)
Totals at estimated running load
(55% of installed load,
38% wet lapping)
Assumptions
 Total installed power of new equipment and pumps of 10.9 MW, assumed to operate for 24 hours
per day, 350 days per year.
 Factor of 1 kWh=0.0036 GJ used to compare increased electricity use.
 GHG emissions calculated using National Greenhouse Accounts emission factor for Victoria
(Scope 2/indirect) of 1.21 kg CO2e/kWh.
 The running load is expected to be 55% of the installed load.
The DIP plant design production rate is 6.5 ADt/h of DIP. This is equivalent to an annual average
production rate of 5.85 ADt/h of DIP, allowing for 90% operating efficiency. On-site paper machines
will normally use 4 t/h (as direct hot stock), and the rest will be wetlapped (38%). The stockpiled
wetlap DIP will be used for 3-4 days per month during the production of products that contain 100% or
65% recycled content paper.
30
43283717/001/B
9 A - Carbon
Pulping and kneading are the most energy intensive steps, with the kneader main drive being 1100kW
and pulper motors 520kW. The proposed DIP plant will have 2 pulpers at the start of the process and
2 kneaders that are used during the oxidative bleaching step and the second thickening step. Other
large motors are associated with the screw presses, and feed pump motors to deinking cells, rejects
cleaners and screens.
Based on the ‘imported electricity’ consumed at the site in 2011, the proposed DIP plant energy use of
5.84 MW running power will account for an additional 23% of electricity imported from the grid.
9.2
Best Practice Carbon Management
9.2.1
Best Practice
As discussed in Section 5, a table summarising techniques to consider in the determination of Best
Practice Energy use, and the expected effect on consumption and emissions levels is included in
Appendix D – Table 2.
The best practices related to ‘energy’ are:




Implementation of a system for monitoring energy usage and performance;
Replacement of equipment with less energy consuming equipment;
Continuous pulping instead of batch; and
New screen designs.
System for monitoring energy usage and performance
AP has in plant controls and monitoring systems for management of energy usage on-site. Based on
reliable energy performance information appropriate action can be taken. Energy management
includes setting, controlling, reviewing and revising energy performance targets.
Replacement of equipment with less energy consuming equipment
When replacing equipment with less energy consuming equipment, there are possibilities for using
automated process control instead of conventional manual systems. Automated controlled systems
are more efficient and can result in more accurate processing and energy savings.
The proposed DIP plant will have automated control systems to minimise energy consumption and
maximise production.
A dissolved oxygen meter will also be installed in the WWTP to control the amount of aeration, thereby
minimising the energy use of the upgraded aeration system.
AP considered replacing one of the kneaders with an alternative process from NPI, however this
option was rejected on the basis of likely product quality issues from the typically “poorer” quality
waste paper supply in Australia compared to Japan.
Continuous pulping instead of batch
The DIP plant will operate continuously which is an improvement from the Fairfield process which
operated as a batch plant. Batch operations are more energy intensive than continuous because
there is increased power usage during start-up and shutdown activities than during steady-state
operation.
43283717/001/B
31
9 A - Carbon
New screen designs
The DIP plant will have second-hand screens installed from one of its Japanese facilities. These
screens are newer and more efficient than the Fairfield screens, requiring less energy to operate.
9.3
Benchmarking
A comparison of electrical load intensity between Fairfield and Maryvale DIP plants under similar
operating conditions was submitted as part of the business case for the Clean Technology Investment
Program earlier in 2012, and is shown in Table 9-3.
Table 9-3
DIP Plant Electrical Load Intensity Benchmarking
Description
Fairfield Baseline
Maryvale
Installed
(kW)
Running
(kW)4
Installed
(kW)
Running
(kW)5
8615
4653
8615
4653
New process changes, NPI
37
20
Dewatering screws for thickening and reductive brightening
stage
66
36
Fairfield DIP plant
Fairfield wet lap machine
Off-line re-slushing & distribution
6
549
297
549
99
448
242
448
81
205
111
9920
4999
Maryvale Hot stock Distribution
Total (kW)
9612
5191
Plant Output (ADt/h)
6.23
6.23
Power usage (MWh/tonne)
0.833
0.802
The proposed AP DIP plant is more energy intensive than the NPI plants that were benchmarked in
Section 5, but is less energy intensive, when considering MWh/tonne, than the Fairfield plant when
compared under similar operating conditions.
There are two main process differences that account for the differences in energy use between the
proposed DIP plant and the NPI plants in Japan:
 The Nippon plants do not use wet-lapping. Approximately 38% of the DIP will be wet-lapped. The
wet lapping process accounts for approximately 549 kW of installed power, or approximately 20
kWh/ADt product.
 The proposed DIP plant uses two kneaders – that are used during the oxidative bleaching step and
the second thickening step. The Nippon facilities only use one kneader. Each kneading step
accounts for approximately 1200 kW installed power, or approximately 100 kWh/ADt product. The
alternative technology in use at the NPI plants has a lower energy demand, supported by the fact
that the quality of office waste is better in Japan than in Australia.
4
5
6
Plant running at 54% of installed load
Plant running at 54% of installed load
Wet lap machine and re-slushing running at 1/3 electrical loading at Maryvale and 2/3 hot stock
32
43283717/001/B
10
10
B - Water
10.1
Water Use
The mill is a large water user in the region, though relative to other mills of its type across the globe, is
extremely water efficient.
Water for process use is supplied from Moondarra reservoir to the Maryvale Mill under a contract with
Gippsland Water. The contract provides for 90 ML/day of fresh water to be supplied to the Maryvale
Mill. The current agreement applies until 2017.
The Maryvale Mill currently uses about 350 ML/day of process water, consisting of 287 ML/day of
water that is reused and recycled from the process, and 63 ML/day of fresh water make-up.
The DIP plant will require 1.68 ML/day of additional fresh water supply. A further 0.84 ML/day of
recycled water will be supplied from existing site wastewater streams (paper machine backwater).
The simplified water balance for the plant is included in Table 10-1.
Table 10-1
Simplified Water Balance
Water Type
Design Basis (kL/ADt)
Predicted average daily
flow at 90% efficiency
(kL/d)
Predicted Annual Volume
(ML)
Fresh Water
12
1,680
590
Recycled Water
(Backwater)
25
3,510
1,228
Wastewater to treatment
16.5
2,320
811
Discharge to River
10.5
1,470
516
This demonstrates that a third of the water use is provided through reuse of recycled water. Net
freshwater make up is 12 kL/ADt while wastewater discharge to the river is 10.5kL/ADt.
A water balance overview is attached in Appendix F – showing water embodied in pulp and waste
products as well as added fresh and recycled water. The flow rates shown in the Appendix F figure are
at full design rates.
As shown in the Process Block Diagram (Figure A in Section 5.1), fresh water make-up to the DIP
plant comes into the washers towards the end of the process. Site recycled water (paper machine
backwater) comes into the dewatering and reductive bleaching steps via a pipe to the Wetlap filtrate
tank (which also receives overflows from the Wetlap machine). Overflows from the washing, reductive
bleaching and dewatering stages are returned to the DIP process via water recycling loops and
treatment in the DAF units.
10.2
Best Practice Water Management
Since 1973, Maryvale Mill has increased its paper production from about 100,000 t/yr. to the present
560,000 t/yr. Water consumption at the site in 1981/1982 was approximately 125kL/T of product, and
this was reduced to around 41-42 kL/T of product (averaged 2002-2005). Overall, since the early
1980’s, water use per tonne of product has been reduced by approximately 67%. (Note: these figures
include all fresh water usage on site).
43283717/001/B
33
10 B - Water
The improvements in water use efficiencies within the mill have been achieved through application of
innovative water recycling and re-use techniques, resulting in an extremely high rate of water reuse for
this class of pulp and paper mill. The site’s average fresh water usage of approximately 40 kL/tonne of
product is less than most other mills of its type worldwide. Data published by the (US) National Council
for Air and Stream Improvement (NCASI, 2003) shows that the average effluent flow for mills in the
US in 2000 was approximately 52 kL/tonne of product. For bleached Kraft mills it was approximately
75 kL/tonne of product. Discharge from the Maryvale Mill is typically about 10% less than input due to
net evaporation.
The DIP plant total water use equates to approximately 18 kL/t. This is the same as at Fairfield,
however only 12 kL/t will be fresh water, with the remainder being recycled mill water. The total water
use is comparable to or better than that at the NPI plants selected for benchmarking.
Best practice water use options for DIP plants summarised in Appendix D Table 1 were:




Separation of less contaminated water from contaminated streams and recycling of process water;
Optimal water management (water loop arrangement), water clarification;
Reduction of fresh water consumption by strict separation of water loops; and
Generation of clarified water for de-inking plants.
All of these options are part of the proposed DIP plant process design at Maryvale. In addition,
approximately 33% of water supply will be recycled water from the paper machine backwater system.
34
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11
11
C - Solid Waste
11.1
Solid Waste Generation
As detailed in Section 6.3, the following solid wastes will be generated by the DIP plant project
Table 11-1
Summary of Solid Waste Generation from the DIP
Type of solid waste
Amount ADt/yr
Destination
WWTP sludge
6,930 t/yr
(including Clarifier sludge from Primary and
Secondary clarifiers)
(approx. 8.5% of feed)
Generated at on-site WWTP. Will be
sent along with current clarifier
sludge to Pinegro for composting.
 consists of fibres, minerals & CaCO3, plus
biological mass from secondary clarifier
DIP plant sludge
(including De-Ink Cleaners, DAF &
Centrifuge Sludge)

21,168 t/yr
consists of cellulose fibres, ink and
mineral fillers
(Tested and classified as Industrial waste)
Detrasher waste
(including Coarse Rejects (Grit) and
High Consistency Cleaner rejects (Sands))

consists of metal, plastic, glass, grit, fibre
3,434 t/yr
Recycled into soil conditioning
products (e.g. to Pinegro for
composting) or other value added
products in conjunction with other
Maryvale by-products (e.g. kitty
litter).
These three wastes are similar in
nature and will be combined and
sent to landfill at Bacchus Marsh as
industrial waste
(Classified as Industrial waste)
The quantities of waste produced are estimated based on the DIP plant yield rate of 61%, incoming
waste paper raw material of 81,000 t/year (at 90% operating efficiency, along with data on waste
quantities produced by the DIP plant at the Fairfield site. Refer to the Solid Waste Overview figure in
Appendix E (NB: the data in the Overview figure is based on design throughputs).
 Detrasher waste is generally 4% of the incoming waste paper stream.
 DIP plant cleaners and centrifuges generate sludge waste equivalent to 26% of the incoming waste
paper mass.
 The WWTP clarifier sludge account for the remaining 8.5% of the incoming waste paper mass.
 The additional WWTP sludge amount is calculated based on testing of Fairfield March & April
Effluents, with an average TSS of 3740 mg/L and filtered COD of 3860 mg/L and DIP effluent flow
of 2.57 ML/d (design rate).
Currently the site generates approximately 40,000 t/year of WWTP sludge from the primary,
secondary and sewer sludge clarifiers, which is sent to Pinegro for composting. These sludge wastes
are classified as Category C due to total petroleum hydrocarbon (TPH) concentrations. The DIP plant
will contribute an additional 6,930 t/year of WWTP sludge, or an increase of 17%.
DIP plant sludge generated during the March 2012 production run at Fairfield were tested and classed
as Industrial Wastes. The de-inking, centrifuge and DAF sludge were further tested in the April 2012
run, and reported the following constituents:
 Moisture: 49.1%
 Fibrous Material: 15% (decomposed at <520°C) (includes pulp, starches, latexes, adhesives and
printing ink compounds)
43283717/001/B
35
11 C - Solid Waste
 Calcium Carbonate: 31.8% (60% on oven dried basis)
 Other Inorganics: 4.0%
Literature indicates that printing inks, coating pigments (calcium carbonate & clays) and adhesives are
trapped in the foam generated during the flotation deinking process. This material is collected and
separated in the DAF units (used to clarify the recycled process water). The printing inks are
deposited in the solid waste.
It was not appropriate to attempt to generate DIP plant treated wastewater sludge for testing, as the
total mill and the wastewater treatment processes at Maryvale and Fairfield are not comparable. The
DIP plant effluent will be treated at Maryvale together with existing site wastewater streams and the
clarifier sludge will therefore be a combination of all streams.
11.2
Best Practice Solid Waste Management
As discussed in Section 5, a table summarising techniques to consider in the determination of BAT
and the expected effect on consumption and emissions levels are included in Appendix D – Table 3,
together with a summary of their relevance to the proposed works.
AP will implement separation of waste types to maximise their reuse potential, which is considered
best practice.
DIP Plant Centrifuge, Screw Press & DAF Sludge
Best practise options that apply to these wastes include:
 Minimisation of waste generation;
 Direct beneficial reuse (e.g.: composting); and
 Energy recovery.
The DAF units are considered best practise for minimising water use, as they allow reuse of water
within the DIP process. The by-product of this is generation of sludge.
AP will pursue direct reuse of the sludge from the DIP plant for kitty litter. Energy recovery is
considered a less desirable option than reuse.
Detrasher Waste
The detrasher waste consists of hard contaminants present in the incoming waste paper stream plus
some lost fibre, which would otherwise have been disposed to landfill along with the waste paper,
unless another reuse was found for the paper.
The options identified for detrasher waste management were landfill or energy recovery, with energy
recovery considered best practise of the two options. At this stage AP does not plan to send the
detrasher waste for energy recovery, as no suitable waste receiver has been identified. However this
option may be investigated in the future. For instance, it may be possible to burn the detrasher waste
in a hog-fuel boiler.
WWTP Sludge
The WWTP clarifier sludge contains minerals, fibre, CaCO3 and some biological mass from the
secondary clarifiers. The site currently generates approximately 40,000 t/year of dewatered WWTP
sludge. Since 2010, 100% of this has been sent to Pinegro for composting.
36
43283717/001/B
11 C - Solid Waste
Best practise options for management of this sludge include:




Reuse of fibres from primary clarifiers in paper making;
Reuse for composting or kitty litter;
Optimise dewatering to enhance dry solids content; and
Energy recovery.
The existing WWTP has two primary clarifiers (refer WWTP process flow diagram in Appendix F).
Wastewater from the site and paper machines is collected in two separate streams, with solids and
fibres from primary Clarifier No.2 being recycled back to paper machine M4 for reuse. Primary Clarifier
No.1 receives wastewater from paper machines M3 and M5. This wastewater has a large proportion of
CaCO3 which cannot be recycled back to M4. Therefore solids separated from this clarifier are
currently sent for composting. It is expected that the DIP plant effluent will also have a high degree of
CaCO3 in the solids making it unsuitable for reuse at M4; therefore it will be treated in primary Clarifier
No.1, with solids going to composting, and supernatant proceeding to the aerobic biological treatment
pond.
AP has a separate approved capital project to replace the Effluent Solids Residue (ESR) presses, to
enable dewatered sludge of 58% solids to be produced (compared to about 28% solids currently). This
capital project originally was designed with 120 m3/hour capacity. The DIP plant is expected to
contribute an additional 41 m3/hour of sludge from the wastewater treatment plant clarifiers. With the
installation of the DIP plant, the ESR project will be augmented to 160 m3/hour capacity. The ESR
project will be installed and commissioned by the end of 2013 and prior to the start-up of the DIP plant.
Energy recovery has not been considered as an option for sludge disposal as no suitable waste
receiver has been identified, and AP’s preference is for sludge reuse in composting.
Waste Receivers
AP has a long-standing business arrangement with Pinegro (located on-site) for receipt and
composting of wood and fibre wastes from the mill. Pinegro also receives the WWTP clarifier sludge
for use in compost materials. Current supply rate is 40,000 t/year. It is expected that this will increase
by 6,930 ADt/year with the commissioning of the DIP plant. Composting produces a soil conditioner
that is sold into the market.
AP has obtained in-principal agreement from Pinegro for reuse of all of the produced DIP plant sludge
in composting/soil conditioners and /or kitty litter. Based on advice from Pinegro on 12/6/12, the
following approach to waste reuse is planned:
 The DIP plant sludge will be transported off-site to a Pinegro recycling facility, as the existing
Pinegro site at Australian Paper is not capable of processing this additional volume. The sludge
will undergo processing to manufacture a marketable product that will be beneficially reused in
Pinegro’s existing agricultural markets. Pinegro have received technical analysis of the waste
streams and indicative quantities and are confident that they can manage these new waste
streams as well as existing waste streams.
 Pinegro intend to manage the additional WWTP sludge in the same way as the current WWTP
sludge and to beneficially reuse it in their existing markets.
43283717/001/B
37
12
12
F - Water
12.1
Water Discharges
12.1.1
Licensed Discharges
Waste water is currently discharged from the site in two waste streams. More concentrated process
wastes are discharged to sewer after primary treatment under a trade waste agreement with
Gippsland Water. Less concentrated wastes are treated by a series of clarifiers, aerobic biological
treatment and maturation ponds onsite. Wastewater is discharged to the Latrobe River under EPA
licence (Licence No. EM30021 issued under Section 20 of the Environment Protection Act 1970),
following treatment at the mill.
All process effluent from the proposed DIP plant will be combined with the site “less concentrated”
wastewaters and treated and discharged to the Latrobe River, under the existing EPA Licence. AP will
be upgrading elements of the existing WWTP to ensure that water quality discharge to the Latrobe
River will remain within current (draft) EPA licence limits, and will be of similar magnitude to, or better,
than the current situation.
The licence is in the process of being converted to the new format; and an extract of the draft licence
limits7 for wastewater discharges is given in Table 12-1 below.
Table 12-1
7
EPA draft Licence specifications
Parameter
Units
Limit Type
Licence limit
Flow
ML/Day
Annual median
55
Total Dissolved Solids
mg/L
Maximum
1000
mg/L
Annual median
850
Suspended solids
mg/L
Maximum
60
Suspended solids
mg/L
Annual median
30
Colour (Pt-Co Units)
Maximum
200
Annual median
140
BOD (total)
mg/L
Maximum
30
Electrical Conductivity
µS/cm
Maximum
1500
Sulphate
mg/L
Maximum
500
Anionic surfactants
mg/L
Maximum
0.5
Total Phosphorus (as P)
mg/L
Annual median
0.25
Total Phosphorus (as P)
mg/L
Maximum
0.3
Nitrate (as N)
mg/L
Annual median
0.4
Nitrate (as N)
mg/L
Maximum
1.0
Ammonia (as NH3)
mg/L
Maximum
3.1
AOX
mg/L
Maximum
1.0
2,3,7,8 TCDD (dioxin)
pg/L
Maximum
20
pH
pH units
Based on May25 2012 draft Licence
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43283717/001/B
6.0 – 8.5
12 F - Water
The effluent discharged to the Latrobe River is continuously monitored for selected parameters, while
conformance to the EPA licence is verified by regular testing in AP’s NATA registered laboratory.
Currently, a high level of compliance with the discharge criteria is achieved. There were three licence
breaches in 2010, being one each for suspended solids (64 mg/L compared to 60 mg/L maximum
limit), ammonia (2.6 mg/L compared to 2.5 mg/L limit) and anionic surfactants (1.0 mg/L compared to
0.5 mg/L limit). In 2009 there were 13 breaches of the suspended solids maximum limit (believed to be
caused by historical incidents at adjacent sand quarries in which sand washing slimes containing
colloidal clays, flowed into the pond), however the annual median limit was met. All other parameters
were within Licence limits in 2009 and 2010.
The final annual monitoring report for 2011 was not available at the time of preparing this Works
Approval, however it is noted that in 2011, the annual median suspended solids result of 34.2 mg/L
exceeded the limit of 30 mg/L. Improvements to treatment at the secondary clarifier implemented in
March 2012 have since seen a reduction in final effluent suspended solids.
Routine monitoring of the effluent over the past 10 years has consistently shown no observable trend
in toxic effects of the site wastewater (within the limits of the test procedures as required by the
licence).
12.1.2
DIP Plant Wastewater Sources
The DIP plant will contribute an additional 1.47 ML/day of treated wastewater to the Latrobe River
compared to average flows of 41.3 ML/day in 2010 and 44.3 ML/day in 2011. This is an increase of
about 4%.
All wastewater generated in the DIP plant will be collected in floor drains which flow to a central
effluent collection pit. The wastewater sources comprise overflows from plant, predominantly from the
centrifuges, and are represented in Figure a (Section 5.1). DIP wastewater will be pumped from the
pit to the existing wastewater treatment plant.
There will be no routine discharges to trade waste from the DIP plant.
A simplified water and wastewater mass balance is included in Section B (chapter 10) and is
reproduced below.
Table 12-2
Water Type
Basis (kL/ADMT)
Average daily flow (kL/d)
Annual Volume(ML)
Fresh Water
12
1680
590
Recycled Water
(Backwater)
6
840
298
16.5
2320
811
Discharge to River
10.5
1470
516
12.1.3
Predicted Wastewater Quality
AP undertook testing of wastewater from two DIP production runs at Fairfield in March and April 2012,
with samples of effluent (and solid wastes) tested to assist with predicting the impact of the DIP plant
at Maryvale site.
43283717/001/B
39
12 F - Water
The production run comprised the following conditions:
Table 12-3
Fairfield DIP production run conditions
Production Run Inputs
Type
Comments
Waste Paper Source
Waste office paper
As proposed for Maryvale
Process Water
100% fresh water at 107
kL/hour
Maryvale will use 107 kL/hour, however 67% is
fresh water, and remainder is mill backwater.
Process Chemicals
As used at Fairfield
Maryvale yet to select chemical supplier & finalise
dosing rates. Expect similar.
The results of the Fairfield DIP plant production run wastewater testing (prior to any treatment) are
contained in Appendix F. Three samples reported anomalously high suspended solids results well
outside the range for a DIP plant effluent. The reason for this has not been fully ascertained, although
a process upset is suspected. Potential process upsets that could lead to elevated suspended solids
in effluent will be addressed in the detailed P&ID HAZOP, to be completed later in 2012.
Appendix F contains a detailed assessment of predicted final effluent quality with the introduction of
the DIP plant. The following data was used to predict the final effluent quality:




Results of DIP plant effluent testing obtained during production runs at Fairfield plant.
Data on current Maryvale final effluent quality – 2010 and 2011.
Data on current Maryvale WWTP performance and removals achieved.
Information on WWTP upgrades to be implemented in order to manage the additional DIP plant
wastewater.
The major additional loads on the WWTP from the DIP relate to suspended solids and BOD. Flow
rates are only marginally increased and an assessment of the clarifiers indicates that they will still
operate within normal hydraulic load design and operating criteria. Therefore it is anticipated that
suspended solids performance should be similar at the increased loads (without consideration of
planned upgrades).
The additional BOD requires upgrading of the aeration and mixing systems in the aerated lagoon, and
this is to be implemented and is undergoing the detailed design process at this time. The addition of
nitrogen and phosphorus is a controlled process and hence the impacts on the effluent quality can be
managed to ensure compliance through appropriate controls and monitoring.
Wastewater Treatment Plant Upgrade
The following summarises the proposed upgrade for the WWTP:






11No x 35.5kW aerators including air blowers to enhance aeration capacity in aeration pond 1A
Additional dissolved oxygen measurement in aeration pond 1A
Upgraded nutrient dosing controls to inflow to aeration pond 1A
Upgraded flow based coagulant & flocculent controls to the primary clarifiers
Upgraded and flow based coagulant and flocculent dosing to the secondary clarifier
DCS monitoring of recently installed TSS Meters on the inlet and outlet of the secondary clarifier
Table 12-4 shows the predicted final effluent concentration using 2011 data as a baseline, with the
addition of the DIP plant effluent and implementation of WWTP upgrades.
40
43283717/001/B
12 F - Water
Table 12-4
Estimated Treated Water Quality for River Discharge based on 2011
PARAMETER
Units
Draft Licence
Limit
Flow
ML/day
mg/L
Total Dissolved
Solids
2011
Average
Average DIP
Effluent
Concentration
(TEST RESULTS)
Combined
effluent ex
Secondary
Clarifier
Predicted
Final
Effluent
55 (annual
median)
44.3
2.3
52.0A
45.8B
1000
(maximum)
493
2973
650
650
850 (annual
median)
Suspended
Solids
mg/L
30 (annual
median)
36
3747
20F
20F
Colour (Pt-Co
Units)
mg/L
200
(maximum)
94
71
92
92C
2100
44
15
140 (annual
median)
BOD (total)
mg/L
30 (maximum)
Anionic
Surfactants
mg/L
0.5 (maximum)
0.20
NM
Total Phosphate
(as P)
mg/L
0.25 (annual
medium)
0.18
2.1
0.18E
0.18
0.04
0.02
0.04E
0.04
C
1.28
0.20D
0.3 (maximum)
Nitrate (as N)
mg/L
0.4 (annual
median)
0.1 (maximum)
Ammonia (as
NH3)
mg/L
3.1 (maximum)
1.24
3.5
1.28
AOX
mg/L
1.0 (maximum)
0.06
NM
NM
6.0 - 8.5
7.3
7.4
pH
0.06
7.50
Notes:-
A. Includes flows that are recycled to the mill
B. Excludes flows that are recycled.
C. Assumes (conservatively) that there are no reduction in DIP ammonia or colour in the WWTP.
D. DIP effluent not measured, non-ionic surfactant used, so no expected impact on anionic surfactant levels.
E. Nitrogen & Phosphorus are dosed to the WWTP to achieve a targeted nutrient level, therefore no increase expected.
F. Suspended solids of less than 20 mg/L are achievable from the secondary clarifier with the proposed upgrades to chemical
dosing.
NM ‐ not measured 43283717/001/B
41
12 F - Water
Suspended Solids
Final effluent suspended solids concentrations in mill effluent are already close to or in excess of the
EPA licence annual median limit of 30 mg/L (2010 annual median was 27 mg/L, annual average was
29 mg/L; 2011 annual average was 36 mg/L). There was also one exceedance in 2010 of the
maximum suspended solids limit of 60 mg/L, being 64 mg/L measured on 1/2/2010. As was reported
in AP’s Discharge to Latrobe River Annual Environmental Report to EPA for 2010, incidents at
adjacent sand quarries may be a contributing factor to observed patterns of elevated suspended solids
measured in AP final effluent discharge. There are 3 sand quarries located around the south and
south-western boundaries of the final detention pond. There were no reported major outbreaks of
blue-green algal blooms that may have impacted the suspended solids results in 2010 (or 2009).
The planned upgrades to the Distributed Control System (DCS) for the WWTP and chemical dosing
are targeted at ensuring the final effluent quality meets the suspended solids licence limit.
Toxicity
As discussed in Section 12.1.1 above, routine monitoring of mill effluent discharge to the river and
river toxicity monitoring has not identified any observable toxic effect trend from mill discharge over the
last 10 years. Three samples of untreated DIP plant effluent were subjected to Microtox testing. EC50
results ranged from 10% to 13%, being the percentage of effluent giving rise to a reduction in light
emission from 50% of the test organisms. Whilst these results indicate a level of toxicity in the
untreated DIP plant effluent, it is expected that treatment in the on-site WWTP in particular the
biological treatment will eliminate the toxicity.
12.2
Best Practice Water Management
The review of best practice for DIP plants (Appendix D) identified the following main areas related to
wastewater pollution reduction:







Implementation of water recycling loops and fibre and filler recovery within the process
Treatment of wastewater using primary and secondary biological processes
Measures to avoid accidental releases of chemicals and wastes
Optimisation of process control
High maintenance levels
Risk management system
Training
All of the above will be applied to the DIP plant in its operation at Maryvale. Most of the above points
are discussed elsewhere in this application. The on-site wastewater treatment system is described
more fully in Section 12.2.1 below. Comparison with available benchmarking data is given in Section
12.2.2.
12.2.1
Maryvale wastewater treatment and disposal system
Water that comes into contact with logs, bark, pulping chemical fibre, papermaking chemicals etc. is
referred to as process water. This water is treated for either reuse in the mill or for discharge. There
are two process effluent streams at the Maryvale Mill. One stream, comprising the more concentrated
process discharges, is treated and pumped to Gippsland Water’s trade waste system. Other more
dilute process discharges are treated onsite in the mill’s WWTP – including aeration ponds to reduce
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43283717/001/B
12 F - Water
BOD and suspended solids, prior to recycling for further use within the plant or discharge into the
Latrobe River.
Refer to the following sections for a more detailed description of site sources and flows of wastewater.
12.2.1.1 Onsite wastewater treatment system
The dilute process discharges from the Maryvale Mill are collected into two streams (East and West
process drains) and after coarse screening, are sent to the onsite effluent treatment plant before
disposal to the Latrobe River. See Appendix F for a schematic representation of the collection,
treatment and discharge of effluent to the Latrobe River.
Eastern process drain to No.1 Primary Clarifier
Process wastewater from the eastern portion of the site (typically 25-28ML/day) is discharged into the
No 1 Clarifier and is primarily excess process waters from Paper Machines M1, M2, M3, and M5.
The DIP plant process wastewater is expected to be discharged to the Eastern process drain.
Sludge from No.1 Clarifier (known as ESR or Effluent Solids Residue) has a high calcium carbonate
content and is collected and dewatered prior to disposal or reuse. This ESR sludge was historically
sent to the on-site landfill, however currently is sent to Pinegro for use in composting.
Western process drain to No.2 Primary Clarifier
Process wastewater water from the western portion of the site (typically 21-24 ML/day) is discharged
into the No 2 Clarifier for treatment and includes effluent from:








press backwater;
Numbers 1, 2 and 3 Water Filtration Plant backwashes;
Paper Machine M4;
excess treated condensates (low sulphur);
NSSC pulp mill;
M1, wetlap, brown backwater system, continuous Kraft mill and batch Kraft mill;
chemical preparation area; and
rainwater run-off from the wood yard.
Sludge from No.2 Clarifier is collected and pumped to the fibre recovery plant, with recovered fibre
sent to Paper Machine M4 for reuse in papermaking.
Aerobic Biological Treatment
The clarified overflow from the No 1 and No 2 Clarifiers is discharged into No 1A Aeration Pond for
biological treatment to breakdown the sugars, starches and other simple organic compounds extracted
during the pulp and papermaking process. Additional nutrients (N & P) are added to assist in the
biological breakdown.
As part of the proposed DIP plant project the WWTP will be upgraded to increase aeration, mixing and
chemical dosing controls and overall pollutant removals.
43283717/001/B
43
12 F - Water
Secondary Clarifier and Polishing Pond
The water from pond No. 1A then goes through a secondary clarifier with coagulant and flocculant
dosing for removal of the biomass generated in the Aeration Pond. Some supernatant is recycled back
to the mill for use as process and flushing waters. Sludge from the secondary clarifier is collected and
dewatered prior to disposal. Historically this was sent to the on-site landfill, currently it is sent to
Pinegro for use in composting.
The majority of supernatant from the secondary clarifier passes onto the No.2 polishing pond prior to
discharge to the Latrobe River. The Polishing Pond is a large shallow pool approximately 1.5m deep
and 70 hectares in area. It has approximately 3-4 weeks retention time. The very large water surface
provides adequate transfer of oxygen to the water, encouraging the microorganisms to grow and
continue to degrade residual compounds. The shallow pond also allows sunlight to penetrate,
encouraging water plants to grow and consume the carbon dioxide produced by the bacteria.
12.2.1.2 On-site Trade Waste System
The Maryvale Mill operates under a Trade Waste Agreement (TWA) with Gippsland Water, allowing
waste water discharge to sewer. The effluent stream discharged to Gippsland Water’s trade waste
system is approximately one third of the total effluent discharged from the Maryvale Mill and includes
the following sources:










the Wood Yard log wash;
the Bleach Plant;
Paper Machine M4 pulp transport water;
the power area gland waters, condensates and demineraliser effluent;
any process spills;
Kraft Batch Mill;
dilute filtrates from the Kraft Continuous Mill during shut downs;
NSSC pulp mill;
dilution water from secondary clarifier; and
surge basin.
The effluent is first treated within the mill’s trade wastewater treatment plant where any fibre and solids
are removed by settling in clarifiers using coagulants and flocculants. Lime is also added at the
clarifiers to control pH (if required). The clarified effluent is then pumped to the Gippsland Water
sewer under a TWA.
12.2.2
Wastewater Benchmarking Data
Data from two other NPI mills with similar DIP plants (Section 5.2) showed wastewater generation
from the DIP plants to be 15 or 55-70 m3/tonne. The proposed DIP plant at Maryvale is assumed to
generate wastewater at the same rate as at Fairfield, being 16.5 m3/tonne. This is comparable to the
more water efficient NPI mill. Both NPI mills discharge wastewater to surface waters.
12.3
Impact on Waterway
The site falls within the area addressed by the Variation to SEPP (Waters of Victoria) Schedule F5
Waters of the Latrobe and Thomson River Basins and Merriman Creek Catchment. The site is located
44
43283717/001/B
12 F - Water
in Segment E (predominantly industrial areas of the Latrobe Valley) being located adjacent to the
Latrobe River downstream of the Lake Narracan dam wall.
Table 12-5 shows the in-stream water quality indicators that apply in the Latrobe River at this location,
along with available monitoring data for the Maryvale site discharge reported in 2010.
Table 12-5
Latrobe River Water Quality Indicators and Results
Indicator
Segment E
Indicator
Limit
AP River
Discharge Data
(2010)
Measurement
Location
Likely Change
with DIP Effluent
& WWTP
Upgrade
Final Effluent
None
None or higher –
additional
aeration
pH
Range
6.0 – 8.5
6.3 – 8.3
pH
Variation from
N
<1.0
results within
agreed
compliance bandA
Dissolved
Oxygen
Min Conc.
>5.0
2.9
Final Effluent
5.7
In Stream
Dissolved
Oxygen
Min Saturation
>55%
Not reported
Toxicants
Maximum
<T
No observed
toxicity trends;
some minor
responses
observed that are
not significant
Salinity (mg/L)
Annual 90th
percentile
<500
584 results within
agreed
compliance bandA
Final Effluent
Higher TDS
Salinity (mg/L)
Maximum
<700
598
Final Effluent
Higher TDS,
Salinity
% increase
<10%
Graphical
presentation
within compliance
band
Suspended
solids (mg/L)
Annual 50th
percentile
<50
27
Final Effluent
Decrease
Suspended
solids (mg/L)
Annual 90th
percentile
<90
44
Final Effluent
Decrease
Turbidity (NTU)
Annual 50th
percentile
<25
Not measured
Turbidity (NTU)
Annual 90th
percentile
<50
Not measured
Colour (Pt.Co
units)
Annual 50th
percentile
<60
93 (results within
agreed
compliance
bandA)
Final Effluent
decrease
Colour (Pt.Co
units)
Annual 90th
percentile
<100
120 (results within
agreed
Final Effluent
decrease
43283717/001/B
None
45
12 F - Water
Indicator
Segment E
Indicator
Limit
AP River
Discharge Data
(2010)
Measurement
Location
Likely Change
with DIP Effluent
& WWTP
Upgrade
Final Effluent
None – manage
compliance
bandA)
Colour
%increase
<20
Graphical
presentation
within compliance
band
Total
phosphorus
(mg/L)
Annual 50th
percentile
<0.06
0.15
Total
phosphorus
(mg/L)
th
Total nitrogen
(mg/L)
Total nitrogen
(mg/L)
through nutrient
dosing
Annual 90
percentile
<0.10
0.20
Final Effluent
None – manage
through nutrient
dosing
th
Annual 50
percentile
th
Annual 90
percentile
Temperature
Variation from N
(oC)
Maximum
Temperature
Variation from N
(oC)
Annual 90
percentile
th
<0.90
<1.60
1.37
2.29
Final Effluent
None – manage
(sum of nitrate &
through nutrient
ammonia as N)
dosing and aeration
Final Effluent
None – manage
(sum of nitrate &
through nutrient
ammonia as N)
dosing and aeration
<2.0
2.0
In stream
None
<1.5
1.1
In steam
None
Table Note A: - It should be noted that the SEPP provides water quality objectives (based on
beneficial uses) for the Latrobe River that are different from the licence compliance requirements. The
impact on the river needs to take into account the mixing that occurs and background (upstream water
quality and its variability). EPA and AP have agreed on a band of concentrations for TDS, colour, pH
and temperature, rather than a particular target concentration. A review of the data for 2009-2012
indicates that AP has complied with this agreed band for the agreed downstream parameters.
The above comparison shows that current site effluent discharges to the Latrobe River meet the instream water quality objectives, with the exception of
 Total nitrogen
 Total phosphorus
Some in stream monitoring data was provided by ALS (Biological Monitoring of the Latrobe River 2010
(ALS Environmental Feb 2011) that includes both upstream and downstream monitoring sites. It
reported: With the exception of one site during spring, all sites complied with the Vic. Gov. (1996)
SEPP objective for total phosphorus (TP) in both seasons. There were no significant seasonal or
location differences in TP with concentrations similar at all sites in both seasons.
There is no SEPP objective for oxidised nitrogen so the ANZECC (2000) objective was used. All
upstream sites complied with the Vic. Gov. (1996) objective for total nitrogen (TN) in both autumn and
46
43283717/001/B
12 F - Water
spring. During spring all downstream sites also complied with the objective while the majority of
downstream sites failed to comply during autumn due to relatively high concentrations. A significant
seasonal difference was detected with higher concentrations at all sites during autumn. There was no
significant location difference detected but a significant interaction (season x location) difference was
detected. This suggests that the upstream and downstream difference in TN concentrations were not
consistent for both seasons. The data highlights this pattern with higher downstream concentrations
during autumn.
The site reported licence compliance for nutrients in 2010 with the exception of one ammonia
exceedance (2.6 mg/L against 2.5 mg/L licence requirement).
AP dose nitrogen and phosphorus into the WWTP system and improved controls will be installed as
part of the WWTP upgrade, to prevent potential non-compliant discharges.
ALS concluded:
The macro invertebrate community assemblages downstream of the discharge were found to have
significant differences to those upstream in the riffle habitat only. However no breach of SEPP
Objective compliance could be specifically attributed to the discharge.
 An exploration of the data found that turbidity, pH, alkalinity, sulphate, chloride and temperature
best explained differences in macro invertebrate community composition in the riffle habitat. In the
edge habitat dissolved oxygen, pH, soluble aluminium, colour and suspended solids were found to
best explain the differences in macro invertebrate distributions. It is important to remember that
these correlations are exploratory and are not necessarily causative, or even necessarily related to
the discharge. It is also interesting to note that only three of these parameters were found to be
significantly affected by the pulp mill discharge (as evidenced by ANOVA analysis) itself. This
implies that macro invertebrate community composition is more affected by catchment scale factors
such as land use and river flow than local scale point source factors such as the pulp mill.
 Summary macro invertebrate indices indicate that the study reach as a whole is degraded with
non-compliance with ecological objectives (i.e. SIGNAL score, O/E score, AUSRIVAS banding,
total number of families, total number of key families) in upstream and downstream zones. This
region is heavily impacted by agricultural impacts due to stock access, land clearing, overgrazing,
irrigation, and the use of pesticides and insecticides. Other local impacts unrelated to the discharge
from Maryvale include mining activities at the Yallourn open cut, saline wastewater release to the
Morwell River for power generation and recreational impacts.
The addition of the DIP plant effluent is not considered likely to impact on the current compliance
status with water quality indicators as seen from Table 12-5.
Stormwater
Stormwater generated at the site is collected separately from process waters at the Maryvale Mill. The
stormwater catchment area is approximately 120 hectares which includes roofs and hard surfaces, but
is mainly grassed and vegetated areas. AP has previously conducted studies on rainwater runoff, and
these have indicated that on average, approximately 25% of rainfall runs off as stormwater, though
this may increase during heavy storm events.
On average, stormwater runoff is around 0.7 ML/day. There is quite a large variation around the
average runoff conditions, varying from no runoff in dry conditions to peaks of 7ML/day in wet weather
43283717/001/B
47
12 F - Water
(heavy rain events expected to occur at least once a year). Higher stormwater flow rates have been
experienced at the site for short durations during storm events.
Stormwater collected is directed to the secondary aeration pond, via a ‘first flush’ settling basin, where
it is treated and discharged to the Latrobe River under the EPA Licence (EM30021).
No significant change will result due to the works proposed.
Flooding
The Latrobe River is subject to flooding during large storm events (approximately one in every two
years). In these circumstances excess stormwater may overflow directly into the Latrobe River.
Approximately 40 ML/day of stormwater flow is required before overflow occurs. Stormwater overflow
is regulated under Waste Discharge Licence (EM30021). All overflows are reported to the EPA in the
monthly report.
River level flood history records the highest flood level as being reached during 1967. This flood is
estimated as a 1:40 year flood. Recent floods have approached 1:40 flood levels but during these
events no operational part of the mill was affected, although the No 2 Wastewater pond was
overtopped by flooding on two occasions (1995 and 1997) in the last twenty years. Samples supplied
to the EPA at the time of flooding showed that the overflows were within licensed limits.
The history of river flooding at the site shows that the Latrobe River is subject to flooding. There is little
risk and no track record of flooding of the operational mill, or any significant detrimental impacts due to
flooding. Environmental Impacts of river flooding overtopping into the waste water treatment ponds
have been shown to be relatively minor. No process is linked to the level of water in the river.
No change will result due to the works proposed.
48
43283717/001/B
13
G - Land and Groundwater
13.1
13
Discharge or Deposit to Land
As stated in Section 7.3, the following solid waste will be disposed to landfill from the proposed DIP
plant:
1. Detrasher waste, consisting of glass, sand, grit, plastic, metal and fibre, which is separated from
the incoming waste paper supply at the start of the DIP plant process. The expected waste quantity
is 3,434 ADt/year.
The detrasher waste quantity of approximately 3,434 ADt/yr is about 4% of the incoming feed rate,
based on 81,000 t/year of waste paper.
13.2
Best Practise Land and Groundwater Management
Best practise with respect to minimising generation of waste was discussed in Section C (Chapter 11)
above. One waste stream will be landfilled, with plans to send it to the EPA-Licenced landfill operated
by Maddingley Brown Coal Pty Ltd at Bacchus Marsh.
It is not expected that wastes generated from the proposed DIP plant will be disposed in the on-site
landfill, however a summary is included here for completeness.
The new eastern extension to the existing landfill at AP is planned to open in 2014, and has been
designed to meet current EPA best practise guidelines. It will be licensed to accept industrial waste
and Category C prescribed wastes. It is not anticipated to increase solid waste volumes to Landfill.
The Maryvale Mill’s EPA licence allows for solid waste landfill disposal at the site. Cleanaway Ltd.
operates the landfill site under an agreement with AP as well as an associated waste recovery plant.
The landfill site is located approximately 750 metres east of the manufacturing site and north of the
Traralgon West Road. Current landfill operations are being conducted in purpose made cells
constructed in 2008. The landfill was fitted with a methane collection system in 2004, however,
generation rates are low so that energy recovery has not proved viable, and so the collected gas is
flared. Groundwater and leachate monitoring systems are in place.
Waste disposal to the onsite landfill and storage during 2011 was approximately 0.024 m3 per tonne of
paper produced. This is compared with a total waste disposal to the onsite landfill during 2008 of
approximately 0.156 m3 per tonne of paper produced. (Note the volumes referred to are ‘as delivered’
before compaction in the landfill).
It is not anticipated that there will be discharges to land or groundwater from the new DIP facility.
13.3
Impact on Land and Groundwater
Impacts to land and groundwater from the disposal of DIP plant sludge to the Bacchus March landfill is
beyond the scope of the DIP plant project. It is assumed that impacts will be managed as part of that
site’s EPA Licence, performance against which is subject to regular independent audit.
43283717/001/B
49
14
I - Environmental Management
14.1
Non-routine Operations
14.1.1
Steps taken to identify potential process upsets or failures
A Hazard Operability (HAZOP) assessment was undertaken on 24th May 2012 to identify potential
process upsets that may occur during operation of the proposed DIP plant. This HAZOP was a level 2
review which was directed at overall risks associated with the DIP Plant and the Wet Lap separately,
followed by an overview. The HAZOP report and associated recommendations is included in
Appendix H. The majority of the discussion was centred on issues that were unresolved within the
Design Process. For this project, detail issues associated with the process design will be included in
the P&ID related HAZOP, planned for later in 2012 once the project is approved by NPI.
Installation Specific Trigger Words included:








External Fire & Explosion
Internal Fire & Explosion
Confined Building Explosion
Explosive Decomposition & Detonation
Physical Over/Under Pressure
Toxic or Harmful Exposure
Violent Energy Release
Exposure to Damaging Energy
Overview Trigger Words included:
















Environment
Materials & Hazards
Major Risk Factors
Electrical Hazards
Structural Issues
Waste Disposal
Risk to Existing facilities
Risk from Existing facilities
Health & Toxicology
Transport & Siting
Consultation with External Authorities
Management Arrangement
Safety Criteria
Emergency facilities
Technical Standards
Staff
Recommendations
Thirty six (36) recommendations were made during the session and are included in the HAZOP report
in Appendix H. Recommendations were made recognising that the risk response strategy may be
inadequate, or at this stage only partially progressed or yet to progress.
50
43283717/001/B
14
14 I - Environmental Management
A summary of the recommendations relating to environmental issues is included in Table 14-1.
Table 14-1
Relevant HAZOP Recommendations
Type of risk
Potential
environmental
impact
Measures to reduce likelihood and impact
Fire (both internal and
external),
Waste
Air
Investigate training staff with new dangerous material in FAS
Consider the bunding requirements for the peroxide day tank
Wastewater
Environmental impacts
Waste
Stormwater
Air
Discuss providing waste paper litter containment to prevent fire
hazard, contamination and housekeeping issues.
Resolve how storm water is collected from the outside concrete
pad. Resolve how to avoid waste paper contamination of storm
water release.
Investigate adequate protection measures for the “Far Western”
drain.
Risk to existing facilities
Noise
Noise of mobile equipment in this area needs to be considered
as part of the environmental impact study.
Health and Toxicology
Air
Include adequate ventilation for buildings where equipment will
be operating inside.
Waste Disposal
Waste
Review waste removal logistics. Compaction now or in the
future should be considered. Consider location to avoid existing
traffic management issues in this area.
Develop operations and manning plan for the DIP and wetlap
areas, including solid waste disposal.
Quality management
14.1.2
All
Ensure compliance with site quality system, ISO14001 plant risk
assessments, operation task risk assessments and maintenance
task assessments.
Managing environmental risks
AP has applied best practice through applying a hierarchy of control to the potential process failures
and risks identified during the HAZOP. The hierarchy is nominally: - prevention by engineering >
ensure early response and prevention by alerting operators > minimise risks if they occur and develop
plans and training.
The site EMS process is also used to identify and manage potential environmental risks.
Chemical storage
The typical chemicals that will be used in the proposed DIP plant are summarised in Appendix G –
Table 1. Appendix G also contains a copy of all of the chemical MSDSs.
The use and storage of chemicals has been designed to prevent incidents. Existing bulk storages will
be utilised (e.g. for caustic soda and hydrogen peroxide) and a smaller chemical area adjacent to the
DIP plant will be constructed using appropriate bunding and in accordance with dangerous goods
storage requirements. The external chemical storage area will include:
43283717/001/B
51
Table 14-2
External chemical storage
Chemical
Storage Tank Size
Comments
Sodium Silicate
60 m3
Relocated tank from Fairfield
3
Hydrogen Peroxide
6m
Sodium Hydroxide 10%
15 m3
Pumped to DIP day tank area from existing bulk
storage
Made down to 10% at existing bulk chemicals area &
pumped to DIP day tank.
The other chemicals (surfactant, defoamer, coagulant, flocculent, biocide, fungicide #1 and #2) will be
stored in packages / bulk containers inside the building located on their own portable bunds.
The proposed DIP plant will involve the use of one new chemical to the site - Formamidine Sulfinic
acid (FAS), or thiourea dioxide. This chemical is a major hazard chemical due to its potential to
spontaneously combust if moist. FAS (a powder) will have a dedicated dry storage room with a makedown tank for metering purposes. The quantity stored on site will be limited to 2-3 tonnes.
The dangerous goods chemicals bunds will have closed drains that are connected to the wastewater
effluent system (river). The contents of the bunds will be tested prior to disposal. If there is a spill the
chemical will be treated and disposed as directed in the MSDS and by the Mill’s Spill Containment
Procedures. Building and waste area drainage will be connected to the stormwater system, which
ultimately discharges to the river. Wastewater litter will be prevented from entering the stormwater
system by strainers.
Surrounding land users
The Maryvale Mill is situated in a rural environment. This means there is a natural buffer between the
manufacturing and storage areas and the local community. The Maryvale Mill is centrally located
between three major townships: Traralgon (11 km east, population 24,000), Morwell (9 km south,
population 19,000) and Moe (29 km to west, population 16,800, including the smaller township of
Newborough). Smaller townships in close proximity are Tyers (8 km northeast of the site, population
250) and Yallourn North (14 km northwest of the site, population 1,200).
The townships of Traralgon, east of the site and Tyers, northeast of the site, are downwind of most of
the prevailing wind conditions experienced in the local area. In addition, easterly winds associated with
sea breezes have the potential to impact on Moe.
The nearest residences are farmhouses located on Old Melbourne Road about 2 km to the south.
Land use and residences located within 4 km of the centre of the site are summarised in Table 14-3
below:
Table 14-3
Distance to surrounding land uses
Distance
Description
Direction
<1km
Maryvale Sports Oval
South
Grand Ridge Plantations Pine Plantation
West
Pine Gully Reservoir (Gippsland Water)
West
Sewage Storage Ponds (Gippsland Water)
South
Grand Ridge Plantations Offices
South
1-2km
52
43283717/001/B
Distance
2-3km
2-3km continued
3-4km
Description
Direction
Sand Quarries
East
Latrobe River
North
Farmhouses
South
4 residential properties
Southwest
Northwest
Bark plant (PineGro)
West
Northwest
West
East
Southeast
Morwell Golf Course
Southwest
Chicken farm
West
Latrobe Valley Airport
Southeast
Sandbank Recreational Reserve
Northeast
Buffer distances
The buffer distance to residents of the Maryvale Mill site exceeds the recommended buffer distance of
5 km for paper and pulp mills that combust sulphur, in EPA Publication ‘AQ2-86 Recommended Buffer
Distances for Industrial Residual Air Emissions’.
The nearest residences are farmhouses located on Old Melbourne Road about 2 km away. It should
be noted that the Maryvale Mill and the nearest residential premises predate the Buffer Distance
Guidelines (1990).
The Guidelines state that if a premises has been located on a site with an inadequate buffer distance,
subsequent remedial action to alleviate offsite effects either within or beyond the buffer distance will
be required if residual emissions episodes occur.
Amenity impacts on residents arising from site operations are therefore managed in a number of ways,
including implementation of process controls, regular community consultation committee meetings
(see Section 4.3), and continuous review and improvement processes such as the site EMS. The
proposed new plant is expected to have minimal impact on noise and odour at residential receptors.
14.2
Monitoring
The proposed DIP plant will be incorporated into existing AP environmental management systems,
programs and plans.
The operation of the plant will be managed with a distributed control system (DCS) which coordinates
the equipment operation and ratios the chemical additions to a set production rate. The DCS has
programmed interlocks and alarms to optimise the efficiency and safety of the process. The current
Fairfield Plant also has on-line consistency and brightness measurement to facilitate this.
AP is intending to add an additional on-line brightness meter and dirt measurement. This is will trigger
a bypass of off-grade DIP to reprocessing if the quality specification is not achieved.
43283717/001/B
53
As with the existing Maryvale plant, there will be a test room that verifies the accuracy of process
instruments such as consistency and brightness during the plant’s operation. Parameters such as
freeness, residual ink (ERIC) and dirt will tested each operating shift, by the process operators.
As with other operating units (e.g. Paper machines & Pulp Mills) on site there will be a sampling facility
installed on the DIP wastewater discharge point. The effluent will be tested during commissioning for
the parameters that are likely to impact on the Waste Water Treatment system. Process indicators will
be confirmed during commissioning and controls established. Final wastewater discharge monitoring
with the DIP operating will be managed as part of the overall site monitoring program for the EPA
Licence.
As noted in Section 14.1.1 above, the detailed process HAZOP is planned for later in 2012, and will
identify any additional DIP process monitoring and controls necessary to minimise risks from nonroutine operations.
54
43283717/001/B
Appendix A Figures
43283717/001/B
A
N
W
E
S
FIGURE 1A
FIGURE 1B
Note:
No wastewater from the
proposed development
flows to the Gippsland
Lakes Ramsar area.
MEL
FIGURE 1C
Source:
AUSTRALIAN
PAPER
PTY LTD
EPA WORKS APPROVAL APPLICATION
MARYVALE PAPER MILL
43283717-figure 1.dwg
LOCATION MAPS
SHOWING AREAS OF INTEREST
-
N
W
E
S
MEL
AUSTRALIAN PAPER
MARYVALE MILL
MORWELL
Source:
AUSTRALIAN
PAPER
PTY LTD
MARYVALE PAPER MILL
DETAILED LOCATION MAP
-
N
W
E
MEL
S
Source:
AUSTRALIAN
PAPER
PTY LTD
MARYVALE PAPER MILL
ZONING MAP
-
This drawing is subject to COPYRIGHT.
N
W
E
SUZ1
Special Use Zone
S
FZ
Farming Zone
2 Kilometres radius
PCRZ
FZ
SUZ1
La
Tr o
b
Public Conservation and Resource
IN2Z
Industrial 2 Zone
RDZ1
Road Category 1 Zone
PUZ1
Public Use Zone - Service and Utility
e
R
iv
e
r
PCRZ
(TA NJ IL
EA ST
ROA D)
RDZ1
ROA D
FZ
RDZ1
IN2Z
A
D
TRA RA L GO
N
WE
ST
RO
MA RYV
ALE
SUZ1
PUZ1
LWEL
MOR
YVA L E ROA D
MA R
FZ
SUZ5
OL D
J:\JOBS\43283717\6 Deliv\figures
PUZ1
RDZ1
PUZ4
MEL
BO
URN
E
RO A D
SUZ7
FZ
FZ
Source:
Whilst every care is taken by URS to ensure the accuracy of the digital data, URS makes no representation or warranties about its accuracy, reliability, completeness, suitability for any particular purpose and disclaims all responsibility and liability (including without limitation, liability in negligence) for any expenses,
losses, damages (including indirect or consequential damage) and costs which may be incurred as a result of data being inaccurate in any way for any reason. Electronic files are provided for information only. The data in these files is not controlled or subject to automatic updates for users outside of URS.
AUSTRALIAN
PAPER
PTY LTD
MARYVALE PAPER MILL
File No: 43283717-Figure 4.cdr
Drawn: BKH
Approved: RH
0
0.5
1
Kilometers
Date: 15/06/2012
LOCATION PLAN
Figure:
4
Rev. A
A3
MEL
AUSTRALIAN
PAPER
PTY LTD
MARYVALE PAPER MILL
DIP PLANT
SITE LAYOUT PLAN
(NEW WORKS LOCATION)
-
MEL
AUSTRALIAN
PAPER
PTY LTD
MARYVALE PAPER MILL
DIP PLANT
SITE LAYOUT PLAN
(TIE IN LOCATIONS)
-
MEL
AUSTRALIAN
PAPER
PTY LTD
MARYVALE PAPER MILL
DIP PLANT
SITE LAYOUT PLAN
(PLAN ACCESS ROAD LAYOUT)
-
MEL
AUSTRALIAN
PAPER
PTY LTD
MARYVALE PAPER MILL
DIP PLANT
LAYOUT PLAN
-
MEL
AUSTRALIAN
PAPER
PTY LTD
MARYVALE PAPER MILL
DIP PLANT
LAYOUT PLAN
(GROUND FLOOR LAYOUT)
-
MEL
AUSTRALIAN
PAPER
PTY LTD
MARYVALE PAPER MILL
DIP PLANT
LAYOUT PLAN
(FIRST FLOOR LAYOUT)
-
MEL
AUSTRALIAN
PAPER
PTY LTD
MARYVALE PAPER MILL
DIP PLANT
LAYOUT PLAN
(PLATOFRM LEVELS)
-
MEL
AUSTRALIAN
PAPER
PTY LTD
MARYVALE PAPER MILL
DIP PLANT
LAYOUT PLAN
(ELEVATION PLAN)
-
MEL
AUSTRALIAN
PAPER
PTY LTD
MARYVALE PAPER MILL
PULP LAPPING AND
BALING BUILDING LAYOUT
(PROPOSED WETLAP MACHINE LAYOUT & ELEVATIONS)
-
N
W
E
MEL
S
AUSTRALIAN
PAPER
PTY LTD
MARYVALE PAPER MILL
DIP PLANT
LOCATION OPTIONS
-
MEL
AUSTRALIAN
PAPER
PTY LTD
MARYVALE PAPER MILL
43283717-FIG 8.dwg
DIP PLANT
SITE LAYOUT PLAN
(PROPOSED TRUCK ROUTE AND CAR PARKING)
-
Appendix B Communication Plan
43283717/001/B
B
Effectively Engage Local
Community on DIP Project
Objectives
Satisfy EPA Works Approval
Community Engagement
requirements
Primary
Inform
IAP2 Spectrum
CCC
Consult
Rohan Wilks
Jenine Smith
Team
Ann Collins
Indri May
Craig Dunn
Shaun Scallan
Susanna York
EPA
Assistance
CCC
Marg Renwick
John Hehir
Gippsland Water
Latrobe City
Jenny Hammett
Geoff Hill
Regular Quarterly Meeting
23rd May 2012
CEO Overview
CCC
Special DIP Project Meeting
Sustainability Aspects
Regulatory and Monitoring Overview
Project Overview
Traralgon
Where
Morwell
Display Stations
AP staff in attendance
Logistics
DIP Project Community Liaison
What
Open House Project Space
Materials available to take
Contact and follow up register
Samples?
Latrobe Valley Express
Tea/Coffee/Water and biscuits
Print
Radio
When
Media
Mid-late June 2012
WinTV
ABC Regional
Provide access to information to local community
TV
1.1. Understand your objective and develop a work plan
Objectives
Elicit feedback
Gather contact details for follow up comms
Traralgon
1.2. Schedule a place and time
Activities
Morwell
Latrobe Valley Express
Interest piece
Advert
1.3. Advertise
ABC Radio
Open House
Interest piece
One Pager Project Overview
One Pager benefits
Article for internal newsletter
Article for local press
Advert for local press
Article for trade press
Process Flow Diagram
1.4. Develop the display and support materials
Incoming waste at Fairfield
Process Equipment
Pictures
Control Room
Output of plant
Map of site showing location
Air, Land & Water Impacts
Walk through the elements of the project
1.5. Set up
Elements at display stations
1.6 Review Effectiveness
1.7 Lessons learnt
Market Stall
Other Community Events
DIP Project Community Liaison.mmap - 12/06/2012 - Shaun Scallan
Pulp
Bales
AP: Strategic Sustainability
DIP Plant Feasibility
Community Engagement Overview
Agenda – Community Engagement Overview
•
•
•
•
2
Approach
Process
Progress
Next Steps
2
Approach
• AP to develop a community engagement plan.
• Objective To maximise communication to public to
minimise objections to ensure timely approval
• CCC is the key to engagement
• Broader stakeholder group to be included
–
3
Not just local community
3
Progress – Local Community
• April 19th Initial Meeting of Stakeholder Group
–
–
Works Approval
Planning Approval
• May 16th Special CCC on DIP Plant
• Wombat Strategy Overview
• Sustainability Aspects of DIP Project
• Environmental Monitoring and Benchmarking
• DIP Project Overview
6
6
Progress – Broader Stakeholders
• 30th March Press Release on DIP Feasibility
• April/May
–
–
–
Briefings of Stakeholder Groups on Wombat Strategy
Government, ENGO’s, Social groups
www.onpaper.com.au launched
• May 18th – Recycled Paper Pledge
–
–
7
www.onpaper.com.au
Promotion of this through social networks
7
MindMap
Stakeholder
Identification
8
8
Next Steps
• Community Engagement
–
–
Based on IAP2 engagement approach
Open House
•
•
•
•
–
Shopping Centre Display
Timing Fri/Saturday
Project Displays with staff on hand
Handouts on project and company information
Promotion through local media
• Latrobe Valley Express – General interest + advertising
• ABC Regional Radio – General interest
–
Internet Promotion
• Recycled Paper Pledge www.onpaper.com.au
9
9
Conclusion
• Sign up at www.onpaper.com.au
10
10
Appendix C Process and Equipment
43283717/001/B
C
Appendix C - Process and Equipment
Table C-1
Process Summary
Key process steps
Key inputs
Step 1 – Pulping

Recovered paper
Recovered paper is dewired then mixed with water in pulpers to produce a slurry/pulp. Surfactants are added at this
point.

Surfactants Recycled
water from DAF
Step 2 – Detrashing
Key outputs

Detrasher waste
(plastics, glass)

Cleaner rejects
(sand)

Solid waste (fibre and
ash), after dewatering
by drum screen and
screw press
The paper slurry is then passed through a coarse screen (Detrasher) and the rejected stream is sent to an equalisation
tank. Some solids are also directly rejected to waste from the detrasher.
Solids are settled out in the equalisation tank (underflow) and sent to detrasher waste, while the overflow is sent back to
the pulpers.
Some of the detrasher rejects pass from the equalisation tank to a coarse drum screen for further removal of large
contaminants. Coarse drum screen rejects are then sent to waste, while the accepted material (recovered pulp) is
pumped back through the Detrasher.
Step 3 – High Consistency Cleaning
The pulp undergoes centrifugal cleaning, where denser contaminants (mainly sand) in the pulp are separated out.
Step 4 – Coarse Screening
The pulp is forced through a series of screens with either round or narrow slot perforations. Fibres, clays, inks and small
contaminants will pass through the screens while coarse contaminants pass over the screen and are sent to the rejects
handling area.
Rotary screens followed by a screw press reduce the water content and thicken the paper slurry.
43283717/001/B
Key process steps
Key inputs
Step 6 – Oxidative Bleaching

Caustic soda
Caustic soda and hydrogen peroxide is used to brighten the pulp, selectively oxidising some of the ink dyes used in
paper. Sodium silicate is also added to aid the bleaching process.

Hydrogen peroxide

Sodium silicate
The pulp is mixed thoroughly with the bleaching chemicals in a kneader, where steam is injected to raise the
temperature and speed up the reaction. The pulp flows through a 175 m3 brightening tower. A two hour residence
time is required for complete reaction.

Low-pressure steam

Surfactant
Key outputs
Surfactant is added again at this point.
Step 7 – Flotation (1st round)

The pulp is diluted and is pumped through a series of deinking cells. Air is bubbled through each cell, collecting ink
particles with the help of surfactants added earlier in the process. A thick inky foam is formed which is removed from
the pulp and sent to the rejects handling area.
ash) after dewatering
by centrifuge

Centrifuge
wastewater to effluent

by centrifuge

Centrifuge

by drum screen and
screw press

Centrifuge
Step 8 – Fine Screening

Pulp is forced through a series of screens with narrower slots. Excluded contaminants are sent to the rejects handling
area.
Step 9 – Heavy Cleaning

A series of centrifuges are used to separate out small dense particles from the pulp, which are sent to the rejects
handling area.
A disc filter followed by a screw press reduces the water content and thickens the paper slurry, which is then kneaded
again.
43283717/001/B

Defoamer– into
centrifuge filtrate tank
Defoamer– into
centrifuge filtrate tank
Possibly a Complexing
agent
Key process steps
nd
Step 11 – Flotation (2
round)
Key inputs
Key outputs


by centrifuge

Centrifuge
Recycled water from DAF
Again, the pulp is diluted and is pumped through a series of deinking cells. Air is bubbled through each cell, collecting
ink particles with the help of complexing agents added earlier in the process. A thick inky foam is formed which is
removed from the pulp and sent to the rejects handling area.

Filtered water

Paper machine
backwater
Step 14 – Reductive Bleaching

Caustic soda
FAS (Formamidine Sulphinic Acid) is a reductive chemical used to modify any remaining chromophores in the pulp. The
pulp is steam heated to speed up the reaction over a 40 minute retention time.

FAS

Low-pressure steam

Paper machine
backwater

Biocide Paper machine
backwater
Step 12 – Washing
Filler particles such as clay and calcium carbonate are separated from the fibre by squirting a jet of very dilute pulp at
an open weave fabric running at high speed. The weave of the fabric allows the filler particles, dispersed ink particles
and some fibre debris to pass through, but retains the fibre.
Step 13 – Dewatering (1st Round)
A series of dewatering screws reduce the water content in the paper pulp
Step 15 – Dewatering (2nd Round)
Biocide is added to the pulp prior to this step.
A series of dewatering screws reduce the water content in the paper pulp.
Step 17 – Hot Stock (62%)
The majority of the DIP will be pumped to a DIP tank at the on-site pulp store for direct use in on-site paper machines
for making white paper.
43283717/001/B
Key process steps
Key inputs
Step 18 – Wetlap (38%)

Fungicide

Flocculent Coagulant
Key outputs
Approximately a third of DIP will be pumped to a wetlap feed tank supplying the new wetlap process, located in the
existing wetlap building.
Fungicide is added to the pulp prior to going to the wetlap press. There, the pulp is formed into a sheet, and water
pressed out of it. This sheet is cut, stacked and wired to form a bale of recycled pulp. These bales will be stored and
used 3-4 days per month for the production of 100% or 65% recycled paper products.
Rejects Handling
Rejects from around the plant are dewatered to produce sludge for disposal or reuse. The water removed is recycled in
the DIP plant directly or after processing by the dedicated DAF (Dissolved Air Flotation) units.
Water Treatment
Water used in the process is recycled within the plant for reuse in earlier stages.
There are two DAF units which use micro-bubbles to float off as much of the solids in the water as possible.
Flocculants and coagulants are added to aid this process.
The solids are sent to the rejects handling area while the clarified water is returned to the process for reuse.
Intermediate Water Storage
The following tanks provide intermediate storage for recycled water of differing grades:
White water storage tank (250m3)
This stores filtrate from the rotary screens and screw press in Step 5 - Thickening. This is pumped back to the
beginning of the process for reuse (Steps 1 – 4).
Cloudy Filtrate Tank (100m3)
Filtrate from the disc filter in Step 10 - Thickening and treated water from DAF are stored here before reuse in Step 7.
Clear Filtrate Tank (60m3)
Filtrate from the disc filter in Step 10 - Thickening and filter water are stored here before reuse in Steps 8 - 10.
Filtered Water Tank (10m3)
Filtered water and other water streams (water flush tank overflow, condensate and cooling water from screw presses
etc.) is stored here before use in Step 12 – Washing.
43283717/001/B
Defoamer

Process water for
reuse in Dip plant
Table C-2
Equipment List, Fairfield De-Inking & Wet Lap Relocation
Process step
PULPING
Description
High Consistency Pulper No.1 25m3
Size
KW
Installed
25m3
Sum of
KW
1124.94
High Consistency Pulper No.1 Gearbox
High Consistency Pulper No.1 Motor No.1
520.00
0.37
1.10
Wastepaper Conveyor No.2
Wastepaper Conveyor No.2 Hydraulic Pack
Wastepaper Conveyor No.2 hydraulic Pack
(Pump) Motor
37.00
Dewiring Unit Conveyor
Bale Dewiring Unit Conveyor Motor
45.00
Bale Dewiring Unit
Bale Dewiring Unit Conveyor Oil Reservoir
(&Fan)
Wastepaper Conveyor No.1
High Consistency Pulper No.2 25m3
25m3
High Consistency Pulper No.2 Gearbox
520.00
0.37
1.10
DETRASHING
355.50
Detrasher 8mm
8mm
Detrasher Motor
90.00
Pulper Dump Chest Centrifugal Pump
Pulper Dump Chest Centrifugal Pump Motor
90.00
Equalising Tank 13m3
13m3
Coarse Rejects Drum Screen
10mm
holes
Coarse Rejects Drum Screen Motor
7.50
Coarse Drum Screen Accepts Tank
Coarse Drum Screen Accepts Return Centrifugal
Pump
Coarse Drum Screen Accepts Return Centrifugal
Pump Motor
43283717/001/B
37.00
Process step
Description
Pulper Dump Chest No.1
Size
KW
Installed
Sum of
KW
114m3
Pulper Dump Chest No.1 Agitator 'A'
Pulper Dump Chest No.1 Agitator 'A' Motor
30.00
Pulper Dump Chest No.1 Agitator 'B'
Pulper Dump Chest No.1 Agitator 'B' Motor
Pulper Dump Chest No.2
30.00
114m3
Pulper Dump Chest No.2 Agitator 'A'
Pulper Dump Chest No.2 Agitator 'A' Motor
30.00
Pulper Dump Chest No.2 Agitator 'B'
Pulper Dump Chest No.2 Agitator 'B' Motor
30.00
HC Cleaner Feed tank Centrifugal Pump
HC Cleaner Feed tank Centrifugal Pump Motor
11.00
High Consistency
Cleaning
75.00
High Consistency Cleaner Feed Tank
15m3
High Consistency Cleaner Feed Tank Agitator
NOT INSTALLED
High Consistency Cleaner Feed Tank Agitator
Motor NOT INSTALLED
x
Centrifugal Pump
Centrifugal Pump Motor
75.00
High Consistency Cleaner No.1
High Consistency Cleaner No.2
Coarse screening
High Consistency Screen Reject Tank No.1
10m3
112.00
Agitator
Agitator Motor
5.50
Secondary High Consistency Screen Holes
Feed Pump
11.00
High Consistency Screens Head Box No.1
4m3
Primary High Consistency Screen Slots Feed
Pump
Primary High Consistency Screen Slots Feed
Pump Motor
43283717/001/B
75.00
Process step
Description
High Consistency Screen Rejects Tank No.2
Size
KW
Installed
Sum of
KW
10m3
Agitator
Agitator Motor
5.50
High Consistency Protection Cleaners Feed
Pump
High Consistency Protection Cleaners Feed
Pump Motor
15.00
Protection High Consistency Cleaner
High Consistency Screen Head Box No 2 (4m3)
Thickening (1)
19.00
No.1 Rotary Screen Thickener
No.1 Rotary Screen Thickener Screw Drive 1
4.00
5.50
No.2 Rotary Screen Thickener
Thickening (2)
4.00
5.50
No.1 Screw Press
1534.20
No.1 Screw Press Hydraulic Power Pack
200.00
No.1 Kneader Feed Screw Conveyor
No.1 Kneader Feed Screw Conveyor Motor
22.00
No.1 Kneader
No.1 Kneader Main Drive
1100.00
No.1 Kneader Hydraulic Power Pack
No.1 Screw Press Filtrate Tank
2.20
20m3
No.1 Screw Press Filtrate Tank Discharge Pump
No.1 Screw Press Filtrate Tank Discharge Pump
Motor
No.1 Kneader Dilution Pulper
45.00
6m3
No.1 Kneader Dilution Pulper Agitator
110.00
Dilution Pulper Discharge Pump
Dilution Pulper Discharge Pump Motor
Primary De-inking Cell Head Box No.3
43283717/001/B
55.00
4m3
Process step
Description
Size
KW
Installed
Floatation
862.00
No.1 Primary Deinking Cell Feed Pump Dilution
Water Tank
No.1 Primary Deinking Cell Feed Pump Motor
110.00
No.1 Primary Deinking Cell Feed Pump
No.1 Primary Deinking Cell Separator
No.1 Primary Deinking Cell Vacuum Drive
No.1 Primary Deinking Cell Vacuum Drive Motor
30.00
No.1 Primary Deinking Cell
132.00
Deinked Stock Chest
60m3
Primary Deinking Cells No.2 & 3 Separator
132.00
Primary Heavy Rejects Cleaners Feed Pump
Primary Heavy Rejects Cleaners Feed Pump
Motor
150.00
No.3 Primary Deinking Cell Recirculating Pump
No.3 Primary Deinking Cell Recirculating Pump
Motor
30.00
No.2 & No.3 Primary Deinking Cells Vacuum
Drive
No.2 & No.3 Primary Deinking Cells Vacuum
Drive Motor
Secondary Deinking Cell Foam Chest
75.00
20m3
Primary Deinking Cells Foam Chest
Secondary Deinking Cell Feed Pump
Secondary Deinking Cell Feed Pump Motor
No.1 Centrifuge Feed Pump
No.1 Centrifuge Feed Pump Motor
No.2 Centrifuge Feed Pump
No.2 Centrifuge Feed Pump Motor
Secondary Deinking Cell
43283717/001/B
Sum of
KW
90.00
Process step
Description
Size
KW
Installed
Sum of
KW
Secondary Deinking Cell Discharge Pump
Secondary Deinking Cell Discharge Pump Motor
90.00
Secondary Deinking Cell Separator
Secondary Deinking Cell Foam Chest Agitator
Secondary Deinking Cell Foam Chest Agitator
Motor
5.50
Primary Deinking Cells Foam Chest Agitator
Primary Deinking Cells Foam Chest Agitator
Motor
7.50
Secondary Deinking Cell Blower/Vacuum Drive
Secondary Deinking Cell Vacuum Drive Motor
10.00
Heavy cleaning
92.00
Heavy Rejects Cleaners Dilution Tank
Primary Heavy Rejects Cleaners 40 Cleaners
Secondary Heavy Rejects Cleaners 15 Cleaners
Tertiary Heavy Rejects Cleaners 7 Cleaners
4th Stage Heavy Rejects Cleaners 3 Cleaners
Fiberwiser 2 Cleaners
4th Stage Heavy Rejects Cleaners Feed Pump
4th Stage Heavy Rejects Cleaners Feed Pump
Motor
15.00
Tertiary Heavy Rejects Cleaners Feed Pump
Tertiary Heavy Rejects Cleaners Feed Pump
Motor
22.00
Secondary Heavy Rejects Cleaners Feed Pump
Secondary Heavy Rejects Cleaners Feed Pump
Motor
Fine Screening
55.00
Gyrocleans Accepts Tank ( Joined by equalizing
valve to Gyroclean Feed Tank)
30m3
Gyroclean Feed Tank ( Joined by equalizing
valve to Gyroclean Accepts Tank)
30m3
284.50
Primary Low Consistency Screen Feed Pump
Primary Low Consistency Screen Feed Pump
Motor
200.00
Stage 1 Fine Screen Deaeration Tube
10m3
5m3
Secondary Low Consistency Screen Feed Pump
Secondary Low Consistency Screen Feed Pump
Motor
43283717/001/B
55.00
Process step
Description
Size
KW
Installed
Sum of
KW
Tertiary Low Consistency Screen Feed Pump
Tertiary Low Consistency Screen Feed Pump
Motor
22.00
5m3
4th Stage Low Consistency Screen Feed Pump
4th Stage Low Consistency Screen Feed Pump
Motor
Water treatment
7.50
Filtered Water Tank
100m3
Clear Filtrate Tank
60m3
Cloudy Filtrate Tank
30m3
Filtered Water Pump High Pressure (35 bar)
Motor
743.12
45.00
Filtered Water Pump Bottom Fabric Washer
Filtered Water Pump Bottom Fabric Washer
Motor
30.00
Filtered Water Pump Top Fabric Washer
Filtered Water Pump Top Fabric Washer Motor
90.00
Clear Water Pump H.C. Screens Flush
Clear Water Pump H.C. Screens Flush Motor
45.00
Clear Water Pump H.D. Cleaners & Sprays
Clear Water Pump H.D. Cleaners & Sprays
Motor
45.00
Filtered Water Pump Seal Water (6 bar)
Filtered Water Pump Seal Water (6 bar) Motor
30.00
Clear Water Pump High Volume Wash (6.5 bar)
Clear Water Pump High Volume Wash (6.5 bar)
Motor
Clear Water Pump Dilution Services Motor
45.00
110.00
Clear Water Pump Dilution Services
Clear Water Pump Disc Filter Spray
Clear Water Pump Disc Filter Spray Motor
45.00
Cloudy Water Pump Consistency Water
Cloudy Water Pump Consistency Water Motor
30.00
Cloudy Water Pump Makeup Water
Cloudy Water Pump Makeup Water Motor
Cloudy Water Pump Deinking Dilution Tank
Feed Pump
43283717/001/B
45.00
Process step
Description
Size
Cloudy Water Pump Deinking Dilution Tank
Feed Pump Motor
KW
Installed
Sum of
KW
18.50
Filter 1
Filter 2
White Water Storage Chest
225m3
White Water Chest to No.2 Pulper Feed Pump
White Water Chest to No.2 Pulper Feed Pump
Motor
37.00
White Water chest to No.1 Pulper Feed Pump
White Water chest to No.1 Pulper Feed Pump
Motor
37.00
Disk Filter
No.1 DAF Bridge Drive
0.37
No.1 DAF
No.1 DAF Scoop Drive
0.55
Compressor
No.1 & No.2 DAFS Air Compressor
5.50
Accumulator
Saturation Tank
No.1 DAF Saturation Pump
No.1 DAF Saturation Pump Motor
45.00
No.1 DAF & Rejects Tank Discharge Pump
No.1 DAF & Rejects Tank Discharge Pump
Motor
2.20
No.1 DAF Feed Chest
60m3
No.1 DAF Filtrate Chest
60m3
No.1 DAF Filtrate to Cloudy Water Pump
No.1 DAF Filtrate to Cloudy Water Pump Motor
22.00
No.1 DAF Feed Pump
No.1 DAF Feed Pump Motor
15.00
No.1 DAF and 4th Stage Fine Screen Rejects
Tank
Thickening (2)
Screw Press 2 Feed Standpipe
143.40
Disc Filter S/Pipe Vacuum Discharge Motor
55.00
Disc Filter S/Pipe Agitator
30.00
Disc Filter S/Pipe Discharge Pump
43283717/001/B
5m3
Process step
Description
Size
KW
Installed
Sum of
KW
Disc Filter S/Pipe Vacuum Pump
Disc Filter S/Pipe Vacuum Pump Motor
5.50
No.1 DAF Filtrate Discharge Pump
No.1 DAF Filtrate Discharge Pump Motor
37.00
Disc Filter Main Drive
7.50
Disc Filter Spray Oscillator
0.90
Disc Filter Discharge Screw Conveyor
7.50
Oxidative
Bleaching
1459.20
No.2 Kneader
Hydraulic Unit Motor/No.2 Screw Press
Hydraulic Power Pack
200.00
Brightening Tower Dilution Screw Conveyor
No.1
Brightening Tower Dilution Screw Conveyor
No.2
Brightening Tower
175m3
Brightening Feed Screw Conveyor No.3
Brightening Tower Support Frame
Brightening Tower Discharge Screw Conveyor
22.00
Brightening Tower No.2 Main Drive
15.00
15.00
15.00
Bright. Tower FD No.2 Screw Conv.
22.00
11.00
Brightening Tower Vertical Lift Discharge Screw
Conveyor
Dispersed Stock Tank
Dispersed Stock Tank Agitator Motor
4.00
20m3
15.00
Dispersed Stock Tank Agitator
Brightening Tower Vertical Discharge Screw
Conveyor
43283717/001/B
15.00
Process step
Description
Size
No.2 Kneader Lube Oil Pump
KW
Installed
Sum of
KW
2.20
No.2 Kneader Main Drive
1100.00
4.00
No.2 Screw Press
4.00
Dispersed Stock Tank Discharge Pump Motor
15.00
Dispersed Stock Tank Discharge Pump
Washing
75.00
Washers Feed Pump
Washers Feed Pump Motor
DAF
75.00
Post Deinking Cell Feed Pump
392.60
Post Deinking Cell Feed Pump Motor
132.00
No.2 DAF Filtrate Chest Discharge Pump
No.2 DAF Filtrate Chest Discharge Pump Motor
No.2 DAF Filtrate Chest
22.00
50m3
Post Deinking Cell Recirculating Pump
Post Deinking Cell Recirculating Pump Motor
30.00
Post Deinking Cell Vacuum Drive Motor
Post Deinking Cell Vacuum Drive
30.00
No.2 DAF
No.2 DAF Scoop Drive
1.50
No.2 DAF Bridge Drive
1.10
No.2 DAF Rejects Tank
5m3
No.2 DAF Rejects Tank Discharge Pump
No.2 DAF Rejects Tank Discharge Pump Motor
11.00
Saturation Tank
No.2 DAF Saturation Tank Feed Pump
No.2 DAF Saturation Tank Feed Pump Motor
150.00
No.2 DAF Feed Pump
No.2 DAF Feed Pump Motor
Washing
No.1 Washer
No.1 Washer Main Drive
43283717/001/B
15.00
123.05
55.00
Process step
Description
Size
KW
Installed
No.1 Washer Oscillator
0.18
No.1 Washer Take-up Doctor
0.37
Sum of
KW
No.2 DAF Feed Chest Agitator
No.2 DAF Feed Chest Agitator Motor
No.2 DAF Feed Chest
7.50
50m3
Washed Thickened Stock Chest Discharge
Pump
Washed Thickened Stock Chest Discharge
Pump Motor
30.00
Washed Thickened Stock Chest Agitator
Washed Thickened Stock Chest Agitator Motor
30.00
Washers Thickened Stock Chest
Dewatering (1)
No.1 Dewatering Screw
81.00
No.1 Dewatering Screw Drive Motor
11.00
11.00
11.00
11.00
11.00
11.00
Dewatering Screws Dilution Conveyor
Dewatering Screws Dilution Conveyor Motor
7.50
Head Tank
Dewatering Screws Filtrate Tank
5m3
Dewatering Screws Filtrate Tank Discharge
Pump
Dewatering Screws Filtrate Tank Discharge
Pump Motor
7.50
Reductive
bleaching
559.37
Brightening Pipe
Brightening Pipe Standpipe Agitator
43283717/001/B
40m3
30.00
Process step
Description
Size
KW
Installed
Sum of
KW
Brightening Pipe Discharge Pump
Brightening Pipe Discharge Pump Motor
90.00
Brightening Pipe Standpipe Vacuum Pump
Brightening Pipe Standpipe Vacuum Pump
Motor
5.50
Brightened Stock Tank No.1
50m3
Brightened Stock Tank No.2
30m3
Brightened Stock Tank No.2 Agitator
Brightened Stock Tank No.2 Agitator Motor
18.50
Brightened Stock Tank No.2 Discharge Pump
Brightened Stock Tank No.2 Discharge Pump
Motor
75.00
Brightening Pipe MC Pump Standpipe
Storage Silo
Silo Agitator
Silo Agitator Pump
75.00
Silo Stock Pump
Silo Stock Pump Motor
90.00
No.3 Machine Stock Pump
No.3 Machine Stock Pump Motor
75.00
Silo Dilution Water Tank
Dilution Water Pump Motor
45.00
Dilution Water Pump
Silo Outlet Dilution Pump
Silo Outlet Dilution Pump Motor
55.00
Consistency Transmitter NOT IN USE
0.37
Wet lap
548.72
Wet Lap Feed Tank
120m3
Wet Lap Feed Tank Agitator
Wet Lap Feed Tank Agitator Motor
75.00
Wet Lap Feed Tank Feed Pump
Wet Lap Feed Tank Feed Pump Motor
Wet Lap Filtrate Tank
43283717/001/B
45.00
50m3
Process step
Description
Size
KW
Installed
Wet Lap Filtrate Tank Discharge Pump No.2
Motor
45.00
Motor
45.00
Wet Lap Consistency Transmitter
0.37
Blower
Wet Lap Press Vacuum Drive
2.20
Wet Lap Double Wire Press Package
Wet Lap Press Top Wire Main Drive
30.00
Wet Lap Press Bottom Wire Main Drive
30.00
Wet Lap Press Auxiliary Top Wire Drive
22.00
Wet Lap Press Auxiliary Bottom Wire Drive
22.00
Wet Lap Press Tailcutter
0.25
Transfer Conveyor
2.20
Cutter Laybory Fly Knife Drive
22.00
Wet Lap Cutter Layboy Vacuum Drive
Wet Lap Cutter Layboy Vacuum Drive Motor
11.00
Wet Lap Broke Conv.
Wet Lap Broke Screw Conveyor
Wetlap Broke Pulper
Wet Lap Broke Pulper Agitator
18.50
11m3
110.00
Wet Lap Broke Pulper Discharge Pump
Wet Lap Broke Pulper Discharge Pump Motor
30.00
Baling Line Package
Belt Conveyor
2.20
Wet Lap High Pressure Deckle Cutter Sprays
Wet Lap High Pressure Deckle Cutter Sprays
Motor
Vacuum Conveyor
43283717/001/B
11.00
3.00
Wet Lap Press No.1 Hyd. Unit
11.00
Wet Lap Press No.2 Hyd. Unit
11.00
Sum of
KW
Process step
Description
Size
KW
Installed
Rejects
322.27
Gyrocleans and Uniflow Cleaners Rejects Tank
Gyrocleans and Uniflow Rejects Tank Discharge
Pump
Gyrocleans and Uniflow Rejects Tank Discharge
Pump Motor
5.50
H.C. Screen Rejects Tank Discharge Pump
H.C. Screen Rejects Tank Discharge Pump
Motor
5.50
Medium Consistency Screens Reject Tank
Fine Rejects Drum Screen (Trommel)
Fine Drum Screen Main Drive
5.50
Solids Separator (Sands)
Solids Separator Main Drive
0.37
Rejects Screw Press
Rejects Screw Press Main Drive
15.00
Coarse Drum Screen Rejects Screw Conveyor
Coarse Drum Screen Rejects Screw Conveyor
Motor
3.00
Detrasher Rejects Screw Conveyor Main Drive
Motor
5.90
Fiberizer Main Drive Motor
30.00
Detrasher Rejects Screw Conveyor
Fiberizer Accepts Pump
Fiberizer Accepts Pump Motor
7.50
Fiberizer (TREX)
Rejects Conveyor No.1
Rejects Conveyor No.1 Main Drive
3.00
Rejects Conveyor No.5 Motor
11.00
4.00
3.00
Centrifuge Filtrate Tank Discharge Pump
Centrifuge Filtrate Tank Discharge Pump Motor
43283717/001/B
Sum of
KW
5.50
Process step
Description
Centrifuges Filtrate Tank
Size
KW
Installed
Sum of
KW
5m3
Centrifuge No.2
No.2 Centrifuge Main Drive
90.00
No.2 Centrifuge Screw Drive
18.50
No.2 Centrifuge Lube Oil Pump
0.25
Centrifuge No.1
No.1 Centrifuge Main Drive
90.00
No.1 Centrifuge Screw Drive
18.50
No.1 Centrifuge Lube Oil Pump
0.25
Ancillary
equipment
37.32
Caustic Soda Unloading Pump Motor
7.50
Caustic Soda Unloading Pump
Caustic Soda Bulk Storage Tank
45m3
Caustic Soda to Pulp Dosing Pump
Caustic Soda to Pulp Dosing Pump Motor
0.75
Caustic Soda to FAS Preparation Tank Feed
Pump
Caustic Soda to FAS Preparation Tank Feed
Pump Motor
0.37
Caustic Soda to No.2 Kneader Conveyor Pump
Caustic Soda to No.2 Kneader Conveyor Pump
Motor
Hydrogen Peroxide Bulk Storage Tank
0.37
50m3
Hydrogen Peroxide Duty Pump 'K'
Hydrogen Peroxide Duty Pump 'K' Motor
4.00
Hydrogen Peroxide Duty Pump 'J'
Hydrogen Peroxide Duty Pump 'J' Motor
1.50
Surfactant Unloading Pump Motor
7.50
Surfactant Unloading Pump
Surfactant Tank
8m3
Surfactant to Pulp Dosing Pump
Surfactant to Pulp Dosing Pump Motor
0.37
Sodium Silicate Unloading Pump Motor
7.50
Sodium Silicate Unloading Pump
43283717/001/B
Process step
Description
Size
KW
Installed
Flush Water, Sodium Silicate & Hot Soap Pump
Flush Water, Sodium Silicate & Hot Soap Pump
Motor
1.10
Sodium Silicate to No.2 Kneader Conveyor
Pump
Sodium Silicate to No.2 Kneader Conveyor
Pump Motor
0.37
Sodium Silicate to Pulp Dosing Pump
Sodium Silicate to Pulp Dosing Pump Motor
Sodium Silicate Bulk Storage Tank
1.50
60m3
Biocide System - Package by Chemical Vendor
Flocculant No.2 - Package by Chemical Vendor
Precipitant - Package by Chemical Vendor
Flocculant No.1 - Package by Chemical Vendor
Complexing Agent to Pulp Dosing Pump
Complexing Agent to Pulp Dosing Pump Motor
1.50
Complexing Agent to Disc Filtrate Standpipe
Feed Pump
Complexing Agent to Disc Filtrate Standpipe
Feed Pump Motor
0.37
Alum Storage Tank (25%)
25m3
Alum Day Storage (10%)
6m3
FAS Hopper
FAS Screw Conveyor
FAS Screw Conveyor Motor
0.75
FAS Preparation Tank Agitator
FAS Preparation Tank Agitator Motor
0.37
FAS Preparation Tank to Brightening Standpipe
Feed Pump
FAS Preparation Tank to Brightening Standpipe
Feed Pump Motor
Static Mixer
Sodium Silicate Metering Tank
Hydrogen Peroxide Metering Tank
Surfactant Metering Tank
Caustic Soda Metering Tank
DTPA Metering Tank
43283717/001/B
1.50
Sum of
KW
Process step
Description
Size
KW
Installed
Sum of
KW
Saveall Tray
Saveall Tray
Mixing Unit
First Stage Heavy Rejects Cleaners Stand Pipe
Second Stage Heavy Rejects Cleaners Stand
Pipe
Third Stage Heavy Rejects Cleaners Stand Pipe
Post Deinking Separator
Coarse screening
Primary High Consistency Screen - Stage 1
1.3mm
Primary High Consistency Screen Drive- Stage 1
Secondary High Consistency Screen - Stage 2
90.00
0.18mm
Secondary High Consistency Screen - Stage 2
Drive
Primary High Consistency Screen Slots Stage 1
30.00
0.18mm
Primary High Consistency Screen Slots Stage 1
Main Drive
High Consistency Screen Rejects Tank 3 (New)
225.00
75.00
10m3
Feed Pump (New)
Feed Pump Motor
Secondary High Consistency Screen Slots
Stage 2
30.00
0.18mm
Secondary High Consistency Screen Slots
Stage 2 Main Drive
Rejects
(New)
10m3
5.50
Agitator
Agitator Motor
Coarse screening
5.50
Tertiary High Consistency Slotted Screen Pump
(New)
Tertiary High Consistency Slotted Screen Pump
Motor (New)
22.50
7.50
Tertiary High Consistency Screen Slots - Stage
3
Tertiary High Consistency Screen Slots - Stage
3 Main Drive
Floatation (2nd
round)
Post Deinking Cell 1
Post Deinking Cell 1 Skimmer?
Post Deinking Cell 1 Recirculating Pump
43283717/001/B
15.00
201.00
0.75
Process step
Description
Post Deinking Cell 1 Recirculating Pump Motor
Size
KW
Installed
Sum of
KW
22.00
Post Deinking Cell 1 Pump
Post Deinking Cell 1 Pump Motor
22.00
0.75
22.00
22.00
0.75
22.00
22.00
0.75
22.00
22.00
Post Deinking Cell Vacuum Drive
Post Deinking Cell Vacuum Drive Motor
Fine screening
22.00
Low Consistency Screens Stage 1 Slots 0.15mm
Primary Low Consistency Screen Main Drive
202.00
55.00
Primary Low Consistency Screen Main Drive x2
55.00
Secondary Low Consistency Screen Main Drive
55.00
Tertiary Low Consistency Screen Main Drive
43283717/001/B
22.00
Process step
Description
Size
KW
Installed
Sum of
KW
4th Stage Low Consistency Screen Main Drive
15.00
Chemicals
Additional chemical pumping
37.00
37.00
Dewatering (1)
Dewatering screws
66.00
66.00
Effluent to WWTP
Effluent to WWTP
152.00
152.00
TOTAL DIP plant
Wetlap
549
205
Reslushing WL
448
391
Additional Sludge Handling
65
DIP Handling TOTAL
TOTAL
43283717/001/B
9306
1657
10964
Appendix D Best Practice Assessment
43283717/001/B
D
Appendix D - Best Practice Assessment
Table D-1
Review of Best Practice (BP) and Best Available Technology (BAT) for the proposed DIP plant - Water
Technique
Integrated Environmental Assessment8
Source
Chemical
use
Energy (E)
and water
(W) use
Emissio
n to
water
Emission
to air
Solid
waste
Applicable
to
AP proposal
Assessment
WATER CONSUMPTION
Separation of less
contaminated water from
contaminated streams and
recycling of process water
IPPC 5.3.1
()

()
-
-
All grades
Yes. DIP Plant will also use
paper machine back water.
Best Practice
Optimal water management
(water loop arrangement),
water clarification
IPPC 5.3.2
()


-
()
All grades
Yes
Best Practice
Reduction of fresh water
consumption by strict
separation of water loops
IPPC 5.3.3
-

()
-
-
All grades
Yes
Best Practice
Generation of clarified water for
de-inking plants
IPPC 5.3.8
()
()
()
-
()
All grades
Yes - DAF units and
centrifuge.
Best Practice
()
E

-

All grades
AP operates a tertiary
WWTP. The DIP
wastewater will be integrated
with the existing pulp mill
facilities.
Best Practice
WATER POLLUTION ABATEMENT
Installation of an equalisation
basin and primary treatment9
8
9
IPPC 5.4.2
 = increase;  = decrease; - = negligible effect; () or () = low influence depending on the conditions
Note: this arrangement is so common that it is considered ‘Good Practice’
43283717/001/B
Technique
Aerobic biological wastewater
treatment
Table D-2
Source
IPPC 5.3.6
Chemical
use
Energy (E)
and water
(W) use
Emissio
n to
water
Emission
to air
Solid
waste
Applicable
to
()
E

-

All grades
AP proposal
Assessment
Wastewater from the DIP
plant will ultimately go to the
wastewater treatment plant
where it will undergo aerobic
biological wastewater
treatment.
Best
available
technology
AP proposal
Assessment
Review of Best Practice (BP) and Best Available Technology (BAT) for the proposed Deinking plant – Energy
Technique
Source
Chemical
use
Energy (E)
and water
(W) use
Emissio
n to
water
Emission
to air
Solid
waste
Applicable
to
Implementation of a system for
monitoring energy usage and
performance.
IPPC 5.4.2
pg. 302
-

-
-
-
All grades
Energy measurement and
monitoring exists, but is
under review and is being
improved.
Best Practice
Replacement of equipment
with less energy consuming
equipment.
IPPC 5.4.2
pg. 302
-

-
-
-
All grades
Coarse and Fine screens
are being replaced from NPI
and will be an improvement
on the Amcor screens.
Good Practice
10
43283717/001/B
Technique
Source
Chemical
use
Energy (E)
and water
(W) use
Emissio
n to
water
Emission
to air
Solid
waste
Applicable
to
AP proposal
Assessment
Continuous pulping instead of
batch
IPPC
S6.01
2.7.3
-

-

-
All grades
AP will operate the DIP
continuously (this is a
change from Amcor which
operated it as a batch plant)
Best practice
New screen designs
IPPC
S6.01
2.7.3
-

-
-
-
All grades
See above
Good Practice
Co-generation of heat and
power
IPPC 5.3.9
-

-
-
-
All grades
AP already has cogeneration plant. No change
to existing facilities.
Outside of the
scope of the
works
approval
Improving existing boilers
IPPC pg.
XI
-

-

-
All grades
No change to existing
boilers planned.
Outside of the
scope of the
works
approval
Auxiliary boilers
IPPC pg.
XI
-

-
-
-
All grades
No change to existing
boilers planned
Outside of the
scope of the
works
approval
43283717/001/B
Table D-3
Review of Best Practice (BP) and Best Available Technology (BAT) for the proposed Deinking plant – Waste
Technique
Control of dust and loose paper
by:
storage indoors or in covered
stockpiles; and / or
Source
IPPC
S6.01
2.3.12
Chemical
use
Energy (E)
and water
(W) use
Emission
to water
Emission
to air
Solid
waste
Applicable
to
-
-
-
()

All grades
AP proposal
Assessment
Waste paper will be supplied
to site in secure bales to
control loose paper.
Good Practice
There will be space for 6
days of paper storage
outside and 1 day of paper
storage inside.
securely fenced areas;
Minimise the generation of
solid waste and recover, reuse
and recycle reusable materials
wherever practicable
IPPC 5.4.2
pg. 301
Depends on
chosen
design
Depends
on chosen
design
-
-

All grades
DIP clarifier sludge will be
reused for composting or to
make kitty litter. 100% of
WWTP sludge will be used
for composting.
Best Practice
Separate collection and
intermediate storage of waste
fractions
IPPC 5.4.2
pg. 301
-
-
-
-

All grades
3 grades of waste will be
generated and tested to
confirm waste classification
and reuse opportunities.
Wastes with common reuse
/ disposal options will be
combined.
Best Practice
11
43283717/001/B
Technique
Source
Chemical
use
Energy (E)
and water
(W) use
Emission
to water
Emission
to air
Solid
waste
Applicable
to
AP proposal
Assessment
Optimise fibre recovery by
upgrading the stock
preparation plants
IPPC 5.4.2
pg. 301
-
-
-
-

All grades
No changes to PM Fibre
Recovery Circuits, but
increased usage of machine
backwater.
Good Practice
Optimisation of the amount of
cleaning stages in the stock
preparation.
IPPC 5.4.2
pg. 301
Depends on
chosen
design
Depends
on chosen
design

-

All grades
Upgrade to existing plant
screening and refurbishment
of existing cleaners
Limited by
Amcor’s
design
Application of DAF as in-line
treatment of water loops to
recover fibres and fillers and to
clarify process water
IPPC 5.4.2
pg. 301

E
-
-

Two DAF units will be
located at the DIP plant to
clarify process water and
recover fibres. Fibres will be
reused to make compost.
Best available
technology
Reject and sludge handling
and processing on-site (dewatering) to enhance dry solids
content
IPPC
5.3.10

()
-
-
-
All grades
DIP sludge is deposited in
walled slab area, and
transported off site for
landfill or beneficial use.
Runoff is collected and
process through the WWTP.
The WWTP is already
collected for compost.
Best Practice
Environmental sound residue
utilisation (energy recover) and
disposal
IPPC
5.3.11
-

()
()

All grades
Detailed below
Detailed below
43283717/001/B
Technique

Incineration of sludge and /
rejects with energy
recovery
Source
IPPC
5.3.11
Chemical
use
Energy (E)
and water
(W) use
Emission
to water
Emission
to air
Solid
waste
Applicable
to
-

-


Mainly
white
paper
grades
AP proposal
Assessment
DIP plant sludge will be
reused, which is a better
waste hierarchy option than
energy recovery.
Best Practice
Common
Practice
Detrasher waste will be
landfilled. May consider
energy recovery off-site at
later stage. See option
below.

Incineration of organic
materials in suitable
designed boilers with
energy recovery
IPPC 5.4.2
pg. 302
-

-


All grades
The Detrasher waste
contains a proportion of
fibre. There may be an
opportunity to incinerate the
waste to recover energy
from the waste fibre in an
off-site hog fuel boiler. This
opportunity will be pursued
after commissioning of the
DIP plant.
Opportunity to
be pursued
after start-up

Use of produced ash as a
raw material in the building
materials industry
IPPC 5.4.2
pg. 302
-
-
-
-

All grades
There is no waste recovery
incinerator on-site.
Outside of the
scope of the
works
approval
43283717/001/B
Table D-4
Review of Best Practice (BP) and Best Available Technology (BAT) for the proposed Deinking plant – Chemical Use
Technique
Source
Chemical
use
Energy (E)
and water
(W) use
Emission
to water
Emission
to air
Solid
waste
Applicable
to
AP proposal
Assessment
Best Practice
Ensure the availability of a
database for all chemicals and
additives
IPPC 5.4.2
pg. 303
-
-
-
-
-
All grades
AP has an electronic
database containing MSDSs
of all substances used.
Application of the principle of
substitution i.e. less hazardous
products are used when
available
IPPC 5.4.2
pg. 303

-
-
-
-
All grades
FAS will be stored in small
quantities on site in powder
form, NaOH will be madedown to 10% solution prior
to pumping to DIP plant
tanks. Hydrogen Peroxide
will be stored in an existing
tank, and pumped to a
smaller DIP Plant tank.
Measures to avoid accidental
discharges to soil and water
from handling and storage of
chemicals (including design
and operation of facilities)
IPPC 5.4.2
pg. 304
-
-
-
-
-
All grades
AP has an OMS (see
section 8) and is accredited
to ISO14001. OMS includes
storage and handling of
chemicals including
accidental discharge and
emergency management.
Facilities and storage of
chemicals will be designed
to comply with EPA bunding
guidelines.
12
43283717/001/B
Best Practice
Table D-5
Review of Best Practice (BP) and Best Available Technology (BAT) for the proposed Deinking plant – General
Technique
Source
AP proposal
Chemical
use
Energy (E)
and water
(W) use
Emission
to water
Emission
to air
Solid
waste
Applicable
to
GENERAL
Training, education and
motivation of staff and
operators
IPPC 5.4.2
pg. 295





All grades
AP has an OMS and is also
certified to ISO14001
standards.
Process control optimisation.
IPPC 5.4.2
pg. 295





All grades
To be completed post
HAZOP
High maintenance level
IPPC 5.4.2
pg. 295





All grades
AP has an OMS which
includes a preventative
maintenance and repair
program
Environmental management
system which clearly define the
responsibilities for
environmentally relevant
aspects
IPPC 5.4.2
pg. 295





All grades
AP has an OMS and is also
certified to ISO14001
standards.
13
43283717/001/B
Assessment
Technique
Source
Chemical
use
Energy (E)
and water
(W) use
Emission
to water
Emission
to air
Solid
waste
Applicable
to
-
-
-

-
All grades
AP proposal
Assessment
The DIP plant will be located
within an isolated industrial
plant.
Good Practice
ODOUR
Building containment,
maintenance of positive
airflows across doorways,
extraction to combustion or
other abatement systems and
the use of fast closing
automatic doors
IPPC
S6.01
2.3.14
The DIP Plant will be
located in a new installation,
approximately 2 stories tall,
with two operating levels.
The wastepaper handling
and pulpers will be enclosed
within the structure, as well
as the FAS make down and
storage. The remainder of
the equipment will be
installed within the
installation’s bunded area.
The de-inking cells are
ventilated by blowers which
will be directed to
atmosphere via roof vents.
RISK MANAGEMENT
Risk management system to:
identify the hazards;
Assess the risks;
Techniques to reduce risks
43283717/001/B
IPPC
S6.01 2.8
-
-
-

-
All grades
AP has an OMS that
includes risk management.
Refer to Section 8 for further
detail. A HAZOP is
scheduled for May 22.
Refer to Section I.
Best Practice
Appendix E Waste
43283717/001/B
E
Yield
DIP Plant ‐ Solid Waste Overview
61%
Wastepaper
255.7 ADt/d
DIP
156 ADt/d
DIP Plant
TSS
Solid Waste ‐ Landfill
10.9 ADt/d
50% solids
20 wet tonnes
3750 mg/L
10.7 ADt/d
2% solids
20 m3/h
Primary Clarifier
Solid Waste ‐ Beneficial Use
Solid Waste ‐ Beneficial Use
67.2 ADt/d
50% solids
121 wet tonnes
ESR Presses
22 ADt/d
28% solids
70 wet tonnes
Secondary Clarifier
COD
11.0 ADt/d
3860 mg/l
River Discharge after No.2 Pond
2% solids
21 m3/h
Catherine Reid
Page 1
18/05/2012
Appendix E ‐ Table 1 ‐ Waste Classification Testing
Industrial Waste Resources Guidelines (Solid Industrial Waste Hazard Categorisation and Management) - July 2009
Sample collected MARCH 2012 from AMCOR at Fairfield
DIP Centrifuge
Solids
DIP Screw
Press Solids
NO
NO
Catherine Reid
Does waste display any hazard characteristic in Table 1?
If Yes Cat A
Poison, toxic or exotoxic constituents?
CAT A
CAT B
CAT C
REQUIRED TEST
PENDING
INDUSTRIAL
Industrial Waste
Cat C - upper limit
Cat B - upper limit
ASLP0
TC0
ASLP1
TC1
ASLP2
TC2
DIP Combined
Centrifuge &
Screw Press
Solids
NO
DIP Centifuge Solids
ASLP Borate ASLP Acetate
mg/L
mg/L
Sample Date
19/03/2012
19/03/2012
Testing Lab
ALS & Leeder
(Iodide)
ALS & Leeder
(Iodide)
Report No
296515 &
M120483
296515 &
M120483
N/A
Totals
mg/kg
DIP Screw Press Solids
Totals
mg/L
mg/kg
mg/L
19/03/2012
19/03/2012
19/03/2012
ALS
ALS & Leeder
(Iodide)
ALS & Leeder
(Iodide)
296515
296515 &
M120483
296515 &
M120483
N/A
N/A
19/03/2012
19/03/2012
19/03/2012
19/03/2012
ALS
ALS & Leeder
(Iodide)
ALS & Leeder
(Iodide)
ALS
296515
296515 &
M120483
296515 &
M120483
296515
N/A
N/A
Compound
INORGANIC SPECIES
mg/L
mg/kg
mg/L
mg/kg
mg/L
mg/kg
Aluminium
Antimony
Arsenic Barium
Beryllium
Boron
Cadmium
Chromium (VI) Copper Lead Mercury Molybdenum
Nickel
Selenium
Silver
Tributyltin oxide
Zinc
N/A
1
0.35
35
0.5
15
0.1
2.5
100
0.5
0.05
2.5
1
0.5
5
0.05
150
N/A
75
500
6250
100
15000
100
500
5000
1500
75
1000
3000
50
180
2.5
35000
N/A
2
0.7
70
1
30
0.2
5
200
1
0.1
5
2
1
10
0.1
300
N/A
75
500
6250
100
15000
100
500
5000
1500
75
1000
3000
50
180
2.5
35000
N/A
8
2.8
280
4
120
0.8
20
800
4
0.4
20
8
4
40
0.4
1200
N/A
300
2000
25000
400
60000
400
2000
20000
6000
300
4000
12000
200
720
10
140000
N/A
12500
1.75
4
75
5
2500
150
N/A
N/A
1250
2500
10000
N/A
N/A
N/A
N/A
25000
3.5
8
150
10
5000
300
N/A
N/A
1250
2500
10000
N/A
N/A
N/A
N/A
N/A
14
32
600
40
20000
1200
N/A
N/A
5000
10000
40000
N/A
N/A
N/A
N/A
18
9
ND
<0.01
<0.01
N/A
N/A
N/A
N/A
N/A
N/A
N/A
0.05
0.0005
N/A
N/A
0.15
15
3
15
100
4
5
325
5000
12
1200
240
1200
8000
0.1
0.001
N/A
N/A
0.3
30
6
30
200
4
5
650
10000
12
1200
240
1200
8000
0.4
0.004
N/A
N/A
1.2
120
24
120
800
16
20
2600
40000
48
4800
960
4800
32000
0.5
75
2
0.15
1.5
3
0.2
10
0.065
15
40
6000
160
12
120
240
16
800
5.2
1200
1
150
4
0.3
3
6
0.4
20
0.13
30
40
6000
160
12
120
240
16
800
5.2
1200
4
600
16
1.2
12
24
1.6
80
0.52
120
24000
640
48
480
960
64
3200
21
4800
32
<0.1
<0.1
<0.8LORR
<0.8LORR
<2LORR
<2LORR
<1LORR
<0.1
<0.8LORR
8.5
<0.1
<0.1
<0.9LORR
<0.9LORR
<2LORR
<2LORR
<1LORR
<0.1
<0.9LORR
12.5
25
0.035
100
1
N/A
7
N/A
1.5
5
0.65
2.5
40
1.5
15
0.6
0.25
200
1
0.015
30
1000
2000
2.8
8000
80
50
560
2
120
400
52
200
3200
120
1200
48
20
16000
80
1.2
2400
25
50
0.07
200
2
N/A
14
see note
3
10
1.3
5
80
3
30
1.2
0.5
400
2
0.03
60
1000
2000
2.8
8000
80
100
560
see note
120
400
52
200
3200
120
1200
48
20
16000
80
1.2
2400
100
200
0.28
800
8
N/A
56
see note
12
40
5.2
20
320
12
120
4.8
2
1600
8
0.12
240
4000
8000
11
32000
320
400
2200
see note
480
1600
210
800
12800
480
4800
190
80
64000
320
4.8
9600
<5
<1
<0.1
<100LORR
<0.1
<0.1
<60LORR
<0.2LORR
<0.8LORR
<0.8LORR
<0.8LORR
<0.8LORR
<0.8LORR
<0.1
<0.8LORR
<0.8LORR
<0.8LORR
<1LORR
<1LORR
<1
<0.8LORR
<5
<1
<0.1
<100LORR
<0.1
<0.1
<60LORR
<0.2LORR
<0.9LORR
<0.9LORR
<0.9LORR
<0.9LORR
<0.9LORR
<0.1
<0.9LORR
<0.9LORR
<0.9LORR
<1LORR
<1LORR
<1
<0.9LORR
0.015
1
1.5
0.05
0.015
1.2
50
120
4
1.2
0.03
2
3
0.1
0.03
1.2
50
120
4
1.2
0.12
N/A
12
0.4
0.12
4.8
50
480
16
4.8
N/A
<5
<5
20
<5
<10
<0.2
<1
28
<5
<0.05
<5
<5
<3
<5
DIP Combined Centifuge & Screw Press Solids
ASLP Acetate
Totals mg/kg
ASLP Borate
mg/L
mg/L
N/A
<5
<5
10
<5
<10
<0.2
<1
20
<5
<0.05
<5
<5
<3
<5
N/A
<5
<5
21
<5
<10
<0.2
<1
34
<5
<0.05
<5
<5
<3
<5
<0.0005
<0.0005
<0.0005
46
34
92
ANIONS
Chloride
Cyanide (amenable) Cyanide (total)
Fluoride
Iodide Nitrate Nitrite Sulphate
19
8
ND
<0.01
<0.01
N/A
N/A
<5
<5
<100
N/A
N/A
N/A
N/A
18
10
ND
<0.01
<0.01
N/A
N/A
<5
<5
<100
N/A
N/A
N/A
N/A
ND
<0.01
<0.01
N/A
ND
<0.01
<0.01
N/A
N/A
<5
<5
<100
N/A
N/A
N/A
N/A
ND
<0.01
<0.01
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
<0.0005
N/A
N/A
<0.0005
N/A
N/A
<0.0005
N/A
N/A
<0.0005
N/A
N/A
<0.0005
N/A
N/A
<0.0005
N/A
N/A
<0.01
<0.01
<0.01
<0.01
CATIONS
Sodium
ORGANIC SPECIES
Benzene Benzo(a)pyrene
C6‐C9 petroleum hydrocarbons
C10‐C36 petroleum hydrocarbons Carbon tetrachloride Chlorobenzene
Chloroform
2 Chlorophenol Cresol (total)
Di (2 ethylhexyl) phthalate (DiOctyl Phthalate)
1,2‐Dichlorobenzene 1,4‐Dichlorobenzene
1,2‐Dichloroethane 1,1‐Dichloroethene 1‐2‐Dichloroethene
Dichloromethane (methylene chloride)
2,4‐Dichlorophenol 2,4‐Dinitrotoluene
Ethylbenzene Ethylene diamine tetra acetic acid (EDTA) Formaldehyde Hexachlorobutadiene Methyl ethyl ketone Nitrobenzene
PAHs (total)
Phenols (total, non‐halogenated)
Polychlorinated biphenyls
Styrene
1,1,1,2‐Tetrachloroethane
Tetrachloroethene
Toluene Trichlorobenzene (total)
1,1,1‐Trichloroethane
Trichloroethene
2,4,5‐Trichlorophenol
Vinyl chloride
Xylenes (total) 160
N/A
N/A
N/A
N/A
<0.01
<0.01
<0.8LORR
<0.1
<20
<2080
<0.8LORR
<0.8LORR
<0.8LORR
<1LORR
<2LORR
N/A
N/A
N/A
N/A
<0.01
<0.01
<0.09LORR
<0.1
<20
<1280
<0.9LORR
<0.9LORR
<0.9LORR
<1LORR
<2LORR
N/A
N/A
N/A
N/A
<0.01
<0.01
<0.8LORR
<0.1
<20
2312
<0.8LORR
<0.8LORR
<0.8LORR
<1LORR
<2LORR
33
<0.1
<0.1
<0.8LORR
<0.8LORR
<2LORR
<2LORR
<1LORR
<0.1
<0.8LORR
<5
<1
<0.1
<100LORR
<0.1
<0.1
<60LORR
<0.2LORR
<0.8LORR
<0.8LORR
<0.8LORR
<0.8LORR
<0.8LORR
<0.1
<0.8LORR
<0.8LORR
<0.8LORR
<1LORR
<1LORR
<1
<0.8LORR
PESTICIDES
Aldrin + dieldrin DDT + DDD + DDE
2,4‐D Chlordane
Heptachlor pH
<0.1LORR
<0.1LORR
<0.04
<0.1LORR
<0.1LORR
HAZARD CATEGORY
Where the results are the sum of several species only the positive results are added. If all results are less than
the detection limit then that is the result reported (ie Aldrin + Dieldrin = <0.05 NOT <0.01). Discussed with
Ecowise June 2009.
Comments <0.1LORR
<0.1LORR
<0.08
<0.1LORR
<0.1LORR
<0.1LORR
<0.1LORR
<0.08
<0.1LORR
<0.1LORR
8.1
8.6
8
INDUSTRIAL
INDUSTRIAL
INDUSTRIAL
All parameters are below the Industrial Waste upper limits therefore the waste stream hazard category is Industrial Waste. All parameters are below the Industrial Waste upper limits therefore the waste stream hazard category is Industrial Waste. All parameters are below the Industrial Waste upper limits therefore the waste stream hazard category is Industrial Waste. Notes:
LDIL = Level of reporting raised due to necessary dilution
LINT = Level of reporting raised due to interferences in the sample matrix
LLTS = Level of reporting raised due to low total solids
LORR = Level of reporting has been raised due to high moisture content, insufficient sample or matrix interference
LWTS = Detection limit raised due to low total solids
J:\JOBS\43283717\6 Deliv\Appendices\Appendix E\2 ‐ Waste classification testing.xlsx
1 of 2
Catherine Reid
Page 2
18/05/2012
Appendix E ‐ Table 2 ‐ Waste Classification Leachate Testing
Above Max TC, requires ASLP analysis
Compound
INORGANIC SPECIES
Aluminium
Antimony
Arsenic Barium
Beryllium
Boron
Cadmium
Nickel
Selenium
Silver
Tributyltin oxide
Zinc
DIP Screw Press
Solids
DIP Combined
Centrifuge & Screw
Press Solids
Total Conc.
mg/kg
Total Conc.
mg/kg
N/A
<5
<5
20
<5
<10
<0.2
<1
28
<5
<0.05
<5
<5
<3
<5
N/A
<5
<5
10
<5
<10
<0.2
<1
20
<5
<0.05
<5
<5
<3
<5
N/A
<5
<5
21
<5
<10
<0.2
<1
34
<5
<0.05
<5
<5
<3
<5
<0.0005
<0.0005
<0.0005
46
34
92
DIP Centrifuge
Solids
Total Conc.
mg/kg
ASLP1
Max. TC
mg/L
mg/kg
N/A
2
0.7
70
1
30
0.2
5
200
1
0.1
5
2
1
10
0.1
300
‐
40
14
1400
20
600
4
100
4000
20
2
100
40
20
200
2
6000
25000
3.5
8
150
10
5000
300
N/A
TC N/A
70
160
3000
TC N/A
TC N/A
TC N/A
‐
N/A
<5
<5
<100
N/A
N/A
N/A
N/A
N/A
<5
<5
<100
N/A
N/A
N/A
N/A
N/A
<5
<5
<100
N/A
N/A
N/A
N/A
N/A
‐
N/A
N/A
N/A
0.1
0.001
N/A
N/A
0.3
30
6
30
200
1
150
4
0.3
3
6
0.4
20
0.13
30
25
50
0.07
200
2
N/A
14
see note
3
10
1.3
5
80
3
30
1.2
0.5
400
2
0.03
60
2
0.02
TC only
TC only
6
600
120
600
4000
20
3000
80
6
60
120
8
400
2.6
600
500
1000
1.4
4000
40
TC only
280
‐
60
200
26
100
1600
60
600
24
10
8000
40
0.6
1200
<0.8LORR
<0.1
<20
<2080
<0.8LORR
<0.8LORR
<0.8LORR
<1LORR
<2LORR
32
<0.1
<0.1
<0.8LORR
<0.8LORR
<2LORR
<2LORR
<1LORR
<0.1
<0.8LORR
<5
<1
<0.1
<100LORR
<0.1
<0.1
<60LORR
<0.2LORR
<0.8LORR
<0.8LORR
<0.8LORR
<0.8LORR
<0.8LORR
<0.1
<0.8LORR
<0.8LORR
<0.8LORR
<1LORR
<1LORR
<1
<0.8LORR
<0.09LORR
<0.1
<20
<1280
<0.9LORR
<0.9LORR
<0.9LORR
<1LORR
<2LORR
8.5
<0.1
<0.1
<0.9LORR
<0.9LORR
<2LORR
<2LORR
<1LORR
<0.1
<0.9LORR
<5
<1
<0.1
<100LORR
<0.1
<0.1
<60LORR
<0.2LORR
<0.9LORR
<0.9LORR
<0.9LORR
<0.9LORR
<0.9LORR
<0.1
<0.9LORR
<0.9LORR
<0.9LORR
<1LORR
<1LORR
<1
<0.9LORR
<0.8LORR
<0.1
<20
2312
<0.8LORR
<0.8LORR
<0.8LORR
<1LORR
<2LORR
33
<0.1
<0.1
<0.8LORR
<0.8LORR
<2LORR
<2LORR
<1LORR
<0.1
<0.8LORR
<5
<1
<0.1
<100LORR
<0.1
<0.1
<60LORR
<0.2LORR
<0.8LORR
<0.8LORR
<0.8LORR
<0.8LORR
<0.8LORR
<0.1
<0.8LORR
<0.8LORR
<0.8LORR
<1LORR
<1LORR
<1
<0.8LORR
0.03
2
3
0.1
0.03
0.6
40
60
2
0.6
<0.1LORR
<0.1LORR
<0.04
<0.1LORR
<0.1LORR
<0.1LORR
<0.1LORR
<0.08
<0.1LORR
<0.1LORR
<0.1LORR
<0.1LORR
<0.08
<0.1LORR
<0.1LORR
ANIONS
Chloride
Fluoride
CATIONS
Sodium
ORGANIC SPECIES
Chloroform
PAHs (total)
Styrene
Tetrachloroethene
Trichloroethene
Vinyl chloride
Xylenes (total) PESTICIDES
2,4‐D Chlordane
Heptachlor J:\JOBS\43283717\6 Deliv\Appendices\Appendix E\2 ‐ Waste classification testing.xlsx
2 of 2
Appendix E ‐ Table 3
Waste to PineGro Composting Facility
Sewer & Secondary
1/01/2010
1/02/2010
1/03/2010
1/04/2010
1/05/2010
1/06/2010
1/07/2010
1/08/2010
1/09/2010
1/10/2010
1/11/2010
1/12/2010
2010 Total
1/01/2011
1/02/2011
1/03/2011
1/04/2011
1/05/2011
1/06/2011
1/07/2011
1/08/2011
1/09/2011
1/10/2011
1/11/2011
1/12/2011
2011 Total
1/01/2012
1/02/2012
1/03/2012
1/04/2012
m3
1455
915
1440
1345
1125
1350
1350
1500
1275
1920
1350
1380
16405
1695
990
450
1620
1530
780
1155
1350
1065
1290
1740
915
14580
975
1515
960
1100
Sewer & Secondary
T
1427.8
894.9
1371.5
1293.9
1104.9
1329.9
1334.3
1493.8
1254.8
1875.5
1308.1
1329.9
16019.2
1630.5
950.2
428.6
1531.0
1436.6
735.9
1088.9
1277.7
1007.5
1221.1
1641.5
863.5
13812.9
913.9
1410.3
894.4
1013.9
ESR
ESR
m3
1980
2020
3070
1850
1820
2270
2610
2480
2620
2290
2630
2590
28230
2130
1735
2390
3910
3040
2810
2200
2150
2170
1760
1590
1550
27435
1910
1500
2060
1360
T
1786.8
1953.7
2857.1
1701.3
1649.4
2049.7
2318.3
2190.8
2289.3
2014.5
2306.7
2258.1
25375.7
1877.8
1541.7
2123.1
3486.4
2725.4
2530.1
1988.1
1941.2
1956.7
1588.6
1429.9
1393.2
24582.2
1717.9
1352.0
1852.6
1227.4
J:\JOBS\43283717\6 Deliv\Appendices\Appendix E\3 ‐ ESR Sew Sec to Pinegro 2010‐2011.xlsx
1 of 1
ESR Hazard Waste Categorisation Test Results 2011 & 2010
ASLP
Borate
mg/L
Industrial Waste
Cat C - upper limit
Cat B - upper limit
ESR
ASLP
Acetate
mg/L
Totals
ASLP
mg/kg
Borate mg/L
Sample Date 21/10/2011 21/10/2011 21/10/2011 20/09/2010
Testing Lab
ALS &
Leeder
(Iodide)
ALS &
Leeder
(Iodide)
ALS
Report No
267973 &
M112084
267973 &
M112084
267973
ESR
ASLP Acetate
Totals
mg/L
mg/kg
20/09/2010
20/09/2010
Leeder Leeder (Iodide) & (Iodide) & Leeder ALS ALS (Iodide) & ALS M101348R1 M101348R1 & M101348R1 & 187317
187317
& 187317
ASLP0
TC0
ASLP1
TC1
ASLP2
TC2
Compound
INORGANIC SPECIES
mg/L
mg/kg
mg/L
mg/kg
mg/L
mg/kg
Aluminium
Antimony
Arsenic Barium
Beryllium
Boron
Cadmium
Nickel
Selenium
Silver
Tributyltin oxide
Zinc
N/A
1
0.35
35
0.5
15
0.1
2.5
100
0.5
0.05
2.5
1
0.5
5
0.05
150
N/A
75
500
6250
100
15000
100
500
5000
1500
75
1000
3000
50
180
2.5
35000
N/A
2
0.7
70
1
30
0.2
5
200
1
0.1
5
2
1
10
0.1
300
N/A
75
500
6250
100
15000
100
500
5000
1500
75
1000
3000
50
180
2.5
35000
N/A
8
2.8
280
4
120
0.8
20
800
4
0.4
20
8
4
40
0.4
1200
N/A
300
2000
25000
400
60000
400
2000
20000
6000
300
4000
12000
200
720
10
140000
N/A
N/A
N/A
<5
<5
30
<5
<10
<0.2
<1
38
6
0.1
<5
6
<3
<5
<0.0005
59
N/A
N/A
N/A
<5
<5
15
<5
<10
<0.2
<1
18
<5
0.06
<5
5
<3
<5
<0.0005
29
12500
1.75
4
75
5
2500
150
N/A
N/A
1250
2500
10000
N/A
N/A
N/A
N/A
25000
3.5
8
150
10
5000
300
N/A
N/A
1250
2500
10000
N/A
N/A
N/A
N/A
N/A
14
32
600
40
20000
1200
N/A
N/A
5000
10000
40000
N/A
N/A
N/A
N/A
21
6
19
7
ND
<0.01
<0.01
N/A
ND
<0.01
<0.01
N/A
N/A
<5
<5
150
N/A
N/A
N/A
N/A
ND
<0.01
<0.01
N/A
ND
<0.01
<0.01
N/A
N/A
<5
<5
150
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
0.05
0.0005
N/A
N/A
0.15
15
3
15
100
4
5
325
5000
12
1200
240
1200
8000
0.1
0.001
N/A
N/A
0.3
30
6
30
200
4
5
650
10000
12
1200
240
1200
8000
0.4
0.004
N/A
N/A
1.2
120
24
120
800
16
20
2600
40000
48
4800
960
4800
32000
<0.001
N/A
N/A
<0.001
N/A
N/A
<0.001
N/A
N/A
<0.001
N/A
N/A
0.5
75
2
0.15
1.5
3
40
6000
160
12
120
240
1
150
4
0.3
3
6
40
4
600
16
1.2
12
24
<0.01
<0.01
6000
160
12
120
240
24000
640
48
480
960
21
<0.1
<0.1
<2 LORR
<2 LORR
<2 LORR
5.4
<1LORR
<1LORR
<0.5
<0.5
<1
0.2
10
0.065
15
16
800
5.2
1200
0.4
20
0.13
30
16
800
5.2
1200
1.6
80
0.52
120
64
3200
21
4800
<4 LORR
<2 LORR
<0.1
<2 LORR
<1
<5LORR
<1LLTS
<0.5
12.5
25
0.035
100
1
N/A
7
N/A
1.5
5
0.65
2.5
40
1.5
15
0.6
0.25
200
1
0.015
30
1000
2000
2.8
8000
80
50
560
2
120
400
52
200
3200
120
1200
48
20
16000
80
1.2
2400
25
50
0.07
200
2
N/A
14
see note
3
10
1.3
5
80
3
30
1.2
0.5
400
2
0.03
60
1000
2000
2.8
8000
80
100
560
see note
120
400
52
200
3200
120
1200
48
20
16000
80
1.2
2400
100
200
0.28
800
8
N/A
56
see note
12
40
5.2
20
320
12
120
4.8
2
1600
8
0.12
240
4000
8000
11
32000
320
400
2200
see note
480
1600
210
800
12800
480
4800
190
80
64000
320
4.8
9600
<5
3
<0.1
<20 LORR
<0.1
<0.2 LORR
<150 LORR
<0.4LORR
<2 LORR
<2 LORR
<2 LORR
<2 LORR
<2 LORR
<0.1
<2 LORR
<2 LORR
<2 LORR
<2 LORR
<2 LORR
<1.2 LORR
<4 LORR
<5
1
<1LORR
<3LINT
<1LLTS
<1LORR
<300
<1LORR
<0.5
<0.5
<0.5
<0.5
<0.5
<1LORR
<0.5
<0.5
<0.5
<5LORR
<5LORR
<1
<0.5
0.015
1
1.5
0.05
0.015
1.2
50
120
4
1.2
0.03
2
3
0.1
0.03
1.2
50
120
4
1.2
0.12
N/A
12
0.4
0.12
4.8
50
480
16
4.8
ANIONS
Chloride
Fluoride
CATIONS
Sodium
ORGANIC SPECIES
Chloroform
PAHs (total)
Styrene
Tetrachloroethene
Trichloroethene
Vinyl chloride
Xylenes (total) 160
N/A
N/A
N/A
N/A
<0.01
<0.01
<2 LORR
<0.2 LORR
<30LORR
9350
<2 LORR
<2 LORR
<2 LORR
<2 LORR
<5 LORR
N/A
<2
N/A
N/A
<2
N/A
<0.02
<0.02
<0.5
<1LORR
<140LDIL
6480
<0.5
<0.5
<0.5
<5LORR
<10
PESTICIDES
2,4‐D Chlordane
Heptachlor pH
<0.2 LORR
<0.2 LORR
<0.08
<0.2 LORR
<0.2 LORR
6.8
HAZARD CATEGORY
Where the results are the sum of several species only the positive results are added. If all results are less
than the detection limit then that is the result reported (ie Aldrin + Dieldrin = <0.05 NOT <0.01). Discussed
with Ecowise June 2009.
<0.5
<0.5
<3LLTS
<0.5
<0.5
CAT C
Comments CAT C
All parameters Cat C or IW. C10‐C36 TPH results within Cat C limits but close to upper Cat C limit
Notes:
J:\JOBS\43283717\6 Deliv\Appendices\Appendix E\4 ‐ ESR Sew Sec Haz Waste Results 2010‐2011.xlsx
1 of 2
Sewer Secondary Hazard Waste Categorisation Test Results 2011 & 2010
Sewer Secondary
Industrial Waste
ASLP0
TC0
Cat C - upper limit
ASLP1
TC1
mg/L
Cat B - upper limit Sample Date 21/10/2011
ASLP2
TC2
Testing
Lab
Report No
mg/L
21/10/2011
ALS & Leeder ALS & Leeder (Iodide)
(Iodide)
267973 & M112084
267973 & M112084
Totals
mg/kg
Sewer Secondary
Totals
ASLP
Acetate
mg/kg
Borate mg/L
mg/L
ASLP
21/10/2011 27/09/2010 27/09/2010 27/09/2010
ALS
267973
ALS & Leeder ALS & Leeder ALS & Leeder
187312 & 187312 & 187312 & M101377
M101377
M101377
Compound
INORGANIC SPECIES
mg/L
mg/kg
mg/L
mg/kg
mg/L
mg/kg
Aluminium
Antimony
Arsenic Barium
Beryllium
Boron
Cadmium
Nickel
Selenium
Silver
Tributyltin oxide
Zinc
N/A
1
0.35
35
0.5
15
0.1
2.5
100
0.5
0.05
2.5
1
0.5
5
0.05
150
N/A
75
500
6250
100
15000
100
500
5000
1500
75
1000
3000
50
180
2.5
35000
N/A
2
0.7
70
1
30
0.2
5
200
1
0.1
5
2
1
10
0.1
300
N/A
75
500
6250
100
15000
100
500
5000
1500
75
1000
3000
50
180
2.5
35000
N/A
8
2.8
280
4
120
0.8
20
800
4
0.4
20
8
4
40
0.4
1200
N/A
300
2000
25000
400
60000
400
2000
20000
6000
300
4000
12000
200
720
10
140000
N/A
N/A
N/A
<5
<5
54
<5
<10
0.3
<1
30
5
0.24
<5
9
<3
<5
<0.0005
61
N/A
N/A
N/A
<5
<5
96
<5
<10
<0.2
<1
17
<5
0.17
<5
8
<3
<5
<0.0005
43
12500
1.75
4
75
5
2500
150
N/A
N/A
1250
2500
10000
N/A
N/A
N/A
N/A
25000
3.5
8
150
10
5000
300
N/A
N/A
1250
2500
10000
N/A
N/A
N/A
N/A
N/A
14
32
600
40
20000
1200
N/A
N/A
5000
10000
40000
N/A
N/A
N/A
N/A
56
7
51
11
ND
<0.05 LINT
<0.05 LINT
N/A
ND
<0.01
<0.01
N/A
N/A
<5
<5
120
N/A
N/A
N/A
N/A
ND
ND
<0.05LINT
<0.05LINT
N/A
<0.01
<0.01
N/A
N/A
<5
<5
200
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
0.05
0.0005
N/A
N/A
0.15
15
3
15
100
0.5
75
2
0.15
1.5
3
0.2
10
0.065
15
12.5
25
0.035
100
1
N/A
7
N/A
1.5
5
0.65
2.5
40
1.5
15
0.6
0.25
200
1
0.015
30
4
5
325
5000
12
1200
240
1200
8000
40
6000
160
12
120
240
16
800
5.2
1200
1000
2000
2.8
8000
80
50
560
2
120
400
52
200
3200
120
1200
48
20
16000
80
1.2
2400
0.1
0.001
N/A
N/A
0.3
30
6
30
200
1
150
4
0.3
3
6
0.4
20
0.13
30
25
50
0.07
200
2
N/A
14
see note
3
10
1.3
5
80
3
30
1.2
0.5
400
2
0.03
60
4
5
650
10000
12
1200
240
1200
8000
16
20
2600
40000
48
4800
960
4800
32000
<0.001
N/A
N/A
<0.001
N/A
N/A
<0.001
N/A
N/A
<0.001
N/A
N/A
6000
160
12
120
240
16
800
5.2
1200
1000
2000
2.8
8000
80
100
560
see note
120
400
52
200
3200
120
1200
48
20
16000
80
1.2
2400
0.4
0.004
N/A
N/A
1.2
120
24
120
800
4
600
16
1.2
12
24
1.6
80
0.52
120
100
200
0.28
800
8
N/A
56
see note
12
40
5.2
20
320
12
120
4.8
2
1600
8
0.12
240
24000
640
48
480
960
64
3200
21
4800
4000
8000
11
32000
320
400
2200
see note
480
1600
210
800
12800
480
4800
190
80
64000
320
4.8
9600
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
<0.01
<0.01
<0.02
<0.02
0.015
1
1.5
0.05
0.015
1.2
50
120
4
1.2
0.03
2
3
0.1
0.03
1.2
50
120
4
1.2
0.12
N/A
12
0.4
0.12
4.8
50
480
16
4.8
ANIONS
Chloride
Fluoride
CATIONS
Sodium
ORGANIC SPECIES
Chloroform
PAHs (total)
Styrene
Tetrachloroethene
Trichloroethene
Vinyl chloride
Xylenes (total) 40
160
<2 LORR
<0.2 LORR
<30LORR
2070
<2 LORR
<2 LORR
<2 LORR
<2 LORR
<5 LORR
<10 LORR
<0.1
<0.1
<2 LORR
<2 LORR
<2 LORR
<4 LORR
<2 LORR
<0.1
<2 LORR
<5
4
<0.1
<20 LORR
<0.1
<0.2 LORR
<150 LORR
<0.4LORR
<2 LORR
<2 LORR
<2 LORR
<2 LORR
<2 LORR
<0.1
<2 LORR
<2 LORR
<2 LORR
<2 LORR
<2 LORR
<1.2 LORR
<4 LORR
<2LORR
<0.7LORR
<100LORR
6670
<2LORR
<2LORR
<2LORR
<1LORR
2
4.8
<0.7LORR
<0.7LORR
<2LORR
<2LORR
<4LORR
<4LORR
<1LORR
<0.1
<2LORR
<5
5
<0.7LORR
<0.5
<0.1
1
<30LORR
<0.1
<2LORR
<2LORR
<2LORR
<2LORR
<2LORR
<0.7LORR
<2LORR
<2LORR
<2LORR
<1LORR
<1LORR
<1LORR
<2LORR
PESTICIDES
2,4‐D Chlordane
Heptachlor pH
<0.2 LORR
<0.2 LORR
<0.08
<0.2 LORR
<0.2 LORR
7.2
HAZARD CATEGORY
Where the results are the sum of several species only the positive results are added. If all results are less than the
detection limit then that is the result reported (ie Aldrin + Dieldrin = <0.05 NOT <0.01). Discussed with Ecowise June 2009.
<0.05
<0.05
<3LDIL
<0.05
<0.05
CAT C
Comments All parameters Cat C or IW. Re‐test of C10‐C36 TPH returned results within IW limits
Notes:
J:\JOBS\43283717\6 Deliv\Appendices\Appendix E\4 ‐ ESR Sew Sec Haz Waste Results 2010‐2011.xlsx
2 of 2
Appendix F Wastewater
43283717/001/B
F
DIP Plant Indicative Water Balance
Production
Yield
6.5 Adt/h
61%
Fresh Water
12 kL/ADt
78 KL/h
1.9 ML/d
Backwater
25 kL/ADt
161 kL/h
3.9 ML/d
Wet Lap
1.5 ADt/h
50% moisture
2.7 KL/h
Steam
4.1 t/h
DIP Plant
Wastepaper
10.7 ADt/h
10% Moisture
1.1 kL/h
Landfill
50% moisture
0.45 Adt/h
0 8 KL/h
of water
0.8
KL/h of water
Hot Stock to Machines
5 ADt/h
96.5% Moisture
128.6 kL/h
3.1 ML/d
Water
Balance kL/h
In
Out
244 2
244 4
244.2
244.4
Note: Have not estimated water
addition via chemicals or losses via evaporation or air emissions.
Beneficial Use
50% moisture
2.8 ADt/h
5.0 kL/h of water
WWTP
To Waste Water Treatment
16.5 kL/ADt
107.25 KL/h
2.6 ML/d
Additional flow to the Latrobe River (Backwater already goes to this system)
1.8 ML/d
Appendix F - Wastewater
Figure F-1
43283717/001/B
Wastewater Treatment Overview
April
Prod
uctio
n Run
e for
Avera
g
lant E
fflue
14:30 nt - Com
bi
pm ID No ned (20/4
/12,
. 300
7719
)
DIP P
lant E
fflue
12:00 nt - Com
bi
pm ID No ned (20/4
/12,
. 300
7718
)
DIP P
lant E
fflue
08:30 nt - Com
bi
am ID No ned (20/4
/12,
. 300
7717
)
DIP P
lant E
fflue
14:30 nt - Com
bi
pm ID No ned (19/4
/12,
. 300
6033
)
lant E
fflue
12:00 nt - Com
bi
pm ID No ned (19/4
/12,
. 300
6032
)
lant E
fflue
08:35 nt - Com
bi
am ID No ned (19/4
/12,
. 300
6031
)
lant E
fflue
14:40 nt - Com
bi
pm ID No ned (18/4
/12,
. 300
4658
)
lant E
fflue
12:10 nt - Com
bi
pm ID No ned (18/4
/12,
. 300
4657
)
lant E
fflue
08:29 nt - Com
bi
am ID No ned (18/4
/12,
. 300
4656
)
lant E
fflue
14:30 nt - Com
bi
pm ID No ned (17/4
/12,
. 300
2979
)
lant E
fflue
12:07 nt - Com
bi
pm ID No ned (17/4
/12,
. 300
2978
)
lant E
fflue
08:36 nt - Com
bi
am ID No ned (17/4
/12,
. 300
2977
)
lant E
fflue
14:30 nt - Com
bi
pm ID No ned (16/4
/12,
. 300
1082
)
lant E
fflue
12:00 nt - Com
bi
pm ID No ned (16/4
/12,
. 300
1081
)
DIP P
3525
DIP P
3995
DIP P
3650
DIP P
169
208
<0.01
<0.01
262
195
13
12
DIP P
186
224
0.02
<0.01
301
250
15
15
DIP P
179
216
0.02
<0.01
279
210
14
15
DIP P
4220
0.06
1.4
<0.1
2100
1200
3.8
44
44
DIP P
5110
0.13
1.8
0.1
2500
1600
3.2
50
50
DIP P
4760
0.11
2.1
<0.1
2400
2100
3.5
50
50
DIP P
7.4
179
3618
1102
2516
69.5
3525
106
DIP P
7.4
208
4474
1646
2828
63.2
3995
294
lant E
fflue
08:28 nt - Com
bi
am ID No ned (16/4
/12,
. 300
1080
)
lant E
ffluen
t - Re
ID No st of Plan
. 061
t (19/
1200
3/12
3)
DIP P
lant E
fflue
(19/3 nt - Pulpe
/12 r
ID No & Reject
s Are
. 061
a
1200
2)
lant E
ffluen
t - Co
mbin
No. 0
ed (1
9/3/1
6112
001)
2 - ID
7.4
195
3848
1142
2706
70.3
3650
283
DIP P
TSS (mg/L) without 3 outliers
DIP P
pH
EConductivity (mS/m)
TDS (mg/L)
Total Inorganic Solids (mg/L)
Total Organic Solids (mg/L)
% Organic TDS
TSS (mg/L)
True Colour (Pt/Co)
COD (mg/L)
COD - Filtered 0.45 um (mg/L)
Total Phosphorus as P - Filtered (mg/L)
Total Phosphorus as P - Unfiltered (mg/L)
EDTA
BOD (mg/L)
Filtered BOD (mg/L)
Ammonia as N(mg/L)
Total Kjeldahl Nitrogen as N (mg/L)
Total Nitrogen as N (mg/L)
Total Nitrogen as N - Filtered (mg/L)
Chloride (mg/L)
Sulphate (mg/L)
Nitrate as N (mg/L)
Nitrite as N (mg/L)
Sodium (mg/L) - Filtered
Calcium (mg/L) - Filtered
Magnesium (mg/L) - Filtered
Potassium (mg/L) - Filtered
NOX as N (DA) - Nitrate + Nitrite as N (mg N/L)
Microtox - 15 Min EC50 (% Effluent conc.)
DIP P
Parameter
130
3600
130
3200
130
3300
120
2700
120
2800
120
2500
140
3200
140
3200
140
3500
160
2900
160
2900
160
3000
140
2700
150
2700
140
2400
139
2973
5900
90
8600
3700
3500
70
5500
3400
4000
90
7000
3400
3200
72
4800
4000
6500
72
6500
4000
14000
56
8700
3600
18000
70
9000
3700
19000
70
10000
4000
3200
80
4900
4000
2500
80
5700
4700
3000
60
5600
4800
560
80
7100
4100
7400
60
9800
4000
2700
60
4600
3400
2500
50
3700
3100
6397
71
6767
3860
2700
1600
1800
2200
1400
2200
1000
2100
1000
38
38
45
45
38
38
35
39
38
31
32
32
55
56
56
48
20
37
19
40
19
44
26
48
26
45
28
0.01
0.14
<0.01
3.4
1.3
0.77
<0.1
<0.1
11
<0.1
<0.1
0.44
13
0.02
3000
560
5900
3500
4000
3200
6500
2100
1133
3200
2500
35
19
36
16
33
22
10
7400
2700
40
41
27
11
2500
3747
F.1
Introduction
URS has reviewed the data from the operation of the existing WWTP at the AP site in the light of the
proposed discharge of DIP plant wastewater to it. The objective was to:
 calculate the current operating parameters and treatment efficiencies
 estimate the impact of the DIP on treated water quality discharge to the river.
The existing plant is shown schematically in the Wastewater Treatment Overview Figure below.
F.2
Proposed DIP Plant
The overall water balance is as follows:
Table F-1
Water Type
Basis (kL/ADMT)
Average daily flow
(kL/d)
Annual Volume(ML)
Fresh Water
12
1685
590
Machine Backwater (reuse of water)
6
842
295
16.5
2317
811
Extra Discharge to River
10.5
1474
516
Therefore the quantity of wastewater produced from the DIP plant to be treated is 2.32 ML/d while
due to reuse of wastewater the net discharge to the river will increase by 1.47ML/d.
The wastewater discharges from the DIP at Amcor Fairfield were tested during production runs in
March and April 2012. Wastewater samples were collected from the central DIP plant wastewater
collection pit, targeted to times when the pulper rejects area, which is a batch operation at Fairfield,
was also discharging to the pit.
The DIP plant effluent quality is presented in Table F-2:
Table F-2
DIP Effluent Quality
PARAMETER
Units
Average DIP Effluent Concentration (TEST RESULTS)
mg/L
2973
Suspended Solids
mg/L
3747
mg/L
71
BOD (total)
mg/L
2100
BOD (filtered)
mg/L
1133
Anionic Surfactants
mg/L
NM but non-ionic surfactant being used, and intend to simulate
impact on MV effluent.
Total Phosphate (as P)
mg/L
2.1
Nitrate (as N)
mg/L
0.02
Ammonia (as N)
mg/L
3.5
43283717/001/B
PARAMETER
Units
Average DIP Effluent Concentration (TEST RESULTS)
AOX
mg/L
NM (not considered relevant to DIP Plant)
2,3,7,8, TCDD (dioxin)
pg/L
NM (not considered relevant to DIP Plant)
-
7.4
pH
NM Not Measured
It should be noted that the suspended solids in the DIP effluent, with majority in range 2,500 – 7,400
mg/L, (excluding very high suspended solids (14,000-19,000mg/L) are very high indicating that it is
unlikely that operation of the DAFs and/or centrifuges was optimised. NPI has provided effluent
suspended solids figures in the range 1341-2197 mg/L for two Japanese DIP mills. These support
the conclusion that operation was non optimal during part of the production run.
URS has based the assessment on the results in Table 2. The use of the Amcor Fairfield production
results is a conservative approach as:
 lower suspended solids would be achieved through optimised DAF and centrifuge operation
 this should also reduce the effluent BOD load.
F.3
Proposed upgrade
AP is proposing to upgrade the operations of the existing wastewater treatment plant in order to treat
the additional load from the DIP plant. The DCS (Distributed Control System) of the plant is currently
being upgraded. The proposed scope (as of 28/5/12) is as follows:






11No x 35.5kW aerators including air blowers to enhance aeration capacity in aeration pond 1A
Additional Dissolved Oxygen Measurement in aeration pond 1A
Upgraded nutrient dosing controls to inflow to aeration pond 1A
Upgraded flow based coagulant & flocculent controls to the primary clarifiers
Upgraded and flow based coagulant and flocculent dosing to the Secondary Clarifier
DCS Monitoring of recently installed TSS Meters on the inlet and outlet of the Secondary Clarifier
43283717/001/B
F.4
Impact on the Existing WWTP
The additional flows and loads on the WWTP for key constituents is summarised in Table F-3
Table F-3
Loads into WWTP
Constituent
DIP Mass load kg/d
Combined Mass Load(kg/d)
BOD (total)
4,865
16,250
Suspended Solids
8,680
Existing inflows not monitored for
suspended solids
Nitrate *
0.05
N/A
Ammonia*
8.1
N/A
Total Phosphorus*
4.9
N/A
*Nitrogen and phosphorus are dosed to enhance biological treatment and hence the DIP mass loads are not relevant for the
assessment
The key elements of the waste water treatment plant and the DIP impact are discussed in Table F-4.
Table F-4
Impact of DIP Wastewater ex DAF on the existing WWTP
Treatment
Plant Element
Key
operating
parameter
Impact
Control options
Impact on
Treated water
Quality
Primary
Clarifiers (40m
dia.)
Hydraulic
load
(m3/m2/hr)
The additional flows are
about 4-5% of total flows.
The hydraulic load remains
within convention
parameters (around 1
m3/m2/hr). Therefore
suspended solids in the
effluent should not change
significantly.
Chemical dosing of
coagulants and
flocculants is currently
used. The dose can be
optimised through the
proposed improved
controls.
The effluent
suspended solids
should remain
around the same
concentration.
Aeration Pond
(No1A)
Retention
time
The additional retention time
required due to a 4-5%
increase in flow is not
considered significant. The
retention remains around 4
days.
BOD removal
efficiency (87%)
should be
maintained.
BOD load
The BOD load is estimated
to increase by around 40%
to about 16 T/d. AP are
proposing to increase the
aeration and mixing by
368.5kW to address the
additional BOD load. This is
more than 1.5 times the
oxygen demand required for
the DIP wastewater, but will
cover peak loads.
Additional aeration is
required and mixing to
maintain the BOD
removal efficiency. The
use of Dissolved
oxygen monitoring and
associated aeration
and mixing controls will
optimise treatment and
minimise energy
usage.
43283717/001/B
Treatment
Plant Element
Secondary
Clarifier
Key
operating
parameter
Impact
Control options
Nutrient
Dosing
The DIP does not change
the situation.
Improved flow based
nutrient dosing and
inline measurement
should assist in
maintaining
compliance for N and
P in the effluent.
Hydraulic
Load
The hydraulic load remains
similar around 1 m3/m2/hr.
It is proposed to
upgrade the existing
chemical dosing (e.g.
coagulant and
flocculant) to be flow
and suspended solids
based. This will further
improve treated water
suspended solids
concentrations.
The effluent
suspended solids
should improve
and be more
manageable.
None proposed, other
than improved
management of
potential slimes
impacts from adjacent
sand quarries.
Effluent quality
should not
change. BOD
removal is around
80% based on
Effluent Soluble
BOD (2010-2012)
and 64 % based
on total BOD
(2000-2009).
(m3/m2/hr)
No2 Aeration
pond
Solids Load
2
(kg/ m /hr)
The solids load is very low
because the aeration pond
has low suspended solids
(normal for an aerated
lagoon). The increased
suspended solids from the
treatment of DIP wastewater
will not result in excessive
solids load.
Retention
time
The retention time is
currently 3-4 weeks. The
increased flow and BOD
load does not significantly
impact on the operations.
Impact on
Treated water
Quality
Maintenance of
compliance for N
and P.
Proposed upgrades are highlighted in green.
The TSS performance ex the secondary clarifier has shown a positive reduction since late March
2012, with the majority of TSS results being below 20 mg/L. The reason for this improvement has
been the new DCS upgrade project for the effluent treatment plant. Part 1 of this upgrade project
included linking the alum dosing pump speed to the flow of effluent going through the secondary
clarifier. This was programmed into the new DCS in late March 2012 and has assisted in better and
more consistent performance. It is expected that this improved performance can be taken as the
baseline scenario going forward. Further proposed upgrades to the secondary clarifier for the DIP
project comprise addition of a flow meter to the alum and polymer dosing, and then have the DCS do
proper flow ratio to targeted ppm addition rates.
43283717/001/B
On the basis of the assessment of the performance of the existing WWTP, the following parameters
(Table F-5) were used to calculate the performance of the upgraded plant and to estimate the changes
to the treated water quality of the discharges to the river.
Table F-5
Operating Parameters for the Existing WWTP
Treatment Step
Assumed Removals Achieved
No 1 Wastewater Primary Clarifier
Maximum Average monthly effluent concentration
used : 112mg/L*
0.1kgBOD/kgSS removed by settling
Aeration Pond ( no 1A)/Secondary clarifier
87% Total BOD removal
Secondary Clarifier
73% SS Removal
Aeration pond No 2
80% BOD removal based on soluble BOD
And 62% based on total BOD
No SS removal
*From January 2009 –April 2012
F.5
Estimated Treated Water Quality of River Discharge
The treated water quality for River Discharge was estimated based on:




The reported river discharge quality;
the calculated loads on the wastewater treatment plant including DIP;
the calculated operating parameters (Table F-6): and
the water monitoring data for the existing WWTP.
Table F-6
PARAMETER
Units
Draft Licence
Limit14
2010 Average
Final Effluent
Concentration
Average DIP
Effluent
Concentration
(TEST
RESULTS)
Combined
effluent ex
Secondary
Clarifier
Discharge to
River Flow
ML/d
ay
55 (annual
median)
41.3
2.58
48.3
42.8B
Total
Dissolved
Solids
mg/L
1000
(maximum)
532
2973
649
649
Suspended
Solids
mg/L
30 (annual
median)
29
3747
20F
20F
Colour (Pt-Co
Units)
mg/L
200
(maximum)
98
71
97C
97
2100
44
15
A
Predicted
Final
Effluent
850 (annual
median)
140 (annual
median)
BOD (total)
14
mg/L
30 (maximum)
Limits taken from Draft EPA Licence with the date 25 May 2012.
43283717/001/B
PARAMETER
Units
Draft Licence
Limit14
2010 Average
Final Effluent
Concentration
Average DIP
Effluent
Concentration
(TEST
RESULTS)
Combined
effluent ex
Secondary
Clarifier
Predicted
Final
Effluent
Anionic
Surfactants
mg/L
0.5 (maximum)
0.20
NM
Total
Phosphate (as
P)
mg/L
0.25 (annual
median)
0.15
2.1
0.15E
0.15
Nitrate (as N)
mg/L
0.15
0.02
0.14 E
0.14
C
1.46
D
0.20
0.3 (maximum)
0.4 (annual
median)
0.1 (maximum)
Ammonia (as
NH3)
mg/L
3.1 (maximum)
1.36
3.5
1.46
AOX
mg/L
1.0 (maximum)
0.01
NM
NM
pH
-
6.0 - 8.5
7.5
7.4
0.01
7.50
Note
A - Includes flows that are recycled to the mill
B - excludes flows that are recycled.
C - assumes (conservatively) that there is no reduction in DIP colour or ammonia in the WWTP.
D - DIP effluent not measured, non-ionic surfactant used, so no expected impact on anionic surfactant levels.
E –Nitrogen & Phosphorus are dosed to the WWTP to achieve a targeted nutrient level – no increase expected.
F – Suspended solids of less than 20 mg/L are achievable from the secondary clarifier with the proposed upgrades to chemical
dosing.
NM - not measured
Table F-7
PARAMETER
Units
Draft
Licence
Limit
2011
Average
Average DIP
Effluent
Concentration
(TEST
RESULTS)
Combined
effluent ex
Secondary
Clarifier
Predicted
Final
Effluent
ML/day
55 (annual
median)
44.3
2.3
52.0A
45.8B
Total
Dissolved
Solids
mg/L
1000
(maximum)
493
2973
650
650
Suspended
Solids
mg/L
30( annual
median)
36
3747
20F
20F
Colour (Pt-Co
Units)
mg/L
200
(maximum)
94
71
92
92C
2100
44
15
Flow
850 (annual
median)
140 (annual
median)
BOD (total)
43283717/001/B
mg/L
30
(maximum)
PARAMETER
Units
Draft
Licence
Limit
2011
Average
Average DIP
Effluent
Concentration
(TEST
RESULTS)
Combined
effluent ex
Secondary
Clarifier
Predicted
Final
Effluent
D
Anionic
Surfactants
mg/L
0.5
(maximum)
0.20
NM
0.20
Total
Phosphate (as
P)
mg/L
0.25 (annual
median)
0.18
2.1
0.18E
0.18
Nitrate (as N)
mg/L
0.04
0.02
0.04E
0.04
C
1.28
0.3
(maximum)
0.4 (annual
median)
0.1
(maximum)
Ammonia (as
NH3)
mg/L
3.1
(maximum)
1.24
3.5
1.28
AOX
mg/L
1.0
(maximum)
0.06
NM
NM
6.0 - 8.5
7.3
7.4
pH
0.06
7.50
Note
A - Includes flows that are recycled to the mill
B - Excludes flows that are recycled.
C - Assumes (conservatively) that there are no reduction in DIP colour or ammonia in the WWTP.
D - DIP effluent not measured, non-ionic surfactant used, so no expected impact on anionic surfactant levels.
E - Nitrogen & Phosphorus are dosed to the WWTP to achieve a targeted nutrient level – no increase expected.
F - Suspended solids of less than 20 mg/L are achievable from the secondary clarifier with the proposed upgrades to chemical
dosing.
NM not measured
The discharge results for 2010 and 2011 demonstrate compliance with the licence requirements
except for suspended solids for 2011. This exceedance will not be impacted by the DIP effluent. This
exceedance appears to be due to poor secondary clarifier performance (34.2 mg/L); this will be
improved through the upgraded chemical dosing systems, as already demonstrated by Part 1 of the
DCS upgrade.
The estimated treated water quality in the discharge to the river has been developed on a
conservative basis due to:
 The DIP effluent characteristics are higher than are expected due to non-optimised DAF operation
during the trial. Therefore DIP effluent ex the DAF should be better quality in terms of BOD and
suspended solids and lower load to the WWTP;
 Total BOD from DIP plant was used for the predicted final effluent quality, rather than filtered BOD;
 No removal of colour from the DIP effluent was assumed: in reality colour removal will occur in the
aerated lagoon and hence give lower colour in treated water; and
 No removal of nutrient from the DIP effluent was assumed: in reality nutrient removal will occur in
the aerated lagoon and lagoon No 2 resulting in better treated water quality.
This approach reported herein together with the associated assumptions and the proposed upgrades
should give confidence that the treated wastewater should comply with licence conditions for the
parameters assessed.
43283717/001/B
Appendix G Chemicals
43283717/001/B
G
Appendix G - Chemicals
Table G-1
Chemical Overview (based on current Fairfield Suppliers, which may be different at Maryvale)
Trade Name
As Rec'd
SG
%
Caustic Soda
Hydrogen
Peroxide
Sodium Silicate
Storage
Usage
m3
kg/Adt
Supplier
Comment
Orica
Intention to use current MV storage &
makedown system to 10% with day tank
at DIP Plant
Solvay
Intention to use MV current storage with
small day tank
1.48
15
4.7
DG
1824
8/II
59.5
1.24
6
7.8
DG,
MHF
2014
5.1/8/II
38
1.4
60
7.2
NA
PQ Australia
Current FRC Tank
8
2
NA
Buckman
Current FRC Tank
1.05
NA
Buckman
Motherbin - approx 1.5 tonnes
9/III
Buckman
Current FRC Tank - poly tank
NA
Buckman
Polymix unit to makedown
BRD 2357
NA
1.02
Defoamer
Bubreak 4305
NA
0.98
Coagulant
Bufloc 5033
NA
1.15
Flocculant
Bufloc 5297
solid
Biocide
Busan 85
NA
1.23
Fungicide #1
Busan 30WB
NA
1.11
0.39
Fungicide #2
Busan 7650
NA
1.0
0.15
FAS
Amtrade
43283717/001/B
DG Class
46
Surfactant
Alum (River)
UN Code
4.5
IBC not
DG
3082
0.4
powder
26
5
0.4
1.3
5
1.8
IBC not
CG
3082
9/III
Buckman
DG
3265
8/III
Buckman
NA
Buckman
4.2/II
Amtrade
Current FAS preparation tank - special
bag to fill hopper
Orica
Part of existing wastewater or effluent
system
DG,
MHF
3341
Na
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Version 1.9.40
Copyright ©
2012 ACOHS
Pty Ltd.
NOHSC 16 Section
Material Safety Data Sheet
Uncontrolled Copy
ALUMINIUM SULFATE SOLUTION
Infosafe™
No.
6AP5U
Issue Date July 2010
Status APPROVED by
APMMARYV
BS:
1.9.40
1. IDENTIFICATION OF THE MATERIAL AND SUPPLIER
Product Name
ALUMINIUM SULFATE SOLUTION
Company Name
ORICA AUSTRALIA PTY LTD (ABN 004 117 828)
Address
1 Nicholson Street East Melbourne
Victoria 3000
Emergency Tel.
61-03-96657624
Telephone/Fax
Number
Tel: +61 3 9665 7111
Fax: +61 3 9665 7937
Recommended Use Water treatment.
Other Names
None Listed
http://pmvlii0001/info2000/MainMenu.asp (1 of 9)3/04/2012 1:45:28 PM
MSDS ONLINE
Additional
Information
Transcribed in Infosafe from the original MSDS from the
Supplier dated 09/05/2005.
2. HAZARDS IDENTIFICATION
Hazard
Classification
HAZARDOUS SUBSTANCE.
NON-DANGEROUS GOODS.
Hazard classification according to the criteria of NOHSC.
Dangerous goods classification according to the Australia
Dangerous Goods Code.
Risk Phrase(s)
R36/38 Irritating to eyes and skin.
Safety Phrase(s) S26 In case of contact with eyes, rinse immediately with
plenty of water and seek medical advice. S24/25 Avoid
contact with skin and eyes. S36/37/39 Wear suitable
protective clothing, gloves and eye/face protection.
3. COMPOSITION/INFORMATION ON INGREDIENTS
Composition,
information on
ingredients
*
50.0-52.3% as Al2(SO4)3.18H2O
Chemical
Characterization Liquid
Ingredients
Name
CAS
Proportion
Aluminium
Sulphate
10043-01-3
25.7-26.8
%
Sulfuric Acid
7664-93-9
Trace
Water
7732-18-5
To 100%
MSDS ONLINE
4. FIRST AID MEASURES
Inhalation
Remove victim from area of exposure - avoid becoming a
casualty. Remove contaminated clothing
and loosen remaining clothing. Allow patient to assume most
comfortable position and keep warm.
Keep at rest until fully recovered. For all but the most
minor symptoms arrange for patient to be
seen by a doctor as soon as possible, either on site or at
the nearest hospital.
Ingestion
Immediately rinse mouth with water. If swallowed, do NOT
induce vomiting. Give a glass of water.
Seek immediate medical assistance.
Skin
If skin or hair contact occurs, immediately remove any
contaminated clothing and wash skin and hair thoroughly
with running water. If swelling, redness, blistering or
irritation occurs seek medical
assistance.
Eye
If in eyes, hold eyelids apart and flush the eye
continuously with running water. Continue flushing
until advised to stop by the Poisons Information Centre or
a doctor, or for at least 15 minutes.
Advice to
Doctor
Treat symptomatically.
5. FIRE FIGHTING MEASURES
Suitable
Extinguishing
Media
Specific
Hazards
Not combustible, however, if material is involved in a fire
use: Water fog (or if
unavailable fine water spray), foam, dry agent (carbon
dioxide, dry chemical powder).
Non-combustible material.
MSDS ONLINE
Precautions in Decomposes on heating emitting toxic fumes, including those
of oxides of sulfur . Fire
connection
fighters to wear self-contained breathing apparatus and
with Fire
suitable protective clothing if
risk of exposure to products of decomposition
6. ACCIDENTAL RELEASE MEASURES
Emergency
Procedures
Clear area of all unprotected personnel. Slippery when
spilt. Avoid accidents, clean up immediately. Wear
protective equipment to prevent skin and eye contact.
Contain - prevent run off into drains and waterways. Use
absorbent (soil, sand or other inert material). Neutralise
with lime or soda ash. Collect and seal in properly
labelled containers or drums for disposal. Wash area down
with excess water. If contamination of sewers or waterways
has occurred advise local emergency services.
7. HANDLING AND STORAGE
Precautions
for Safe
Handling
Avoid skin and eye contact and breathing in vapour, mists
and aerosols.
Conditions for Store in cool place and out of direct sunlight. Store away
from incompatible materials described in
Safe Storage
Section 10. Keep containers closed when not in use - check
regularly for leaks.
8. EXPOSURE CONTROLS/PERSONAL PROTECTION
MSDS ONLINE
National
Exposure
Standards
No value assigned for this specific material by the
National Occupational Health and Safety Commission.
However, Exposure Standard(s) for constituent(s):
Aluminium, soluble salts (as Al): 8hr TWA = 2 mg/m3
Sulfuric acid: 8hr TWA = 1 mg/m3, 15 min STEL = 3 mg/m3
As published by the National Occupational Health and Safety
Commission.
TWA - The time-weighted average airborne concentration over
an eight-hour working day, for a five-day working week over
an entire working life.
STEL (Short Term Exposure Limit) – the average airborne
concentration over a 15 minute period which should not be
exceeded at any time during a normal eight hour work day.
According to current knowledge this concentration should
neither impair the health of, nor cause undue discomfort
to, nearly all workers. These Exposure Standards are guides
to be used in the control of occupational health hazards.
All atmospheric contamination should be kept to as low a
level as is workable. These exposure standards should not
be used as fine dividing lines between safe and dangerous
concentrations of chemicals. They are not a measure of
relative toxicity.
Engineering
Controls
Ensure ventilation is adequate and that air concentrations
of components are controlled below quoted Exposure
Standards. If inhalation risk exists: Use with local
exhaust ventilation or while wearing suitable mist
respirator. Keep containers closed when not in use.
Personal
Protective
Equipment
Orica Personal Protection Guide No. 1, 1998: C - OVERALLS,
SAFETY SHOES, CHEMICAL GOGGLES, GLOVES.
Wear overalls, chemical goggles and impervious gloves.
Always wash hands before smoking, eating, drinking or using
the toilet. Wash contaminated clothing and other protective
equipment before storage or re-use. If risk of inhalation
exists, wear suitable mist respirator meeting the
requirements of AS/NZS 1715 and AS/NZS 1716.
9. PHYSICAL AND CHEMICAL PROPERTIES
Form
Liquid
MSDS ONLINE
Other
Information
Physical state: Liquid
Colour: Clear to Pale Brown
Odour: Odourless
Solubility: Miscible with water.
Specific Gravity: 1.29-1.32 @25°C
Relative Vapour Density (air=1): Not available
Vapour Pressure (20 °C): Not available
Flash Point (°C): Not applicable
Flammability Limits (%): Not applicable
Autoignition Temperature (°C): Not available
Boiling Point/Range (°C): >100
pH: 2.3-2.8
10. STABILITY AND REACTIVITY
Chemical
Stability
This material is considered stable. Hazardous
polymerization will not occur. Hazardous decomposition
products may include oxides of sulfur. Reacts with
alkalis . Corrosive to most metals .
11. TOXICOLOGICAL INFORMATION
Toxicology
Information
No adverse health effects expected if the product is
handled in accordance with this Safety Data Sheet and the
product label. Symptoms or effects that may arise if the
product is mishandled and overexposure occurs are:
Inhalation
Breathing in mists or aerosols may produce respiratory
irritation.
Ingestion
Swallowing can result in nausea, vomiting, diarrhoea, and
gastrointestinal irritation.
Skin
Contact with skin will result in severe irritation.
Eye
An eye irritant
Chronic Effects No information available for the product.
MSDS ONLINE
Other
Information
Toxicological Data:
No LD50 data available for the product. For the constituent
ALUMINIUM SULFATE:
Oral LD50 (mice): 6207 mg/kg.
12. ECOLOGICAL INFORMATION
Ecological
Information
Avoid contaminating waterways.
13. DISPOSAL CONSIDERATIONS
Refer to Waste Management Authority. Dispose of material
Disposal
Considerations through a licensed waste contractor. Decontamination and
destruction of containers should be considered.
14. TRANSPORT INFORMATION
Transport
Information
Road and Rail Transport
Not classified as Dangerous Goods by the criteria of the
Australian Dangerous Goods Code (ADG Code) for transport by
Road and Rail.
Marine Transport
International Maritime Dangerous Goods Code (IMDG Code) for
transport by sea.
Air Transport
International Air Transport Association (IATA) Dangerous
Goods Regulations for transport by air.
15. REGULATORY INFORMATION
Poisons
Schedule
Not Scheduled
MSDS ONLINE
Hazard Category Irritant
AICS
(Australia)
All the constituents of this material are listed on the
Australian Inventory of Chemical Substances (AICS).
16. OTHER INFORMATION
Date of
preparation or Supplier Material Safety Data Sheet; 02/ 2005.
last revision This material safety data sheet has been prepared by SH&E
Shared Services, Orica.
of MSDS
Manufacturers
Advice
This MSDS summarises to our best knowledge at the date of
issue, the chemical health and safety hazards of the
material and general guidance on how to safely handle the
material in the workplace. Since Orica Limited cannot
anticipate or control the conditions under which the
product may be used, each user must, prior to usage, assess
and control the risks arising from its use of the material.
If clarification or further information is needed, the user
should contact their Orica representative or Orica Limited
at the contact details on page 1. Orica Limited's
responsibility for the material as sold is subject to the
terms and conditions of sale, a copy of which is available
upon request.
Last Change
Reason(s) for Issue:
Change in Formulation
Change in Physical Properties
End of MSDS
(C) Copyright ACOHS Pty Ltd
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files rendered by an Infosafe system for Infosafe MSDS displayed is the
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Copyright in the layout, presentation and appearance of each Infosafe MSDS
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The compilation of MSDS's displayed is the intellectual property of Acohs Pty
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Copying of any MSDS displayed is permitted for personal use only and otherwise
is not permitted. In particular the MSDS's displayed cannot be copied for the
purpose of sale or licence or for inclusion as part of a collection of MSDS
without the express written consent of Acohs Pty Ltd.
Print Date: 03/04/2012
BS: 1.9.40
MATERIAL SAFETY DATA SHEET
Section 1. Identification of the Material and Supplier
Product Name
BRD 2357
Other Names
Not applicable
Recommended
Use
Deinking aid used in the paper industry.
Supplier Details
Buckman Laboratories
East Bomen Road
Wagga Wagga NSW 2650
Australia
A.B.N. 53 000 922 118
Telephone 02 69 235 888, Freecall 1800 257 272
Fax 02 69 235 889
Website: www.buckman.com
Emergency Contact 24 hours emergency phone
0408 255 124
Freecall 1800 127 295
Only for use in case of human exposure or chemical spills
Section 2. Hazards Identification
Hazard
Classification
Classified as hazardous according to the criteria of the
Safe Work Australia. Not classified as a Dangerous
Goods according to the criteria of the Australian
Dangerous Goods Code for transport by road and rail.
HAZARDOUS SUBSTANCE. NON-DANGEROUS
GOODS.
Risk Phrases
R36 – Irritating to eyes
Safety Phrases
S24/25 – Avoid contact with skin and eyes
S36/37 – Wear suitable protective clothing and gloves
BRD 2357
Issued: 1 January 2011
1 of 7
Section 3. Composition and Information on Ingredients
Name of hazardous Ingredients
Nonionic surfactant
CAS
Number
Proprietary
Conc.
Range,
% w/w
10 - 30
Section 4. First Aid Measures
Eye Exposure
Flush immediately with copious amounts of tap water or
normal saline for a minimum of 15 minutes. Take
exposed individual to a health care professional,
preferably an ophthalmologist, for further evaluation.
Skin Exposure
Wash exposed area with copious quantities of water.
Repeat washing. Remove contaminated clothing and
wash thoroughly before use. If irritation persists consult a
health care professional.
Inhalation
If exposure by inhalation is suspected, immediately
remove exposed individual to fresh air. If individual
experiences nausea, headache, dizziness, has difficulty
breathing or is cyanotic, seek a health care professional
immediately.
Ingestion
DO NOT INDUCE VOMITING. Rinse mouth with copious
amounts of water or milk initially. Irrigate the oesophagus
and dilute stomach contents by slowly giving one to two
glasses of water or milk. Avoid giving alcohol or alcohol
related products. In cases where the individual is semicomatose, comatose or convulsing DO NOT GIVE
FLUIDS BY MOUTH. In case of intestinal ingestion of the
product seek medical assistance immediately – take the
individual to the nearest medical facility.
Advice to Doctor
Medical consultation is available 24 hours a day. Call the
Buckman office on 0408 255 124. If no response, call toll
free on 1800 127 295.
Section 5. Fire Fighting Measures
Extinguishing
Media
Water fog, carbon dioxide, foam, dry chemical.
Hazardous
Combustion
Products
Oxides of carbon.
BRD 2357
2 of 7
Section 5. Fire Fighting Measures (continued)
Special Firefighting
Procedures
Firefighters should wear positive pressure self-contained
breathing apparatus (SCBA).
Hazchem Code
Not applicable.
Section 6. Accidental Release Measures
Emergency
Procedures
Clean Up
Procedures
Wear appropriate Personal Protective Equipment (PPE) –
see Section 8 of this MSDS. Initially minimise the area
affected by the spill. Block any potential routes to water
systems (streams, lakes, sewers). For technical advice
ring 0408 255 124.
Recover as much of the pure product as possible into
appropriate containers. Check with the Buckman
representative prior to use of recovered product. Absorb
remaining spill with an inert dry material like clay, soil,
sand or other non-flammable absorbent material.
Dispose of contaminated absorbent at a registered EPA
waste treatment facility. Wash away residues with water.
If washing spill residual to an industrial sewer ensure
there will be no contact with incompatible materials check with the operator of your facility’s industrial sewer
prior to intentionally flushing spill residual to the sewer.
Section 7. Handling and Storage
Safe Handling
Precautions
Safety showers and eyewashes are recommended in the
workplace. Avoid contact with eyes, skin and clothing.
Do not eat, drink or smoke when working with this
product. Wash hands after use and remove PPE before
entering eating areas. Where applicable provide spill
containment compliant with the National Code of Practice
for the Storage and Handling of Workplace Dangerous
Goods [NOHSC: 2017].
Conditions for Safe
Storage
Store in a cool, dry, ventilated area away from direct
sunlight. Keep containers tightly closed. Do not store
with strong acids, strong bases or strong oxidisers.
BRD 2357
3 of 7
Section 7. Handling and Storage (continued)
Compatible
Materials of
Construction
This product has not been tested for satisfactory materials
of construction.
Section 8. Exposure Controls and Personal Protection
National Exposure
Standards
None allocated.
Biological Limit
Values
Engineering
Controls
No biological limit allocated.
Use in a well ventilated area. Ensure that eyewash
stations and safety showers are in close proximity to the
work area.
Personal Protective
Equipment
Wear safety glasses or safety goggles, nitrile gloves,
safety boots.
Section 9. Physical and Chemical Properties
Appearance
Odour
pH (neat)
pH (100 ppm
in water)
Vapour Pressure
Boiling Point
Melting Point
Solubility
Density
Flashpoint
Very light yellow to colourless, hazy liquid
Sweet (Slight)
7.5
Not available
Not available
Not available
Not available
Soluble in cold water
Approx. 1.02 g/ml
CLOSED CUP: > 120oC (Expected)
Section 10. Stability and Reactivity
Chemical Stability
BRD 2357
This product is stable under normal ambient and
anticipated storage and handling conditions of
temperature and pressure. Typical product shelf life is 12
months.
4 of 7
Section 10. Stability and Reactivity (continued)
Conditions to
Avoid
Not applicable.
Incompatible
Materials
Strong acids, strong bases and strong oxidisers.
Hazardous
Decomposition
Products
Oxides of carbon.
Hazardous
Reactions
None known.
Section 11. Toxicological Information
Acute Health
Effects
Not tested but based on the toxicity of components this
product is expected to be of low toxicity.
Inhalation
Not expected to be harmful by inhalation
Eye Contact
Irritating to eyes – inflammation of the eye is
characterised by redness, watering and itching.
Skin Contact
May be mildly irritating to skin – skin inflammation is
characterised by itching, scaling, reddening and,
occasionally, blistering.
Sensitization
Non-sensitizer for skin.
Chronic Health
Effects
The effects from chronic exposure have not been fully
evaluated. This product is not considered a carcinogen –
no components are shown as carcinogens by the
International Agency for Research on Cancer.
Section 12. Ecological information
Ecotoxicity
BRD 2357
No information available.
5 of 7
Section 13. Disposal considerations
Disposal Methods
Follow state EPA regulations governing the disposal of
waste materials. The waste generator has the
responsibility for proper waste classification,
transportation and disposal. Only use EPA licensed
transport and waste facility providers.
For disposal of neat product, contact your Buckman
representative. Do not dispose of contaminated materials
to an industrial effluent system without first determining
the impact on the system.
Check the characteristics of the material to be disposed
of and/or the physical and reactivity data provided in this
MSDS for the neat product.
Where possible, Buckman will assist with the recycling of
product containers.
Special Precautions
For Landfill or
Incineration
Product is suitable for incineration at an EPA approved
facility. Triple rinsed 15L cubes are suitable for disposal
at an approved landfill.
Section 14. Transport information
Road and Rail
Transport
Special
Precautions
Marine Transport
Not classified as a Dangerous Good according to the
criteria of the Australian Dangerous Goods Code for
transport by road and rail.
Not applicable.
criteria of the International Maritime Dangerous Goods
Code for transport by sea.
Section 15. Regulatory information
Poisons Schedule Not scheduled.
NICNAS
Components are listed on the Australian Inventory of
Chemical Substances (AICS).
FDA
This product is approved under the following FDA (21
CFR) section: 176.210.
BRD 2357
6 of 7
Section 16. Other information
Date of MSDS
Preparation
1 January 2011.
Reason for Issue
5 year update required.
Contact
Regulatory Affairs Manager
02 69 235 888
Free call 1800 257272
Emergency 1800 127 295, 0408 255 124
The information on this Material Safety Data Sheet reflects the latest information
and data that we have on hazards, properties, and handling of this product
under the recommended conditions of use. Any use of this product or method of
application which is not described in the product data sheet is the responsibility
of the user.
END OF MSDS
BRD 2357
7 of 7
Product Name
BUBREAK® 4305
Other Names
Not applicable
Recommended
Use
Defoamer for use in the pulp and paper industry.
Supplier Details
East Bomen Road
Australia
A.B.N. 53 000 922 118
Fax 02 69 235 889
0408 255 124
Freecall 1800 127 295
Hazard
Classification
Not classified as hazardous according to the criteria of
the Safe Work Australia. Not classified as a Dangerous
NON-HAZARDOUS SUBSTANCE. NON-DANGEROUS
GOODS.
Risk Phrases
Not applicable
Safety Phrases
The components of this product comprise proprietary information.
Bubreak 4305
Issued: 28 December 2010
1 of 7
Eye Exposure
Skin Exposure
Inhalation
immediately.
Ingestion
Advice to Doctor
free on 1800 127 295.
Extinguishing
Media
Hazardous
Combustion
Products
Oxides of carbon.
Procedures
Hazchem Code
Bubreak 4305
Not applicable.
2 of 7
Emergency
Procedures
Clean Up
Procedures
ring 0408 255 124.
Dispose of contaminated absorbent at an EPA registered
Safe Handling
Precautions
Conditions for Safe
Storage
sunlight. Keep containers tightly closed. This product is
incompatible with strong acids and oxidisers.
Compatible
Materials
of Construction
Bubreak 4305
This product has not been tested for satisfactory materials
of construction.
3 of 7
National Exposure
Standards
No exposure standard allocated.
Biological Limit
Values
Engineering
Controls
work area.
Personal Protective
Equipment
safety boots.
Appearance
Odour
pH (neat)
Vapour Pressure
Melting Point
Solubility
Specific Gravity
at 15oC
Flashpoint
Thick white liquid
Bland
8.5
Very low
Not tested
Disperses
0.98
Not applicable
Chemical Stability
months.
Conditions to
Avoid
Not applicable
Incompatible
Materials
Strong acids and oxidisers
Hazardous
Decomposition
Products
Oxides of carbon.
Bubreak 4305
4 of 7
Hazardous
Reactions
Not applicable
Acute Health
Effects
Not tested but based on components expected to be of
low toxicity.
Inhalation
Not expected to be harmful by inhalation.
Eye Contact
May be mildly irritating to eyes.
Skin Contact
May be mildly irritating to skin.
Sensitization
Chronic Health
Effects
evaluated.
Ecotoxicity
Not available.
Disposal Methods
Bubreak 4305
Follow EPA regulations governing the disposal of waste
materials. The waste generator has the responsibility for
proper waste classification, transportation and disposal.
Only use licensed EPA transport and waste facility
providers.
product containers.
5 of 7
Section 13. Disposal considerations (continued)
Special Precautions
For Landfill or
Incineration
Road and Rail
Transport
Special
Precautions
Marine Transport
Not applicable.
NICNAS
FDA
CFR) sections: 176.210, 176.170.
Date of MSDS
Preparation
28 December 2010.
Reason for Issue
Bubreak 4305
6 of 7
Section 16. Other information (continued)
Contact
02 69 235 888
Free call 1800 257272
Emergency 1800 127 295, 0408 255 124
of the user.
END OF MSDS
Bubreak 4305
7 of 7
Product Name
BUFLOC® 5033
Other Names
Cationic polymer.
Recommended
Use
Coagulant for water treatment
Supplier Details
Buckman Laboratories Pty Ltd
East Bomen Road
Australia
A.B.N. 53 000 922 118
Fax 02 69 235 889
0408 255 124
Freecall 1800 127 295
Hazard
Classification
Safety Phrases
Classified as non-hazardous according to the criteria of
Dangerous Goods Code for transport by road and rail
GOODS
Bufloc 5033
Issued: 18 April 2011
1 of 7
Eye Exposure
Skin Exposure
Inhalation
immediately.
Ingestion
Advice to Doctor
free on 1800 127 295.
Extinguishing
Media
Hazardous
Combustion
Products
Oxides of carbon and nitrogen.
Procedures
Hazchem Code
Bufloc 5033
Not applicable.
2 of 7
Emergency
Procedures
Clean Up
Procedures
ring 0408 255 124.
Safe Handling
Precautions
Conditions for Safe
Storage
incompatible with strong acids, strong bases, strong
oxidisers and reducing agents.
Compatible
Materials
of Construction
Bufloc 5033
This product has not been tested for satisfactory
materials of construction. Based on industrial
experience, Teflon, polyethylene, polypropylene, PVC
and nylon appear to be compatible.
3 of 7
National Exposure
Standards
Biological Limit
Values
Engineering
Controls
work area.
Personal Protective
Equipment
safety boots.
Appearance
Odour
pH (neat)
pH
(100 ppm in water)
Vapour Pressure
Boiling Point
Melting Point
Solubility
Density
Flashpoint
Yellow liquid
Amine (slight)
5.5
6–7
24 mm Hg at 20oC
> 100oC
< - 5oC
Readily soluble in cold water
1.15 g/ml
CLOSED CUP: > 100oC (Pensky-Martens.)
Chemical Stability
Conditions to
Avoid
months.
Contact with strong acids, strong bases, strong oxidisers
and reducing agents.
Incompatible
Materials
Anionic polymers.
Hazardous
Decomposition
Products
Oxides of carbon and nitrogen may form on burning.
Bufloc 5033
4 of 7
Hazardous
Reactions
Not applicable
Acute Health
Effects
Oral (LD50): > 5000 mg/kg Rat
Dermal (LD50): > 2000 mg/kg Rabbit
Inhalation
Not harmful by inhalation.
Eye Contact
May be mildly irritating to eyes – inflammation of the eye
is characterised by redness, watering and itching.
Skin Contact
Not irritating to skin.
Sensitization
Dermal sensitization studies in guinea pigs show no
evidence of sensitization.
Chronic Health
Effects
evaluated. However, a 52 week dog study revealed only
minor clinical signs of toxicity. The no observed effects
level was determined to be 15000 ppm.
This product is not considered a carcinogen – it is not
shown as a carcinogen by the International Agency for
Research on Cancer.
Ecotoxicity
LC50: 0.34 mg/l 96 hours [Fish (Fathead minnow)]
Other Information
This product is cationic and will be quickly adsorbed onto
organic suspended matter.
Disposal Methods
Bufloc 5033
5 of 7
the impact on the system. Check the characteristics of
the material to be disposed of and/or the physical and
reactivity data provided in this MSDS for the neat product.
product containers.
Special Precautions
For Landfill or
Incineration
Road and Rail
Transport
Special
Precautions
Marine Transport
Bufloc 5033
transport by road and rail (ADG7). Special Provision
AU01 states that substances meeting the description of
UN 3082 are not subject to the Code when transported by
road or rail in packagings or IBCs.
Incompatible with dangerous goods of Class 1
(Explosives).
Classified as a Dangerous Good according to the criteria
of the International Maritime Dangerous Goods Code for
transport by sea.
UN Number
3082
Class
9
Hazchem Code
3Z
Packing Group
III
Proper Shipping
Name
ENVIRONMENTALLY HAZARDOUS
SUBSTANCE, LIQUID N.O.S.
(Polyamine Resin);
MARINE POLLUTANT.
6 of 7
Poisons Schedule S5.
NICNAS
Listed on the Australian Inventory of Chemical
Substances (AICS).
FDA
CFR) sections: 176.170, 176.180.
Date of MSDS
Preparation
18 April 2011.
Reason for Issue
Compliance with ADG7.
Contact
02 69235 888
Free call 1800 257272
Emergency 1800 127 295, 0408 255 124
of the user.
END OF MSDS
Bufloc 5033
7 of 7
Product Name
BUFLOC® 5297
Other Names
Not applicable
Recommended
Use
Industrial flocculant.
Supplier Details
East Bomen Road
Australia
A.B.N. 53 000 922 118
Fax 02 69 235 889
0408 255 124
Freecall 1800 127 295
Hazard
Classification
Not classified as hazardous according to the criteria of
GOODS.
Risk Phrases
Not applicable
Safety Phrases
S81 – Spills are very slippery
Bufloc 5297
1 of 7
Eye Exposure
Skin Exposure
Inhalation
immediately.
Ingestion
Advice to Doctor
free on 1800 127 295.
Extinguishing
Media
Hazardous
Combustion
Products
Ammonia, oxides of carbon and nitrogen. Dust may be
explosive if mixed with air in critical proportions and in the
presence of a source of ignition.
Procedures
Hazchem Code
Bufloc 5297
Not applicable.
2 of 7
Emergency
Procedures
Clean Up
Procedures
ring 0408 255 124.
Note: Spills are very slippery when wet.
Safe Handling
Precautions
Conditions for Safe
Storage
incompatible with strong oxidising agents.
Compatible
Materials
of Construction
Bufloc 5297
Not available.
3 of 7
National Exposure
Standards
Biological Limit
Values
Engineering
Controls
work area.
Personal Protective
Equipment
safety boots.
Appearance
Odour
pH
pH (5 g/L
in water)
% Volatile (by wt%)
Boiling Point
Melting Point
Solubility
Specific Gravity
Flashpoint
White solid
None
Not applicable
5-7
7 - 12
Not applicable
Not available
Soluble in cold water
0.65 – 0.85
Not applicable
Chemical Stability
months.
Conditions to
Avoid
None known.
Incompatible
Materials
Strong oxidisers.
Bufloc 5297
4 of 7
Hazardous
Decomposition
Products
Hazardous
Reactions
Thermal decomposition may produce ammonia and
oxides of carbon and nitrogen.
None known.
Acute Health
Effects
Inhalation (LC50): > 20 mg/L (4 hours) Rat
Inhalation
Not harmful by inhalation.
Eye Contact
Not irritating to eyes.
Skin Contact
Sensitization
Chronic Health
Effects
evaluated. This product is not considered a carcinogen –
it is not shown as a carcinogen by the International
Agency for Research on Cancer.
Ecotoxicity
Not available.
Disposal Methods
Bufloc 5297
5 of 7
product containers.
Special Precautions
For Landfill or
Incineration
Road and Rail
Transport
Special
Precautions
Marine Transport
Not applicable.
NICNAS
FDA
Not available.
Date of MSDS
Preparation
1 January 2011.
Reason for Issue
Bufloc 5297
6 of 7
Section 16. Other information (continued)
Contact
02 69 235 888
Free call 1800 257272
Emergency 1800 127 295, 0408 255 124
of the user.
END OF MSDS
Bufloc 5297
7 of 7
MSDS ONLINE
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Version 1.9.40
Copyright ©
2012 ACOHS
Pty Ltd.
NOHSC 16 Section
Uncontrolled Copy
BUSAN® 30WB
Infosafe™
No.
HXYBD
Issue Date February 2011 Status APPROVED by
APMMARYV
BS:
1.9.40
Product Name
BUSAN® 30WB
Company Name
BUCKMAN LABORATORIES (ABN 53 000 922 118)
Address
EAST BOMEN ROAD WAGGA WAGGA
NSW 2650
Emergency Tel. 0408 255 124
Telephone/Fax
Number
Tel: (02) 69 235 888
Fax: (02) 69 235 889
Recommended Use Industrial microbicide.
Other Names
Not Available
MSDS ONLINE
Additional
Information
Freecall: 1800 257 272
Emergency Contact: 24 hours emergency phone
Freecall: 1800 127 295
Hazard
Classification
DANGEROUS GOODS.
Risk Phrase(s)
R22
R23
R34
R41
R43
Safety Phrase
(s)
Harmful if swallowed.
Toxic by inhalation.
Causes burns.
Risk of serious damage to eyes.
May cause sensitization by skin contact.
S23 – Do not breathe mists or spray.
S24/25 – Avoid contact with skin and eyes.
S36/37 – Wear suitable protective clothing and gloves.
Ingredients
Name
CAS
Proportion
221564-17-0 30 % w/w
(Thiocyanomethylthio)
benzothiazole (TCMTB)
MSDS ONLINE
Inhalation
If exposure by inhalation is suspected, immediately remove
exposed individual to fresh air. If individual experiences
nausea, headache, dizziness, has difficulty breathing or is
cyanotic, seek a health care professional immediately.
Ingestion
DO NOT INDUCE VOMITING. Rinse mouth with copious amounts of
water or milk initially. Irrigate the oesophagus and dilute
stomach contents by slowly giving one to two glasses of
water or milk. Avoid giving alcohol or alcohol related
products. In cases where the individual is semi-comatose,
comatose or convulsing DO NOT GIVE FLUIDS BY MOUTH. In case
of intestinal ingestion of the product seek medical
assistance immediately – take the individual to the nearest
medical facility.
Skin
Wash exposed area with copious quantities of water. Repeat
washing. Remove contaminated clothing and wash thoroughly
before use. If irritation persists consult a health care
professional.
Eye
normal saline for a minimum of 15 minutes. Take exposed
individual to a health care professional, preferably an
ophthalmologist, for further evaluation.
Advice to
Doctor
free on 1800 127 295.
Suitable
Extinguishing
Media
Hazards from
Combustion
Products
Thermal decomposition can produce toxic vapours of hydrogen
cyanide and sulphur dioxide. Exposure to fire or flames may
generate oxides of sulphur, nitrogen and/or carbon.
Specific
Methods
MSDS ONLINE
Hazchem Code
2X
Emergency
Procedures
Emergency Procedures:
Wear appropriate Personal Protective Equipment (PPE) – see
Section 8 of this MSDS. Initially minimise the area
systems (streams, lakes, sewers). For technical advice ring
0408 255 124.
Methods and
Materials for
Containment
and Clean Up
Procedures
sand or other non-flammable absorbent material. Dispose of
contaminated absorbent at a registered EPA waste treatment
facility. Wash away residues with water. If washing spill
residual to an industrial sewer ensure there will be no
contact with incompatible materials - check with the
operator of your facility’s industrial sewer prior to
intentionally flushing spill residual to the sewer.
Precautions
for Safe
Handling
workplace. Avoid contact with eyes, skin and clothing. Do
not eat, drink or smoke when working with this product.
Wash hands after use and remove PPE before entering eating
areas. Where applicable provide spill containment compliant
with the National Code of Practice for the Storage and
Handling of Workplace Dangerous Goods [NOHSC: 2017].
Conditions for Store in a cool, dry, ventilated area away from direct
Safe Storage
incompatible with strong acids, strong bases and strong
oxidisers. Do not heat and/or store above 50°C as
decomposition may increase packaging pressure.
MSDS ONLINE
Other
Information
Compatible Materials of Construction: PVC - rigid,
Polyethylene – low density, Polyethylene – high density,
Polypropylene, Teflon, Silicone rubber, Van leer epoxy
liner 136.
The materials listed above have been tested with Busan
30WB. With respect to all other materials not listed above,
user should be aware that use of such materials with Busan
30WB may be hazardous and result in damages to such
materials and other property and personal injuries. No data
concerning such materials not listed above should be
implied by the user.
National
Exposure
Standards
Biological
Limit Values
Engineering
Controls
Use in a well ventilated area. Ensure that eyewash stations
and safety showers are in close proximity to the work area.
Personal
Protective
Equipment
Wear safety glasses or safety goggles, chemical resistant
gloves, safety boots. When splashing can occur, a full
chemical suit and a face shield should be worn. If the risk
of inhalation of mists exists, wear a P1 face mask or a
half-face respirator with an organic vapour cartridge.
Appearance
Opaque cream to tan coloured viscous liquid
Odour
Mild
Melting Point
Not available
Boiling Point
> 100°C
MSDS ONLINE
Solubility in
Water
pH Value
Dispersible in cold water
3 - 4 (neat)
5 - 6 (100 ppm in water)
Vapour Pressure 28 mm Hg at 20°C
Density
1.11 g/ml
Flash Point
CLOSED CUP: > 100°C (Pensky-Martens.)
Chemical
Stability
This product is stable under normal ambient and anticipated
storage and handling conditions of temperature and
pressure. Typical product shelf life is 6 months.
Conditions to
Avoid
Heating and/or storage above 50°C.
Incompatible
Materials
Strong bases, strong acids and strong oxidisers.
Hazardous
Decomposition
Products
Thermal decomposition can produce toxic vapours of hydrogen
cyanide and sulphur dioxide. Exposure to fire or flames may
generate oxides of sulphur, nitrogen and/or carbon.
Hazardous
Reactions
Cyanide salts are formed when product contacts strong
alkali. Hydrogen cyanide forms on contact with strong
acids. Oxides of carbon, nitrogen and sulphur may form on
contact with strong oxidisers.
Inhalation
Toxic by inhalation. Inhalation toxicity was conducted with
a four hour exposure under misting conditions. Normal use
of the product under non-misting conditions should not
present an occupational hazard.
MSDS ONLINE
Ingestion
Harmful if swallowed.
Skin
Causes burns. Skin inflammation is characterised by
reddening and blistering.
Eye
Risk of serious damage to eyes – inflammation of the eye is
Chronic Effects The effects from chronic exposure have not been fully
evaluated. However, chronic toxicity testing and chronic
feeding studies on the active ingredient did not reveal any
significant adverse effects. In vitro mutagenicity tests on
the active ingredient were negative. This product is not
considered a carcinogen – it is not shown as a carcinogen
by the International Agency for Research on Cancer.
Acute Toxicity
LD50: 1200 mg/kg Rat
- Oral
Acute Toxicity
LD50: > 2000 mg/kg Rabbit
- Dermal
Acute Toxicity
LC50: 0.4 mg/L (4 hours) Rat
- Inhalation
Skin
Sensitisation
May cause sensitisation by skin contact.
Ecotoxicity
This product may be considered very toxic to aquatic
organisms and may cause long-term adverse effects in the
aquatic environment.
LC50: 0.176 mg/l 96 hours [Fish (Rainbow trout)]
LC50: 0.06 mg/l 48 hours [Invertebrate (Daphnia Magna)]
MSDS ONLINE
Waste Disposal Follow state EPA regulations governing the disposal of
waste materials. The waste generator has the responsibility
for proper waste classification, transportation and
disposal. Only use EPA licensed transport and waste
facility providers.
representative. Do not dispose of contaminated materials to
an industrial effluent system without first determining the
impact on the system. Check the characteristics of the
material to be disposed of and/or the physical and
Where possible, Buckman Laboratories will assist with the
recycling of product containers.
Special
precautions
for landfill
or incineration at an approved landfill.
Transport
Information
Road and Rail Transport: Classified as Dangerous Goods
according to the criteria of the Australian Dangerous Goods
Code for transport by road and rail
UN Number: 3265
Class: 8
Hazchem Code: 2X
Packing Group: III
Proper Shipping Name: CORROSIVE LIQUID, ACIDIC, ORGANIC, N.
O.S. (2-(Thiocyanomethylthio)benzothiazole)
Special Precautions: Incompatible with dangerous goods of
Class 1 (Explosives), Class 4.3 (Substances that in contact
with water emit flammable gases), Class 5 (Oxidising
Substances and Organic Peroxides), Class 6 cyanides and
Class 8 alkalis and strong acids.
Marine Transport: Classified as a Dangerous Good according
to the criteria of the International Maritime Dangerous
Goods Code for transport by sea.
UN Number: 3265
Class: 8
Hazchem Code: 2X
Packing Group: III
Proper Shipping Name: CORROSIVE LIQUID, ACIDIC, ORGANIC, N.
MSDS ONLINE
O.S. (2-(Thiocyanomethylthio)benzothiazole)
MARINE POLLUTANT
U.N. Number
3265
Proper
Shipping Name
CORROSIVE LIQUID, ACIDIC, ORGANIC, N.O.S.
DG Class
8
Hazchem Code
2X
Packaging
Method
3.8.8
Packing Group
III
EPG Number
8A1
IERG Number
36
Regulatory
Information
FDA: This product is approved under the following FDA (21
CFR) sections: 176.300.
Poisons
Schedule
S6
Hazard Category Toxic,Corrosive
AICS
(Australia)
NICNAS: Listed on the Australian Inventory of Chemical
Substances (AICS).
Contact Person/ Regulatory Affairs Manager
02 69 235 888
Point
Free call 1800 257272
Emergency 1800 127 295, 0408 255 124
MSDS ONLINE
Uses and
Restrictions
Reason for Issue: New NOHSC MSDS format.
User
Information
Application made by Keith White to trial this biocide on
lapped pulp.
Other
Information
This MSDS has been transcribed into Infosafe NOHSC format
from an original issued by the manufacturer on the date
shown. Any disclaimer by the manufacturer may not be
included in the transcription.
End of MSDS
Ltd.
BS: 1.9.40
Product Name
BUSAN® 7650
Other Names
Not applicable
Recommended
Use
Fungicide used in the leather industry.
Supplier Details
East Bomen Road
Australia
A.B.N. 53 000 922 118
Fax 02 69 235 889
0408 255 124
Freecall 1800 127 295
Hazard
Classification
Classified as hazardous according to the criteria of the
ASCC. Not classified as a Dangerous Goods according
to the criteria of the Australian Dangerous Goods Code
for transport by road and rail.
HAZARDOUS SUBSTANCE. NON-DANGEROUS
GOODS.
Risk Phrases
R46 – May cause heritable genetic damage
R60 – May impair fertility
R61 – May cause harm to the unborn child
Safety Phrases
Busan 7650
1 of 7
Name of hazardous Ingredients
2-(Methoxycarbonylamino)benzimidazole
CAS
Number
10605-21-7
Conc.
Range,
% w/w
30
Eye Exposure
Skin Exposure
Inhalation
immediately.
Ingestion
Advice to Doctor
free on 1800 127 295.
Extinguishing
Media
Hazardous
Combustion
Products
Busan 7650
2 of 7
Section 5. Fire Fighting Measures (continued)
Procedures
Hazchem Code
Not applicable.
Emergency
Procedures
Clean Up
Procedures
ring 0408 255 124.
Dispose of contaminated absorbent at a registered DECC
Safe Handling
Precautions
Conditions for Safe
Storage
sunlight. Keep containers tightly closed. Do not store
with strong oxidisers.
Busan 7650
3 of 7
Section 7. Handling and Storage (continued)
Compatible
Materials of
Construction
This product has not been tested for satisfactory
materials of construction.
National Exposure
Standards
Biological Limit
Values
Engineering
Controls
work area.
Personal Protective
Equipment
safety boots.
Appearance
Odour
pH (neat)
pH (100 ppm
in water)
Vapour Pressure
Boiling Point
Melting Point
Solubility
Density
Flashpoint
Opaque off-white liquid
Slight
Not available
Approx. 6.5
Not available
Not tested
Not tested
Miscible
1.0 g/ml
CLOSED CUP: > 100oC (Predicted)
Chemical Stability
Conditions to
Avoid
Busan 7650
months.
Contact with strong oxidisers.
4 of 7
Incompatible
Materials
Strong oxidisers.
Hazardous
Decomposition
Products
Hazardous
Reactions
Oxides of carbon and nitrogen may be generated on
contact with strong oxidisers.
Acute Health
Effects
The following LD50s are for the active ingredient:
Inhalation
Not expected to be harmful by inhalation
Eye Contact
May be mildly irritating to eyes – inflammation of the eye
is characterised by redness, watering and itching.
Skin Contact
Sensitization
Chronic Health
Effects
Busan 7650
evaluated. The active ingredient has been classified as a
Category 2 Mutagen – there is sufficient evidence to
provide a strong presumption that the substance may
result in the development of heritable genetic damage.
The active ingredient has also been classified as a
Category 2 substance that is toxic to reproduction – this
substance should be regarded as if it may impair fertility
and cause developmental toxicity in humans. The active
ingredient has not been evaluated by the International
Agency for Research on Cancer.
5 of 7
Ecotoxicity
The active ingredient is considered toxic to the aquatic
environment. However the strong adsorption of the
active to soil and sediment particles reduces its
bioavailability to terrestrial and aquatic systems.
Similarly, the mobility of the active in soils is limited, and it
is not expected to leach to ground water.
Disposal Methods
Follow state DECC regulations governing the disposal of
transportation and disposal. Only use DECC licensed
Where possible, Buckman Laboratories will assist with
the recycling of product containers.
Special Precautions
For Landfill or
Incineration
Product is suitable for incineration at an DECC approved
Road and Rail
Transport
Special
Precautions
Marine Transport
Busan 7650
Incompatible with strong oxidisers.
6 of 7
Poisons Schedule S7 (currently under review with NDPSC).
NICNAS
FDA
Not available.
Date of MSDS
Preparation
10 April 2010.
Reason for Issue
Five year update required, Poisons Schedule change,
Risk Phrase change.
Contact
02 69 235 888
Free call 1800 257272
Emergency 1800 127 295, 0408 255 124
of the user.
END OF MSDS
Busan 7650
7 of 7
MSDS ONLINE
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Version 1.9.40
Copyright ©
2012 ACOHS
Pty Ltd.
NOHSC 16 Section
Uncontrolled Copy
BUSAN® 85
Infosafe™
No.
HXEMC
Issue Date February 2011 Status APPROVED by
APMMARYV
BS:
1.9.40
Product Name
BUSAN® 85
Product Code
Company Name
BUCKMAN LABORATORIES (ABN 53 000 922 118)
Address
EAST BOMEN ROAD WAGGA WAGGA
NSW 2650
Emergency Tel. 0408 255 124
Telephone/Fax
Number
Tel: (02) 69 235 888
Fax: (02) 69 235 889
Recommended Use Microbicide for use in the paper industry and leather
industry.
MSDS ONLINE
Other Names
None Listed
Hazard
Classification
NON-DANGEROUS GOODS.
Risk Phrase(s)
R38 Irritating to skin.
R41 Risk of serious damage to eyes.
R43 May cause sensitization by skin contact.
Safety Phrase
(s)
S23 Do not breathe mists or spray.
S24/25 Avoid contact with skin and eyes.
S36/37 Wear suitable protective clothing and gloves.
Sensitization
of Product
This product has been shown to be a weak sensitiser
according to animal data. No instances of human
sensitisation are known.
Ingredients
Name
CAS
Potassium
128-03-0
dimethyldithiocarbamate
Proportion
30-60 %w/w
MSDS ONLINE
Inhalation
If exposure by inhalation is suspected, immediately remove
exposed individual to fresh air. If individual experiences
nausea, headache, dizziness, has difficulty breathing or is
cyanotic, seek a health care professional immediately.
Ingestion
DO NOT INDUCE VOMITING. Rinse mouth with copious amounts of
water or milk initially. Irrigate the oesophagus and dilute
stomach contents by slowly giving one to two glasses of
water or milk. Avoid giving alcohol or alcohol related
products. In cases where the individual is semi-comatose,
comatose or convulsing DO NOT GIVE FLUIDS BY MOUTH. In case
of intestinal ingestion of the product seek medical
assistance immediately - take the individual to the nearest
medical facility.
Skin
Wash exposed area with copious quantities of water. Repeat
washing. Remove contaminated clothing and wash thoroughly
before use. If irritation persists consult a health care
professional.
Eye
normal saline for a minimum of 15 minutes. Take exposed
individual to a health care professional, preferably an
ophthalmologist, for further evaluation.
Advice to
Doctor
free on 1800 127 295.
Suitable
Extinguishing
Media
Hazards from
Combustion
Products
Methyl isothiocyanates, oxides of sulphur, nitrogen and
carbon. Thermal decomposition can produce hydrogen sulphide.
Specific
Methods
Fire fighters should wear positive pressure self-contained
MSDS ONLINE
Emergency
Procedures
Emergency Procedures:
Wear appropriate Personal Protective Equipment (PPE) - see
Section 8 (Exposure Controls/Personal Protection) of this
MSDS. Initially minimise the area affected by the spill.
Block any potential routes to water systems (streams,
lakes, sewers). For technical advice ring 0408 255 124.
Methods and
Materials for
Containment
and Clean Up
Procedures
sand or other non-flammable absorbent material. Dispose of
contaminated absorbent at a registered EPA waste treatment
facility. Wash away residues with water. If washing spill
residual to an industrial sewer ensure there will be no
contact with incompatible materials - check with the
operator of your facility's industrial sewer prior to
intentionally flushing spill residual to the sewer.
Precautions
for Safe
Handling
workplace. Avoid contact with eyes, skin and clothing. Do
not eat, drink or smoke when working with this product.
Wash hands after use and remove PPE before entering eating
areas. Where applicable provide spill containment compliant
with the National Code of Practice for the Storage and
Handling of Workplace Dangerous Goods [NOHSC: 2017].
Conditions for Store in a cool, dry, ventilated area away from direct
Safe Storage
incompatible with strong acids and strong oxidisers.
MSDS ONLINE
Recommended
Materials
Compatible Materials of Construction: ABS (Plastic), Buna-N
rubber, Butyl rubber, EPDM rubber, Morton test liner (108 T
44LV), Neoprene, 6/6 Nylon, Polyethylene - low density,
Polyethylene - high density, Polyethylene - crosslink,
C1010 mild steel, Tyril 880, Polypropylene, PVC - flexible,
PVC - rigid, Silicone rubber, Stainless steels 304 and 316,
Teflon, Tygon R3603, Viton, Plexiglas, Hypalon, Dow
Silastic Tube, Rehau Tube, Polyurethane liner, Norprene
Tubing FRP G-10, Pharmed Tubing.
Other
Information
The materials listed above have been tested with Busan 85.
With respect to all other materials not listed above, user
should be aware that use of such materials with Busan 85
may be hazardous and result in damages to such materials
and other property and personal injuries. No data
concerning such materials not listed above should be
implied by the user.
National
Exposure
Standards
Biological
Limit Values
Engineering
Controls
Use in a well ventilated area. Ensure that eyewash stations
and safety showers are in close proximity to the work area.
Personal
Protective
Equipment
safety boots. If the risk of inhalation of mists exists,
wear a P1 face mask.
Appearance
Clear green liquid
Odour
Ammoniacal (Pungent)
MSDS ONLINE
Melting Point
< - 35°C
Boiling Point
Not available
Solubility in
Water
Readily soluble in cold water
pH Value
>13.5 (neat)
7.0 - 9.0 (100 ppm in water)
Vapour Pressure Not available
Density
1.23 g/ml
Flash Point
CLOSED CUP: > 100°C
Chemical
Stability
This product is stable under normal ambient and anticipated
storage and handling conditions of temperature and
pressure. Typical product shelf life is 12 months.
Conditions to
Avoid
Not applicable
Incompatible
Materials
This product is incompatible with strong acids and strong
oxidisers.
Hazardous
Decomposition
Products
Carbon disulfide and dimethylamine may be generated upon
acidification. Contact with fire or strong oxidants may
generate methyl isocyanates, oxides of sulphur, nitrogen
and carbon. Thermal decomposition can produce hydrogen
sulphide.
Hazardous
Reactions
Carbon disulfide and dimethylamine may be generated upon
acidification. Contact with strong oxidants may generate
methyl isocyanates, oxides of sulphur, nitrogen and carbon.
MSDS ONLINE
Inhalation
May be harmful by inhalation. Effects will depend on
concentration and length of time of exposure - headaches
and dizziness may occur.
Skin
Irritating to skin - skin inflammation is characterised by
itching, scaling, reddening and, occasionally, blistering.
Eye
Risk of serious damage to eyes - inflammation of the eye is
Mutagenicity
evaluated. 90 day exposure studies did not reveal any
adverse effects. This product has tested positive in
several in vitro mutagenicity tests. This product is not
considered a carcinogen - it is not shown as a carcinogen
by the International Agency for Research on Cancer.
Acute Toxicity
LD50: 2030 mg/kg Rat
- Oral
Acute Toxicity
LD50: 2990 mg/kg Rabbit
- Dermal
Ecotoxicity
LC50: 0.36 mg/l 96 hours [Fish (Rainbow trout)]
LC50: 0.34 mg/l 48 hours [Invertebrate (Daphnia Magna)]
MSDS ONLINE
Waste Disposal Follow state EPA regulations governing the disposal of
waste materials. The waste generator has the responsibility
for proper waste classification, transportation and
disposal. Only use EPA licensed transport and waste
facility providers.
representative. Do not dispose of contaminated materials to
an industrial effluent system without first determining the
impact on the system. Check the characteristics of the
material to be disposed of and/or the physical and
Where possible, Buckman Laboratories will assist with the
recycling of product containers.
Special Precautions For Landfill or Incineration: Product
Special
is suitable for incineration at an EPA approved facility.
precautions
Triple rinsed 15L cubes are suitable for disposal at an
for landfill
or incineration approved landfill.
Transport
Information
Road and Rail Transport:
Special Precautions:
Incompatible with dangerous goods of Class 1 (Explosives).
Class 8 (acidic corrosives) and Class 5 (Oxidisers).
Marine Transport:
Classified as a Dangerous Good according to the criteria of
the International Maritime Dangerous Goods Code for
transport by sea.
UN Number: 3082
Class: 9
Hazchem Code: 2X
Packing Group: III
Proper Shipping Name: ENVIRONMENTALLY HAZARDOUS SUBSTANCE,
LIQUID N.O.S. (Potassium dimethyldithiocarbamate); MARINE
POLLUTANT.
MSDS ONLINE
Regulatory
Information
FDA: This product is approved under the following FDA (21
CFR) sections: 176.300.
Poisons
Schedule
Not Scheduled
Hazard Category Irritant
AICS
(Australia)
NICNAS: Listed on the Australian Inventory of Chemical
Substances (AICS).
Contact Person/ Regulatory Affairs Manager
02 69 235 888
Point
Free call 1800 257272
Emergency 1800 127 295, 0408 255 124
Revisions
Highlighted
User
Information
Reason for Issue: New NOHSC MSDS format.
Approved for Trial to preserve pine pulp crumbs. The
Environment Specialist has put conditions to this trial.
See below:
Maryvale Mill - Safety Health & Environment
PO Box 37, Morwell, 3840
Phone: (03) 5136 0360
Fax: (03) 5136 0470
TO: June Yew
FROM: Alan Eagle
DATE: 28th September 2006
CC:
File No. 4.12.6 S Kewish B Green
S Testa M Reddy B Wilkinson
Subject: Busan 85 Trial - Effluent Monitoring Requirements
(MCR 06/079)
Background
The proposal to dose pulp from the pine mill with Busan 85,
has been identified as having potential to have an adverse
MSDS ONLINE
impact on the sites effluent treatment system and increase
toxicity of the effluent.
To date the extremely limited testing that has been
undertaken suggests that levels of Busan 85 in effluent
leaving No1A Pond must be less than 1 mg/l to avoid
toxicity as measured by the sites normal test procedures. A
single trial has also indicated that no short term
impairment of respiration rates in No 1A pond is expected
for concentrations up to 40 mg/l.
Breakdown rates for Busan 85 are essentially unknown under
the conditions in which it will be applied.
In consideration of the above, and recognizing the
uncertainties that exist, approval for the trial is
conditional upon the following requirements being
implemented.
Requirements
1. Testing for Busan 85 at the inlet to #2 Clarifier 2
hourly at commencement of trial, reducing to daily when
levels stabilize.
2. If Busan 85 is detected at the inlet to #2 Clarifier,
commence testing outlet at least daily.
3. If Busan 85 is detected in the outlet of #2 Clarifier,
commence daily testing of the discharge from No 1A Pond.
4. Daily monitoring of #1A Pond on key parameters off the
four 'jetties in #1A Pond' including o Dissolved Oxygen,
o COD,
o respiration rate, and;
o microscopic examination.
5. Microtox testing daily ex #1A pond, commencing at the
start of the trial and lasting for at least 10 days.
It will be the responsibility of those conducting the trial
to ensure that the above testing is undertaken. If the
trial is commenced mid-week then arrangements must be in
place to ensure testing for the first five days of the
trial is performed in a timely manner.
All effluent test results are to be collated and provided
to the Environment Specialist and the Environment Supt.
Power/Recovery within 1 month of the trial commencement
date.
Criteria Requiring Immediate Cessation of Trial
o Busan 85 concentration exceeds 4 mg/l ex No 2 Clarifier
or 1 mg/l ex No 1A Pond (it is understood that the limit of
detection for the test method is 1 mg/l).
o Respiration rates and/or COD removal in No 1A pond show
MSDS ONLINE
evidence of measurable decrease during the trial.
o A measurable increase in toxicity, as determined by the
Microtox test is observed at the discharge of No 1A Pond.
The Environment Supt. Power/Recovery is to be advised
immediately any of these criteria are exceeded.
Ongoing Trials
Approval for ongoing trials will be conditional upon the
outcome of the first trial.
Alan Eagle
Environment Specialist
Other
Information
Supplier Details: Buckman Laboratories
Freecall 1800 257 272
Emergency Contact: 24 hours emergency phone
0408 255 124 Freecall 1800 127 295
End of MSDS
Ltd.
BS: 1.9.40
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NOHSC 16 Section
Uncontrolled Copy
CAUSTIC SODA - LIQUID (46%-50%)
Infosafe™
No.
ICI9L
Issue Date August 2011
Status APPROVED by
APMMARYV
BS:
1.9.40
Product Name
CAUSTIC SODA - LIQUID (46%-50%)
Product Code
Company Name
ORICA AUSTRALIA PTY LTD (ABN 004 117 828)
Address
1 Nicholson Street East Melbourne
Victoria 3000
Emergency Tel. 61-03-96657624
Telephone/Fax
Number
Tel: +61 3 9665 7111
Fax: +61 3 9665 7937
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Recommended Use Chemical manufacture; neutralising agent; pulp and paper,
aluminium, detergent, and textile processing; vegetable oil
refining; reclaiming rubber; etching and electroplating;
food additive.
Other Names
Name
Product Code
Sodium hydroxide - liquid (46%50%), Soda lye solution (46%50%), Caustic soda solution (46%50%), Sodium hydroxide solution
(46%-50%), Liquid caustic soda
(46%-50%), LCS 46%, Rezolv 46.
Hazard
Classification
DANGEROUS GOODS.
Risk Phrase(s)
R35 Causes severe burns.
R41 Risk of serious damage to eyes.
Safety Phrase(s) S26 In case of contact with eyes, rinse immediately with
plenty of water and seek medical advice. S45 In case of
accident or if you feel unwell seek medical advice
immediately (show the label whenever possible). S24/25
Avoid contact with skin and eyes. S36/37/39 Wear suitable
protective clothing, gloves and eye/face protection.
Chemical
MSDS ONLINE
Information on
Composition
Components Risk Phrases
Sodium hydroxide R35, R41
Water -
Ingredients
Name
CAS
Proportion
Sodium hydroxide
1310-73-2
46-50 %
Water
7732-18-5
50-54 %
First Aid
Measures
For advice, contact a Poisons Information Centre (Phone eg.
Australia 131 126; New Zealand 0 800 764766) or a doctor.
Inhalation
Remove victim from area of exposure - avoid becoming a
casualty. Remove contaminated clothing and loosen remaining
clothing. Allow patient to assume most comfortable position
and keep warm. Keep at rest until fully recovered. For all
but the most minor symptoms arrange for patient to be seen
by a doctor as soon as possible, either on site or at the
nearest hospital.
Ingestion
Immediately rinse mouth with water. If swallowed, do NOT
induce vomiting. Give a glass of water. Seek immediate
medical assistance.
Skin
If spilt on large areas of skin or hair, immediately drench
with running water and remove clothing. Continue to wash
skin and hair with plenty of water (and soap if material is
insoluble) until advised to stop by the Poisons Information
Centre or a doctor.
Eye
If in eyes, hold eyelids apart and flush the eye
continuously with running water. Continue flushing until
advised to stop by the Poisons Information Centre or a
doctor, or for at least 15 minutes.
Advice to
Doctor
Treat symptomatically. Can cause corneal burns.
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Suitable
Extinguishing
Media
Not combustible, however, if material is involved in a fire
use: Water fog (or if unavailable fine water spray), foam,
dry agent (carbon dioxide, dry chemical powder).
Hazards from
Combustion
Products
Non-combustible material.
Hazchem Code
2R
Precautions in Not combustible, however following evaporation of aqueous
component residual material can decompose if involved in a
connection
fire, emitting toxic fumes. Contact with metals may
with Fire
liberate hydrogen gas which is extremely flammable. Fire
fighters to wear selfcontained breathing apparatus and
suitable protective clothing if risk of exposure to
products of decomposition.
Emergency
Procedures
Emergency procedures:
Clear area of all unprotected personnel. If contamination
of sewers or waterways has occurred advise local emergency
services.
Methods and
Materials for
Containment
and Clean Up
Procedures
Slippery when spilt. Avoid accidents, clean up immediately.
Wear protective equipment to prevent skin and eye contact
and breathing in vapours. Work up wind or increase
ventilation. Contain - prevent run off into drains and
waterways. Use absorbent (soil, sand or other inert
material). Collect and seal in properly labelled containers
or drums for disposal. Caution - heat may be evolved on
contact with water.
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Precautions
for Safe
Handling
Avoid skin and eye contact and breathing in vapour, mists
and aerosols.
Conditions for Store in cool place and out of direct sunlight. Store away
from incompatible materials described in Section 10. Store
Safe Storage
away from foodstuffs. Do not store in aluminium or
galvanised containers nor use die-cast zinc or aluminium
bungs; plastic bungs should be used. At temperatures
greater than 40°C, tanks must be stress relieved. Keep
containers closed when not in use - check regularly for
leaks.
Other
Information
This material is a Scheduled Poison S6 and must be stored,
maintained and used in accordance with the relevant
regulations.
National
Exposure
Standards
No value assigned for this specific material by the
National Occupational Health and Safety Commission.
However, Exposure Standard(s) for constituent(s): Sodium
hydroxide: Peak Limitation = 2 mg/m³
As published by the National Occupational Health and Safety
Commission.
Peak Limitation - a ceiling concentration which should not
be exceeded over a measurement period which should be as
short as possible but not exceeding 15 minutes.
These Exposure Standards are guides to be used in the
control of occupational health hazards. All atmospheric
contamination should be kept to as low a level as is
workable. These exposure standards should not be used as
fine dividing lines between safe and dangerous
concentrations of chemicals. They are not a measure of
relative toxicity.
Engineering
Controls
Ensure ventilation is adequate and that air concentrations
of components are controlled below quoted Exposure
Standards. If inhalation risk exists: Use with local
exhaust ventilation or while wearing suitable mist
respirator. Keep containers closed when not in use.
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Personal
Protective
Equipment
The selection of PPE is dependant on a detailed risk
assessment. The risk assessment should consider the work
situation, the physical form of the chemical, the handling
methods, and environmental factors.
Orica Personal Protection Guide No. 1, 1998: D - OVERALLS,
RUBBER BOOTS, CHEMICAL GOGGLES, FACE SHIELD, SAFETY SHOES,
GLOVES (Long), APRON.
Wear overalls, chemical goggles, face shield, elbow-length
impervious gloves, splash apron and rubber boots. Always
wash hands before smoking, eating, drinking or using the
toilet. Wash contaminated clothing and other protective
equipment before storage or re-use.
If risk of inhalation exists, wear suitable mist respirator
meeting the requirements of AS/NZS 1715 and AS/NZS 1716.
Form
Liquid
Freezing Point 12ºC
Boiling Point
Not available
Solubility in
Water
Miscible with water.
Specific
Gravity
1.48-1.52 @ 20°C
pH Value
>14
Vapour Pressure Not available
Vapour Density
Not available
(Air=1)
Colour
Colourless to Slightly Coloured
Flash Point
Not applicable
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Auto-Ignition
Temperature
Not applicable
Flammable
Limits - Lower Not applicable
Flammable
Limits - Upper Not applicable
Chemical
Stability
Stable under normal ambient and anticipated storage and
handling conditions of temperature and pressure.
Conditions to
Avoid
None known.
Incompatible
Materials
Incompatible with aluminium, ammonium salts, tin, and zinc.
Hazardous
Decomposition
Products
None known.
Hazardous
Reactions
Reacts violently with acids. Reacts exothermically on
dilution with water.
Toxicology
Information
Toxicological Data:
No LD50 data available for the product. For the constituent
Sodium hydroxide:
SKIN: Severe irritant (rabbit).
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Health Hazard
No adverse health effects expected if the product is
handled in accordance with this Safety Data Sheet and the
product label. Symptoms or effects that may arise if the
product is mishandled and overexposure occurs are: For WSA
format, please refer to Health Effects Section for acute
effects.
Inhalation
Breathing in mists or aerosols may produce respiratory
irritation.
Ingestion
Swallowing can result in nausea, vomiting, diarrhoea,
abdominal pain and chemical burns to the gastrointestinal
tract.
Skin
Contact with skin will result in severe irritation.
Corrosive to skin - may cause skin burns.
Eye
A severe eye irritant. Corrosive to eyes; contact can cause
corneal burns. Contamination of eyes can result in
permanent injury.
Chronic Effects No information available for the product.
Ecotoxicity
Avoid contaminating waterways.
Waste Disposal Refer to Waste Management Authority. Dispose of material
through a licensed waste contractor. Decontamination and
destruction of containers should be considered.
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Transport
Information
Road and Rail Transport:
Classified as Dangerous Goods by the criteria of the
Australian Dangerous Goods Code (ADG Code) for Transport by
Road and Rail; DANGEROUS GOODS.
UN No: 1824
Class-primary 8 Corrosive
Packing Group: II
Proper Shipping Name: SODIUM HYDROXIDE SOLUTION
Hazchem Code: 2R
Marine Transport:
International Maritime Dangerous Goods Code (IMDG Code) for
transport by sea; DANGEROUS GOODS.
UN No: 1824
Class-primary: 8 Corrosive
Packing Group: II
Air Transport:
International Air Transport Association (IATA) Dangerous
Goods Regulations for transport by air; DANGEROUS GOODS.
UN No: 1824
Class-primary: 8 Corrosive
Packing Group: II
U.N. Number
1824
Proper
Shipping Name
SODIUM HYDROXIDE SOLUTION
DG Class
8
Hazchem Code
2R
Packaging
Method
3.8.8RT8
Packing Group
II
EPG Number
8A1
MSDS ONLINE
IERG Number
37
Regulatory
Information
Classification: This material is hazardous according to
criteria of NOHSC; HAZARDOUS SUBSTANCE.
Poisons Schedule: S6 Poison.
Poisons
Schedule
S6
Hazard Category C: Corrosive
AICS
(Australia)
All the constituents of this material are listed on the
Australian Inventory of Chemical Substances (AICS).
Revisions
Highlighted
Reason(s) for Issue:
5 Yearly Revised Primary MSDS
User
Information
Approved for use at M5 for pH control trial. Application
made by Mery Philipp. 6/7/10.
Other
Information
'Registry of Toxic Effects of Chemical Substances'. Ed. D.
Sweet, US Dept. of Health & Human Services: Cincinatti,
2006.
This material safety data sheet has been prepared by SH&E
Shared Services, Orica.
Substance No: 000031006701
Version: 3
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End of MSDS
Ltd.
BS: 1.9.40
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NOHSC 16 Section
Uncontrolled Copy
HYDROGEN PEROXIDE
Infosafe™
No.
HXFI0
Issue Date June 2011
Status APPROVED by
APMMARYV
BS:
1.9.40
Product Name
HYDROGEN PEROXIDE
Product Code
Company Name
SOLVAY INTEROX PTY LTD (ABN 70 000 882 137)
Address
20-22 McPherson Street Banksmeadow
NSW 2019
Emergency Tel. 1800 023 488 24 H
Telephone/Fax
Number
Tel: (02) 9316 8000
Fax: (02) 9316 6445
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Recommended Use Bleaching agents
Chemical industry
Electronic industry
Metal treatment
Odour agents
Oxidising Agents
Textile industry
Water treatment
Pulp and paper
Other Names
Name
INTEROX ® ST-60
Hydroperoxide, Hydrogen dioxide
Product Code
Hazard
Classification
DANGEROUS GOODS.
Risk Phrase(s)
R34 Causes burns.
Safety Phrase(s) S3 Keep in a cool place. S1/2 Keep locked up and out of
reach of children. S28 After contact with skin, wash
immediately with plenty of water. S45 In case of accident
or if you feel unwell seek medical advice immediately
(show the label where possible). S36/39 Wear suitable
protective clothing and eye/face protection.
Sensitization
of Product
Guinea pig, Did not cause sensitization on laboratory
animals.
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Other
Information
Classified as hazardous according to criteria of NOHSC.
Classified as dangerous goods according to the ADG Code.
Corrosive
Non-combustible, but may contribute to the combustion of
other substances and causes violent and explosive
reactions.
Chemical
Information on
Composition
Ingredients
Hydrogen peroxide
Symbol(s): O, C
R-phrase(s): R8, R34
Name
CAS
Hydrogen peroxide 7722-84-1
Proportion
59-59.9 %
Inhalation
In case of accident by inhalation: remove casualty to fresh
air and keep at rest.
Oxygen or artificial respiration if needed.
Keep warm and in a quiet place.
Victim to lie down in the recovery position, cover and keep
him warm.
Call a physician immediately.
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Ingestion
The following actions are recommended:
Call a physician immediately.
Take victim immediately to hospital.
If victim is conscious:
If swallowed, rinse mouth with water (only if the person is
conscious).
Do NOT induce vomiting.
If victim is unconscious but breathing:
Artificial respiration and/or oxygen may be necessary.
Skin
Take
Wash
Keep
Wash
Call
off contaminated clothing and shoes immediately.
off immediately with plenty of water.
warm and in a quiet place.
contaminated clothing before re-use.
a physician immediately.
Eye
Rinse immediately with plenty of water, also under the
eyelids, for at least 15 minutes.
In the case of difficulty of opening the lids, administer
an analgesic eye wash (oxybuprocaine).
Consult with an ophthalmologist immediately in all cases.
Take victim immediately to hospital.
Suitable
Extinguishing
Media
Special
Protective
Equipment for
fire fighters
Specific
Hazards
Water
Water spray
Evacuate personnel to safe
In the event of fire, wear
apparatus.
When intervention in close
over suit.
Clean contaminated surface
areas.
self-contained breathing
proximity wear acid resistant
thoroughly.
Oxidising
Oxygen released in thermal decomposition may support
combustion
Contact with combustible material may cause fire.
Contact with flammables may cause fire or explosions.
Risk of explosion if heated under confinement.
MSDS ONLINE
Hazchem Code
2P
Decomposition
Temp.
>= 60 °C
Remarks: Self-Accelerating decomposition temperature (SADT)
< 60 °C
Remarks: Slow decomposition
Unsuitable
Extinguishing
Media
Other
Information
None.
Keep product and empty container away from heat and sources
of ignition.
Keep containers and surroundings cool with water spray.
Approach from upwind.
Methods and
Materials for
Containment
and Clean Up
Procedures
Dam up.
Soak up with inert absorbent material.
Dilute with plenty of water.
Do not add chemical products.
Treat recovered material as described in the section
'Disposal considerations'.
Never return spills in original containers for re-use.
Personal
Precautions
Refer to protective measures listed in sections 7 (Handling
and Storage) and 8 (Exposure Controls / Personal
Protection).
Isolate the area.
Keep away from Incompatible products.
Prevent further leakage or spillage if safe to do so.
In case of contact with combustible material, keep material
wet with plenty of water.
Environmental
Precautions
Limited quantity
Flush into sewer with plenty of water.
Large quantities:
If the product contaminates rivers and lakes or drains
inform respective authorities.
MSDS ONLINE
Precautions
for Safe
Handling
Use only in well-ventilated areas.
Keep away from heat.
May not get in touch with:
organic materials
Use only equipment and materials which are compatible with
the product.
Before all operations, passivate the piping circuits and
vessels according to the procedure recommended by the
producer.
Never return unused material to storage receptacle.
Use only in an area with adequate water supply
Containers and equipment used to handle the product should
be used exclusively for that product.
Conditions for Keep in a cool, well-ventilated place.
Keep away from heat.
Safe Storage
Keep away from combustible material.
Store in a receptacle equipped with a vent.
Store in original container.
Keep container closed.
Keep in a bunded area.
Regularly check the condition and temperature of the
containers.
Information about special precautions needed for bulk
handling is available on request.
Other
Information
Specific use(s):
For further information, please contact: Supplier
Packaging material:
Aluminium 99,5 %:
Stainless steel 304L / 316L
Approved grades of HDPE.
Other information:
Protection).
Do not confine the product in a circuit, between closed
valves, or in a container without a vent.
MSDS ONLINE
In industrial installations, apply the rules for the
prevention of major accidents (consult an expert).
National
Exposure
Standards
Hydrogen peroxide
US. ACGIH Threshold Limit Values 2005
TWA = 1 ppm
WEL (UK) 2005
TWA = 1 ppm
TWA = 1.4 mg/m³
WEL (UK) 2005
STEL = 2 ppm
STEL = 2.8 mg/m³
TLV (NOHSC) 11/2004
TWA = 1 ppm
TWA = 1.4 mg/m³
Engineering
Controls
Ensure adequate ventilation.
Apply technical measures to comply with the occupational
exposure limits.
Protection).
Respiratory
Protection
In case of emissions, face mask with type NO-P3 cartridge.
Self-contained breathing apparatus in medium confinement/
insufficient oxygen/in case of large uncontrolled emissions/
in all circumstances when the mask and cartridge do not
give adequate protection.
Use only respiratory protection that conforms to
international/ national standards.
Eye Protection Chemical resistant goggles must be worn.
If splashes are likely to occur, wear:
Tightly fitting safety goggles
Face-shield
MSDS ONLINE
Hand Protection Protective gloves - impervious chemical resistant:
PVC
Rubber gloves
Take note of the information given by the producer
concerning permeability and break through times, and of
special workplace conditions (mechanical strain, duration
of contact).
Body Protection Protective suit
If splashes are likely to occur, wear:
Apron
Boots
Suitable material
PVC
Rubber products
Hygiene
Measures
Use only in an area equipped with a safety shower.
Eye wash bottle with pure water
When using do not eat, drink or smoke.
Handle in accordance with good industrial hygiene and
safety practice.
Other
Information
Environmental exposure controls:
Dispose of rinse water in accordance with local and
national regulations.
Form
Liquid
Odour
Pungent
Decomposition
Temperature
>= 60 °C
Remarks: Self-Accelerating decomposition temperature (SADT)
< 60 °C
Remarks: Slow decomposition
Freezing Point -56 °C
(H2O2 59 % )
Boiling Point
119 °C
(H2O2 59 %)
MSDS ONLINE
pH Value
1 - 4
Remarks: Apparent pH
Vapour Pressure 1 mbar
Temperature: 30 °C
(H2O2 50 %)
12 mbar
Temperature: 20 °C
Remarks: Total pressure (H2O2 + H2O) (H2O2 50 %)
72 mbar
Temperature: 50 °C
Remarks: Total pressure (H2O2 + H2O) (H2O2 50 %)
Vapour Density 1
(H2O2 50 %)
(Air=1)
Viscosity
1.17 mPa.s
Temperature: 20 °C
(H2O2 50 %)
Colour
Colourless
Octanol/Water
Partition
Coefficient
log Pow: -1.1
Density
1.24
(H2O2 59 %)
Surface Tension 75.6 mN/m
Temperature: 20 °C(H2O2 50 %)
Flash Point
Remarks: The product is not flammable.
Auto-Ignition
Temperature
Explosion
Properties
Molecular
Weight
Remarks: With certain materials (see section 10 Stability
and Reactivity).
Remarks: In case of heating
34 g/mol
MSDS ONLINE
Oxidising
Properties
Remarks: yes
Explosion
Limit - Lower
Other
Information
Solubility:
Soluble in:
Water
Polar organic solvents
Chemical
Stability
Potential for exothermic hazard
Stable under recommended storage conditions.
Conditions to
Avoid
Contamination
To avoid thermal decomposition, do not overheat.
Incompatible
Materials
Acids, bases, metals, Salts of metals, reducing agents,
organic materials, flammable materials
Hazardous
Decomposition
Products
Oxygen, The release of other hazardous decomposition
products is possible.
Toxicology
Information
Genetic toxicity in vitro:
In vitro tests have shown mutagenic effects.
Genetic toxicity in vivo:
Animal testing did not show any mutagenic effects.
Health Hazard
Main effects:
The product causes burns of eyes, skin and mucous membranes.
Possible hazards (summary):
Corrosive effects
Carcinogenic effect not applicable to human
MSDS ONLINE
Inhalation
Inhalation of vapours is irritating to the respiratory
system, may cause throat pain and cough.
Breathing difficulties
Inhaled corrosive substances can lead to a toxic oedema of
the lungs.
Nausea
Vomiting
Repeated or prolonged exposure: Risk of sore throat, nose
bleeds, chronic bronchitis.
Ingestion
Paleness and cyanosis of the face.
If ingested, severe burns of the mouth and throat, as well
as a danger of perforation of the oesophagus and the
stomach.
Risk of shock.
Excessive fluid in the mouth and nose, with risk of
suffocation.
Risk of throat (o)edema and suffocation.
Bloating of stomach, belching.
Nausea
Bloody vomiting
Cough
Breathing difficulties
Risk of chemical pneumonitis and pulmonary (o)edema.
Skin
Severe skin irritation
Redness
Swelling of tissue
Causes burns
Eye
Severe eye irritation
Redness
Lachrymation
Swelling of tissue
Risk of serious damage to eyes.
May cause permanent eye injury.
May cause blindness.
Carcinogenicity Oral, Prolonged exposure, mouse, Target Organs: duodenum,
carcinogenic effects.
Dermal, Prolonged exposure, mouse, Animal testing did not
show any carcinogenic effects.
Acute Toxicity
LD50, rat, 841 mg/kg (H2O2 60 %)
- Oral
MSDS ONLINE
Acute Toxicity
LD50, rabbit, > 2.000 mg/kg (H2O2 70 %)
- Dermal
Acute Toxicity
LC50, 4 h, rat, 2.000 mg/m³ (Hydrogen peroxide)
- Inhalation
Eye Irritation Risk of serious damage to eyes. (H2O2 70 %)
Skin Irritation Rabbit, corrosive effects, 1 h (H2O2 50 %)
Respiratory
Irritation
Inhalation, mouse, Irritating to respiratory system., RD 50
= 665 mg/m³ (Hydrogen peroxide)
Subchronic/
Chronic
Toxicity
Oral, Prolonged exposure, Various species, Target Organs:
Gastrointestinal tract, observed effect
Inhalation, Repeated exposure, rat, LOEL: 14.6 mg/m3,
irritant effects
Ecotoxicity
Acute toxicity:
Fishes, Pimephales
Fishes, Pimephales
Crustaceans, EC50,
Crustaceans, NOEC,
promelas, LC50, 96 h, 16.4 mg/l
promelas, NOEC, 96 h, 5 mg/l
48 h, 2.4 mg/l
48 h, 1 mg/l
Chronic toxicity:
Molluscs, NOEC, 56 Days, 2 mg/l
Algae, Chlorella vulgaris, EC50, growth rate, 72 h, 4.3 mg/l
Algae, Chlorella vulgaris, NOEC, 72 h, 0.1 mg/l
Persistence /
Degradability
Abiotic degradation:
Air, indirect photo-oxidation, t 1/2 from 16 - 20 h
Conditions: sensitizer: OH radicals
Water, redox reaction, t 1/2 from 25 - 100 h
Conditions: mineral and enzymatic catalysis, fresh water
Water, redox reaction, t 1/2 from 50 - 70 h
Conditions: mineral and enzymatic catalysis, salt water
Soil, redox reaction, t 1/2 from 0.05 - 15 h
Conditions: mineral catalysis
Biodegradation:
Aerobic, t 1/2 < 2 min
Conditions: biological treatment sludge
MSDS ONLINE
Remarks: Readily biodegradable.
Aerobic, t 1/2 from 0.3 - 5 d
Conditions: fresh water
Remarks: Readily biodegradable.
Anaerobic
Remarks: not applicable
Effects on waste water treatment plants, Inhibitor > 30 mg/l
Remarks: inhibitory action
Mobility
Air, Volatility, Henry's law constant (H) = 1 Pa.m³/mol
Conditions: 20 °C
Remarks: not significant
Air, condensation on contact with water droplets
Remarks: rain washout
Water
Remarks: The product evaporates slowly.
Soil/sediments
Remarks: non-significant evaporation and adsorption
Bioaccumulative Bioaccumulative potential
Result: Does not bioaccumulate.
Potential
Other
Information
Other adverse effects:
No data available
Possible hazards (summary):
Toxic to aquatic organisms.
Nevertheless, hazard for the environment is limited due to
product properties:
. no toxicity of degradation products (H2O and O2).
Inherently biodegradable.
Does not bioaccumulate.
Waste Disposal In accordance with local and national regulations.
Limited quantity
Dilute with plenty of water.
Flush into sewer with plenty of water.
Large quantities:
Contact manufacturer.
MSDS ONLINE
Other
Information
Packaging treatment:
Empty containers.
Clean container with water.
Dispose of rinse water in accordance with local and
national regulations.
Do not rinse the dedicated containers.
The empty and clean containers are to be reused in
conformity with regulations.
Transport
Information
UN-No: 2014
IATA-DGR
Class: 5.1
Sub-risks: CORROSIVE
Packing group: II
ICAO-Labels: 5.1 + 8
Proper shipping name: HYDROGEN PEROXIDE, AQUEOUS SOLUTION
IMDG
Class: 5.1
Sub-risks: Corrosive
Packing group: II
IMO-Labels: OXIDIZING AGENT + CORROSIVE
HI/UN No.: 2014
EmS: F-H, S-Q
ADG
Class: 5.1
Sub-risks: 8
Packing group: II
ADG-Labels: 5.1 + 8
HI/UN No.: 58/2014
Remarks:
- IATA: forbidden over 40 %
- HAZCHEM Code: 2P
U.N. Number
2014
MSDS ONLINE
Proper
Shipping Name
HYDROGEN PEROXIDE, AQUEOUS SOLUTION
DG Class
5.1
Sub.Risk
8
Hazchem Code
2P
Packaging
Method
3.8.5.1RT7,RT8
Packing Group
II
EPG Number
5.1.005
IERG Number
31
Regulatory
Information
Label:
Hazardous components which must be listed on the label:
Hydrogen peroxide
Classified as hazardous according to criteria of NOHSC.
Other information:
The percentage concentration of the solution has to be
indicated next to the product name.
Inventory Information:
Korean Existing Chemicals List (ECL):
In compliance with inventory.
Japanese Existing and New Chemical Substances (MITI List)
(ENCS):
One or more components not listed on inventory.
Inventory of Existing Chemical Substances (China) (IECS):
New Zealand Inventory (in preparation) (NZ):
One or more components not on composite list considered for
transfer.
MSDS ONLINE
Schweizer Giftliste-1 (GL-1):
Symbol
C Corrosive
Hazard Category Corrosive
EINECS/ELINCS
(EC)
TSCA (USA)
AICS
(Australia)
DSL (Canada)
PICCS
(Philippines)
Empirical
Formula &
Structural
Formula
User
Information
H2O2
-----Original Message----From: Russell Crowe [mailto:[email protected].
com.au]
Sent: Monday, 2 June 2008 2:10 PM
To: Gordon Bayley
Subject: RE: MSDS's
This MSDS applies for both grades as the products are
indistinguishable from a risk/hazard perspective. We have
asked Europe (who handle all MSDS for the world) to update
the MSDS to include the name Interox LC-60.
Regards,
Russell
MSDS ONLINE
Other
Information
Company: SOLVAY INTEROX Pty Ltd
Emergency telephone number
Telephone:
1 800 023 488 (Emergency 24 Hour)
+44 1865 407333 [CareChem 24] (Australia, New Zealand)
AU: +61-2-93168000 (Product information)
Administrative information:
Australian version
General revision
Distribute new edition to clients
Text of R phrases mentioned in Section 2 (Composition/
Information on Ingredients):
R8: Contact with combustible material may cause fire.
R34: Causes burns.
SAFETY DATA SHEET
Australian version - NOHSC: 2011 (2003)
FDS / P 14253 / 19/04/2006 / Australia / Report version 1.0
End of MSDS
Ltd.
BS: 1.9.40
SODIUM SILICATE SOLUTION
Hazardous Substance according to the Criteria of the Australian NOHSC.
Not a Dangerous Good according to the ADG Code.
Section 1. IDENTIFICATION OF THE MATERIAL AND SUPPLIER
IDENTIFICATION
Product Name
Sodium Silicate Solution
Other Names
Silicic Acid, Sodium Salt Solution; Water Glass; Soluble Glass.
Trade Names:
As Defined
Manufacturer:
PQ AUSTRALIA PTY LTD
USE
May be used as a: detergent ingredient; adhesive; binder; feedstock silica source; general chemical.
COMPANY DETAILS
Company Name
Address
PQ Australia Pty Ltd
A.C.N. No. 005 399 100
HEAD OFFICE:
9-13 Rhur Street
PO Box 4380
Dandenong South
VICTORIA 3164
Tel: (03) 9708 9200
Fax: (03) 9708 9250
N.S.W. Branch
8-10 Riverside Road
Chipping Norton
New South Wales 2170
Tel: (03) 9708 9200
Emergency Telephone No:
1800 240 779
Section 2. HAZARDS IDENTIFICATION
Emergency Overview:
Clear to hazy, colorless, odorless, thick liquid.
Causes eye, skin, and digestive tract irritation.
Spray mist causes irritation to respiratory tract.
Spills are slippery. High pH is harmful to aquatic life.
Reacts with acids, ammonium salts, reactive metals and some organics.
Noncombustible, but flammable hydrogen gas may be produced on prolonged
contact with metals such as aluminium, tin, lead, and zinc.
Dangerous Goods Information:
Not a Dangerous Good according to the ADG Code.
Hazardous Substances Information:
Hazardous Substance according to the Criteria of the Australian
NOHSC.
Poison Schedule
Scheduled Poison S5
Issued by: PQ Australia Pty Ltd
Issue: Sodium Silicate Solutions-MSDS-March 9th 2011
Page 1 of 7
Acute Health Effects
Swallowed
Swallowing can result in nausea, vomiting, abdominal pain and diarrhoea. May
cause severe irritation to the mouth, throat and stomach.
Eye
A severe eye irritant. May cause conjunctivitis (inflammation of the eyes) and
possibly corneal burns and ulceration.
Skin
Irritating to skin. May cause itching and skin rash.
Inhaled
Exposure to vapours at room temperature is an unlikely route of exposure due to its
low vapour pressure.
Spray mist will cause respiratory irritation and may result in coughing as well as
inflammation of nose, throat and windpipe.
Chronic Health Effects
All Routes
Prolonged or repeated skin contact may cause dry skin. Defatting of the skin can
result in irritation and dermatitis (inflammation of the skin).
Section 3. COMPOSITION / INFORMATION ON INGREDIENTS
Chemical Identity of Ingredients
Sodium Silicate
Water
CAS No.
1344-09-8
7732-18-5
Prop’n
30-60 %
30-60 %
Risk Phrases as 100%
R22-36/37/38
-
Section 4. FIRST AID MEASURES
Swallowed
Eye
Skin
Inhaled
First-Aid Facilities
Advice to Doctor
Immediately rinse mouth with water. Repeat until product is thoroughly removed.
Give water to drink. DO NOT induce vomiting due to risk of further damage. If
vomiting occurs give water to drink to further dilute the product. Get medical attention.
Contact the Poisons Information Centre (available in each State capital city).
Immediately rinse with plenty of water for at least 15 minutes. Eyelids to be held
open. Urgently get medical assistance. Transport to hospital or medical centre.
Immediately wash contaminated skin with plenty of water. Soaked clothing should be
removed while under the safety shower and skin washed with running water for a
minimum of 30 minutes. No attempt should be made to neutralize the alkali with acid
solutions, as this could aggravate the burns. Get medical attention if health effects
develop or persist.
Remove victim to fresh air. Get medical attention if health effects develop or persist.
Safety shower and eye wash facilities.
Treat symptomatically as for strong alkalis.
Section 5 - FIRE FIGHTING MEASURES
Fire or Explosion
Hazard:
Extinguishing
Media:
Aqueous solution, not flammable under normal conditions of use. Flammable
hydrogen gas may be produced on prolonged contact with metals such as aluminium,
tin, lead, and zinc.
Compatible with dry chemical water spray, regular foam and carbon dioxide fire
extinguishing media.
Page 2 of 7
Combustion
Product Hazards
Special Protective
Precautions &
Equipment
Flammable hydrogen gas may be produced on prolonged contact with metals such
as aluminium, tin, lead, and zinc.
Fire fighters to wear full protective clothing.
Chemical goggles, body-covering protective clothing, chemical resistant gloves, and
rubber boots.
Section 6 - ACCIDENTAL RELEASE MEASURES
Emergency
Procedures
Small spill cleanup: Mop up and neutralize liquid, then discharge to sewer in
accordance with federal, state and local regulations or permits.
Large spill cleanup: Keep unnecessary people away; isolate hazard area and deny
entry. Do not touch or walk through spilled material. Stop leak if you can do so
without risk. Prevent runoff from entering into storm sewers and ditches which lead to
natural waterways. Isolate, dike and store discharged material, if possible. Use sand
or earth to contain spilled material. If containment is impossible, neutralize
contaminated area and flush with large quantities of water.
See Section 13 for Disposal Considerations
Special Issues
Spilled material is very slippery. Only water will evaporate from a spill of this material.
Dries to form glass film which can easily cut skin.
Sinks and mixes with water. High pH of this material is harmful to aquatic life.
Section 7 - HANDLING and STORAGE
Safe Handling
Safe Storage
Avoid contact with eyes, skin and clothing. Avoid breathing spray mist.
Keep container closed. Promptly clean residue from closures with cloth.
Keep containers closed at all times. Store away from acids and foodstuffs. Store in
clean steel or plastic containers. Separate from acids, reactive metals, and
ammonium salts. Storage temperature 0-95º C. Loading temperature 45-95 º C. Do
not store in aluminum, fiberglass, copper, brass, zinc or galvanized containers.
Mild steel is the most suitable material of construction for drums, tanks, valves, pipework, etc. Concrete storage tanks can be used but must be strong enough to hold
the weight of Sodium Silicate solution to be stored and thick enough to prevent
seepage of water.
Section 8 - EXPOSURE CONTROLS / PERSONAL PROTECTION
National Exposure
Standards
No exposure standards have been established for the ingredients in this product by
NOHSC (Worksafe Australia).
SUBSTANCE
Sodium Silicate
ppm
-
TWA
mg/m3
5
ppm
-
STEL
mg/m3
5
This standard is the manufacturers recommended limit for good practice.
All atmospheric contamination should be minimised.
Design and
Engineering
Control Measures
Use in well ventilated area. Avoid generating and inhaling mists.
Page 3 of 7
Personal Protective
Equipment
Avoid skin and eye contact. Avoid inhaling the vapour or mist. Follow normal
industrial safety practices. The use of protective clothing and equipment depends on
the degree and nature of exposure. The following personal protective equipment
should be used:
(1) Safety glasses, goggles or faceshield as appropriate.
(2) Plastic or Rubber gloves.
(3) Chemical resistant safety boots.
(4) Overalls, splash apron or similar protective apparel.
Respiratory protection is not normally required due to low inhalation risk.
Wash contaminated clothing and protective equipment before storing and re-using.
The use of barrier cream is recommended.
Where applicable refer to the following Standards:
AS/NZS 1337 Eye protectors for industrial applications
AS 2161
Industrial safety gloves and mittens
AS 2210
Safety footwear
AS 3765
Clothing for protection against hazardous chemicals.
Section 9 - PHYSICAL and CHEMICAL PROPERTIES
Appearance and Odour
Chemical Formula
Melting Point / Boiling Point
Decomposition Temperature
Vapour Pressure
Relative Vapour Density
Specific Gravity or Density
Solubility
pH
Percent Volatile
Octanol/Water Partition
Co-efficient
Corrosiveness
Flammable Properties
Flashpoint
Flammability Limits (FL) (%)
Autoignition Temp
Clear to hazy, colorless, odorless, thick liquid.
Varying proportions of sodium oxide, silica and water depending on the
grade. Mean weight ratio for SiO2/Na2O: is from 2.0 to 3.3
MP: 0°C approx.
BP: 105 to 108°C
Water Boils off at 105 to 108°C
Not determined
Not applicable
1.2 to 1.7 (typical range)
Soluble in water.
11 to 13 (of the concentrate)
30-60%
log P(octanol/water) – Not available
Some corrosive effects on Aluminium, Copper, Tin, Zinc, Lead etc
Non combustible liquid. The aqueous solution is not flammable under
normal conditions of use. Flammable hydrogen gas may be produced on
prolonged contact with metals such as aluminium, tin, lead, and zinc.
Not applicable to aqueous solutions
Page 4 of 7
Section 10 - STABILITY AND REACTIVITY
Chemical Stability
Conditions To Avoid:
Incompatible
Materials:
Unsuitable Container
Materials:
Hazardous
Decomposition
Products:
Hazardous
Reactions:
Stable in sealed containers. Absorbs Carbon Dioxide on exposure to air, which
results in the deposition of Insoluble Silica.
Leaving solutions exposed to carbon dioxide in the air.
Strong Acids.
Sodium Silicate solutions are strongly alkaline and are not compatible with
aluminium, copper, brass, bronze, zinc, tin and lead.
Can etch glass if not promptly removed.
If Overheated: The solution will boil and irritating Sodium Silicate containing mists
will be released.
Flammable hydrogen gas will form on reaction with aluminium, copper, zinc etc.
Gels and generates heat when mixed with acid.
May react with ammonium salts resulting in evolution of ammonia gas.
Section 11 - TOXICOLOGICAL INFORMATION
Toxicity Data:
Acute Oral Toxicity LD50 (rat): 1280 mg/kg (as 100%)
The acute oral toxicity of this product has not been tested. When Sodium Silicates
were tested on a 100% solids basis, their single dose acute oral LD50 in rats ranged
from 1280 mg/kg (above) to 3200 mg/kg. The acute oral lethality resulted from
nonspecific causes. These products contain 30-60% Sodium Silicate thus each
overall product has an Acute Oral Toxicity LD50 (rat): >2000 mg/kg.
Eye Irritation: Severe Irritant.
Produced corneal, iridal and conjunctival irritation.
Skin Irritation: Irritant.
When tested for primary skin irritation potential, this material produced irritation with a
primary irritation index of 3 to abraded skin and 0 to intact skin.
Human experience confirms that irritation occurs when this material gets on clothes
at the collar, cuffs or other areas where abrasion may occur.
Subchronic Data: In a study of rats fed Sodium Silicate in drinking water for three
months, at 200, 600 and 1800 ppm, changes were reported in the blood chemistry of
some animals, but no specific changes to the organs of the animals due to Sodium
Silicate administration were observed in any of the dosage groups. Another study
reported adverse effects to the kidneys of dogs fed Sodium Silicate in their diet at
2.4g/kg/day for 4 weeks, whereas rats fed the same dosage did not develop any
treatment-related effects. Decreased numbers of births and survival to weaning was
reported for rats fed Sodium Silicate in their drinking water at 600 and 1200 ppm.
Special Studies: Sodium Silicate was not mutagenic to the bacterium E. Coli when
tested in a mutagenicity bioassay. There are no known reports of carcinogenicity of
Sodium Silicates. Frequent ingestion over extended periods of time of gram
quantities of silicates is associated with the formation kidney stones and other
siliceous urinary calculi in humans. Sodium Silicate is not listed by IARC, NTP or
OSHA as a carcinogen.
Page 5 of 7
Section 12 - ECOLOGICAL INFORMATION
General:
Ecotoxicity Data:
Persistence &
Degradability
Mobility
Avoid contaminating waterways. Soluble in water.
Sinks and mixes with water. Only water will evaporate from this material.
The following data is reported for Sodium Silicates on a 100% solids basis:
A 96 hour median tolerance for fish (Gambusia affnis) of 2320 ppm; a 96 hour
median tolerance for water fleas (Daphnia magna) of 247 ppm; a 96 hour median
tolerance for snail eggs (Lymnea) of 632 ppm; and a 96 hour median tolerance for
Amphipoda of 160 ppm. These products contain 30-60% Sodium Silicate.
This material is not persistent in aquatic systems, but its high pH when undiluted or
unneutralized is acutely harmful to aquatic life. Diluted material rapidly depolymerizes
to yield dissolved silica in a form that is indistinguishable from natural dissolved silica.
It does not contribute to BOD. This material does not bioaccumulate except in
species that use silica as a structural material such as diatoms and siliceous
sponges.
Neither silica nor sodium will appreciably bioconcentrate up the food chain.
Expected to be mobile in soil. Diluted material rapidly depolymerizes to yield
dissolved silica in a form that is indistinguishable from natural dissolved silica.
Section 13 - DISPOSAL CONSIDERATIONS
Disposal Methods
& Containers
Disposal to be in accordance with Local, State & Federal EPA waste regulations.
Normally suitable for disposal at approved land waste site after dilution or
neutralisation.
Landfill,
Incineration
After dilution or neutralisation may be landfilled.
Not suitable for incineration.
Section 14 - TRANSPORT INFORMATION
ROAD & RAIL:
SEA:
AIR:
Not defined as a Dangerous Good: by the Australian Code for the Transport of
Dangerous Goods by Road & Rail.
Not a Dangerous Good according to the International Maritime Dangerous Goods
Code (IMDG Code).
Not a Dangerous Good according to the International Air Transport Association
(IATA) Dangerous Goods Regulations.
Section 15 - REGULATORY INFORMATION
Labelling:
Workplace Hazardous Substance Labelling
Hazard Category: Irritant
R36/38 - Irritating to eyes and skin.
S24/25 Avoid contact with skin and eyes.
S37/39 Wear suitable gloves and eye/face protection.
S26 In case of contact with eyes, rinse immediately with plenty of water and seek
medical advice.
S28 After contact with skin, wash immediately with plenty of water.
Scheduled Poison Labelling for S5
The labelling requirements of the SUSDP do not apply to a poison that: 1/ is packed
and sold solely for dispensary, industrial, laboratory or manufacturing purposes; and
Page 6 of 7
2/ is labelled in accordance with the NOHSC National Code of Practice for the
Labelling of Workplace Hazardous Substances [NOHSC:2012]
Packaging
Not a Dangerous Good:
Mild steel is the most suitable material of construction for drums, tanks, valves, pipework, etc.
Australian Chemical Control Schemes
All ingredients are on the Australian Inventory of Chemical Substances.
NICNAS – AICS
Not applicable
Aust. Pesticides & Veterinary Medicine Authority - Ag & Vet Chemicals
Not applicable
Therapeutic Goods Administration Medicines
Not applicable
Food Standards Australian & New Zealand Food
Not applicable
Not applicable
Chemicals
Ozone Depleting
Weapons Act
Substance Act
Section 16 - OTHER INFORMATION
MSDS Dates and Revisons
th
MSDS Original Preparation Date
:
26 November 2004
th
MSDS Latest Revision Date
:
9 March 2011
Sections Changed in Latest Revison :
Contact details
Technical Manager:
phone: (03) 9708 9200
Adrian Hill
email:
[email protected]
th
MSDS APPROVED : 26 November 2004
Acronyms Used
ADG Code
NOHSC
WHS
CAS No.
UN No.
MSDS Code Used
fax:
(03) 9708 9255
Australian Dangerous Goods Code for the Transport of Dangerous Goods by Road &
Rail
Australian National Occupational Health and Safety Commission
Workplace Hazardous Substance
Chemical Abstracts Service Registry Number
United Nations Dangerous Goods Number
This MSDS has been prepared according to the National Code of Practice for the
Preparation of Material Safety Data Sheets [NOHSC:2011(2003)
This MSDS summarises to the best of our knowledge the health and safety hazard information on the
product and how to safely handle and use the product in the workplace. Each user should read this MSDS
and consider the information in the context of how the product will be handled and used in the workplace,
including in conjunction with other products. If clarification or further information is needed to ensure that an
appropriate risk assessment can be made, the user should contact this company.
Page 7 of 7
Appendix H HAZOP
43283717/001/B
H
Revision History
Revision Nº
Prepared By
Description
Date
A
Mark Robertson
DRAFT – For Client Review
29/05/2012
Document Acceptance
Action
Name
Prepared by
Mark Robertson
Signed
Date
Reviewed by
Approved by
on behalf of
Beca AMEC Limited
Beca AMEC // 29 May 2012
2471159 // AU1868071384 0.4
Summary
th
HAZOP Details – One HAZOP session was carried out on the 24 May 2012 to review the
documentation and plans developed to date for the project.
Tony Johnson was the HAZOP Leader and Mark Robertson was the scribe. The full attendance
register of 12 people is attached.
The Hazard Study 2 guidewords were based on AMEC / Beca AMEC methodology and tailored
for this particular purpose.
The guidewords were applied sequentially to the whole project. The procedure was to review
Cause, Consequences, Risk Response Strategy and Recommendations.
A cause for risk was first established, then the significance of potential consequences was
assessed and the risk response strategy was itemised. Procedures and controls in place now or
planned in the future were listed and this generally meant the risk level was reduced.
Recommendations were made only when the risk response strategy was deemed inadequate or
extra work was required to follow up on items raised.
Responsibility for action was assigned to either Australian Paper or Beca AMEC individuals to
carry this out.
Thirty six (36) recommendations were made during the session. While not all participants
necessarily agreed these items were risks, they were noted and are to be considered further by
the project team members. Recommendations were made recognising that the risk response
strategy may be inadequate, or at this stage only partially progressed or yet to progress.
The recommendations list includes reference to the identified project risk and the responsibility
for action.
The final consolidated list of 36 recommendations is included in this report. This is essentially the
working document for follow8up action.
Full documentation of the HS2 session is included in this report.
Tony Johnson
Risk Review Facilitator
Distribution by email: All attendees.
Beca AMEC // 29 May 2012 // Page 1
2471159 // AU1868071384 0.4
Appendix A
HS2 Review Minutes
Beca AMEC // 29 May 2012 // Page 2
2471159 // AU1868071384 0.4
2471159 Deinked Pulp Project HAZOP Report
Project Information
Project Information:
Company: 507 BECA AMEC LIMITED
Project Locations: Fairfield; Maryvale
Unit:
Project Title: Deinked Pulp Project
Project ID: 2471159
HAZOP Sessions
Date
1. 24/05/2012
Duration
2.00 hr
Description
HAZOP Level 2
Leader
Tony Johnson
Scribe
Mark Robertson
HAZOP Attendance
HAZOP Sessions
Team Members
Company
1. 24/05/2012
Attendance
Paul Huddart
Beca Amec
Present
Matthew Lilja
Beca Amec
Present
Tony Johnson
Beca Amec
Present
Mark Robertson
Beca Amec
Present
Steve Lau
Australian Paper
Present
Hiroshi Tenasaka
Australian Paper
Present
Ann Collins
Australian Paper
Present
Mitsuhiro Sugino
Australian Paper
Present
Peter Berrgman
Australian Paper
Present
Keith White
Australian Paper
Present
Peter Kivisalv
Australian Paper
Present
David Jettner
Australian Paper
Present
1 of 15
25/05/2012
HAZOP Recommendations
Recommendations
Places Used
HAZOP Ref #
Responsibility %Comp
Recommendation Estimated Dates
Status
Est. Start Est. End
Resolution /
Action Taken
Actual Dates
Act. Start
Act. End
Cost
Est.
Completed By
Act.
Name
Date
39. Investigate NSSC fire
HAZ.1.1.111
protection system tie in with
main ring.
40. Investigate maintenance
HAZ.1.1.112
access of west grassland to
reduce fire hazard.
41. Investigate protection
methods against ember
attack from bushfire within
pine forest.
HAZ.1.1.113
42. Consider waste paper fire
and impact on M4 raw
material store and
safeguards.
HAZ.1.2.115
43. Investigate training staff with HAZ.1.2.116
new dangerous material in
FaS.
44. Investigate the NPI
HAZ.1.2.116
learning’s of handling FaS to
avoid moisture ingress and
explosions.
45. Investigate installing lagging HAZ.1.2.117
on peroxide pipework to
prevent heating and
subsequent explosion during
hot days.
46. Consider the bunding
requirements for the
peroxide day tank
HAZ.1.2.117
47. Ensure that the AP peroxide HAZ.1.3.119
piping standard is followed
during the project.
48. Source, review and possibly HAZ.1.3.119
implement the NPI FaS
technical standard.
49. Source and review the
AMCOR FaS technical
standard.
HAZ.1.3.119
2 of 15
25/05/2012
Recommendations
Places Used
HAZOP Ref #
Status
Est. Start Est. End
Resolution /
Action Taken
Actual Dates
Act. Start
Act. End
Cost
Est.
Completed By
Act.
Name
Date
50. Investigate when to flush the HAZ.1.2.123
system, how to handle pulp HAZ.2.4.154
with a higher biological
content. Check hot work
requirements and are they
any different to normal pulp.
51. Review Fairfield operations HAZ.1.2.123
and tank cleaning
procedures, maintenance
access, operating
procedures, venting, clean
out of tanks and equipment.
52. Traffic management
HAZ.2.8.124
concerns in the wetlap area
are being covered as part of
the layout review. Consider
an alternative layout
arrangement to avoid the
traffic issues.
53. Review when the fire
HAZ.2.2.127
protection system piping is
to be replaced in the future
due to rapid corrosion.
54. Ensure that the Fungicide HAZ.2.6.129
operation goes through the
new chemical use
procedure.
55. Review guarding of the
equipment in the wetlap
area including the bail
dewiring, nips and rotating
equipment.
HAZ.2.8.131
56. Discuss providing waste
paper litter containment to
prevent fire hazard,
contamination and
housekeeping issues.
HAZ.3.1.132
57. Resolve how site generated HAZ.3.1.132
clean waste paper is to be
processed.
58. Resolve how storm water is HAZ.3.1.133
collected from the outside
3 of 15
25/05/2012
Recommendations
Places Used
HAZOP Ref #
Status
Est. Start Est. End
Resolution /
Action Taken
Actual Dates
Act. Start
Act. End
Cost
Est.
Completed By
Act.
Name
Date
concrete pad. Resolve how
to avoid waste paper
contamination of storm
water release.
59. Investigate adequate
HAZ.3.1.133
protection measures for the
"Far Western" drain.
60. Check the ambient air
quality in this area
HAZ.3.1.135
61. Check with regulator and
HAZ.3.4.137
AMCOR if there is a trigger
for the hazardous area
electrical compliance
regulations due to the
relocation of the power lines.
62. Review waste removal
HAZ.3.6.139
logistics. Compaction now or
in the future should be
considered. Consider
location to avoid existing
traffic management issues in
this area.
63. Develop operations and
HAZ.3.6.139
manning plan for the DIP
and wetlap areas, including
solid waste disposal
64. Noise of mobile equipment HAZ.3.7.140
in this area needs to be
considered as part of the
environmental impact study.
65. Resolve pedestrian access HAZ.3.8.141
in the DIP area especially
surrounding the
maintenance staff workshop
and carpark.
66. As part of the traffic
HAZ.3.10.142
management plan consider
access with existing carpark
and potential weighbridge.
67. Consider impact on process HAZ.3.8.143
of contamination from NSSC
liquor when it blows through
4 of 15
25/05/2012
Recommendations
Places Used
HAZOP Ref #
Status
Est. Start Est. End
Resolution /
Action Taken
Actual Dates
Act. Start
Act. End
Cost
Est.
Completed By
Act.
Name
Date
the vents.
68. Consider how after hours
HAZ.3.9.144
maintenance requirements
will be done around elevated
equipment.
69. Include adequate ventilation HAZ.3.9.145
for buildings where
equipment will be operating
inside.
70. Part of the construction
review consider lay down
areas, site offices,
emergency planning etc.
HAZ.3.12.147
71. Minimize impact on site
operations and consider
separate facility (cafeteria,
toilets etc.) during
construction.
HAZ.3.12.147
72. Develop a response strategy HAZ.3.14.149
for mill alarms during the
construction and DIP
operation.
73. Source vibration database
for historical data from
AMCOR
HAZ.3.17.152
74. Ensure compliance with
HAZ.3.17.152
plant regulations due to the
purchase of second hand
equipment
75. Ensure compliance with site HAZ.3.18.153
quality system. ISO14000
plant risk assessments,
operation task risk
assessments and
maintenance task
assessments.
5 of 15
25/05/2012
Project / Plant Areas
Areas
HS 2 Areas
Node
Design
HAZOP Session
Conditions/Parameters
1. DIP
1. 24/05/2012
2. Wetlap
1. 24/05/2012
3. Overview
1. 24/05/2012
Comment
6 of 15
25/05/2012
HAZOP Worksheet
Areas: HS 2 Areas
HAZOP:
Node: 1. DIP
Deviation
1. EXTERNAL FIRE /
EXPLOSION
(flammables,
combustibles,
wastes, pyrophoric,
dusts, unstable
compounds)
2. INTERNAL FIRE /
EXPLOSION
(flammables, mists,
combustibles,
pyrophoric,
dusts, oxygen,
unstable
compounds)
Cause / Risk / Hazard
111. Loader exhausts igniting pulp.
Consequence
Current Control
1. NSSC pulp ignition and fire
1. Washed down regularly
Recommendations
Responsibility
HAZOP Ref #
39. Investigate NSSC fire
protection system tie in
with main ring.
HAZ.1.1.111
1. Fire emergency crew
40. Investigate
maintenance access of
west grassland to
reduce fire hazard.
HAZ.1.1.112
113. Bushfire ember attack within pine 1. Fire within DIP
forest
1. Fire emergency crew
41. Investigate protection
methods against
ember attack from
bushfire within pine
forest.
HAZ.1.1.113
114. Wood Chips fire
1. No real consequence
1. Wood Chips decommissioned
115. Deink fire
1. M4 waste material store damage
and disruption
1. Operate M4 with door shut
42. Consider waste paper
fire and impact on M4
raw material store and
safeguards.
HAZ.1.2.115
1. Delivered in an ISO size small
container (approx. 1T), used
within hopper.
43. Investigate training
staff with new
dangerous material in
FaS.
HAZ.1.2.116
2. Fire monitors
3. Plan to extend main past the
waste paper plant to the DIP
112. West grassed area fire hazard
1. Fire in grassed area
2. Disrupt operation and damage to
DIP
116. FaS explodes as a wet powder. 1. Explosion
Need to protect it from moisture.
2. Segregation intention with
concrete division to protect area
HAZ.1.1.114
2. Used in a separate dedicated
building
44. Investigate the NPI
learning’s of handling
FaS to avoid moisture
3. Purpose built container
ingress and
4. Moisture needs to be kept away,
explosions.
keeping door closed
118. NPI have experienced explosions 1. Explosion
with Fa S
1. Changed the design of the
package to avoid moisture
ingress
117. Peroxide at 59.5% existing
1. Explosion
pipework being used to transfer to
a new day tank.
1. Lagging pipework to prevent
heating of peroxide during hot
days
7 of 15
HAZ.1.2.118
45. Investigate installing
lagging on peroxide
pipework to prevent
HAZ.1.2.117
25/05/2012
Areas: HS 2 Areas
HAZOP:
Node: 1. DIP
Deviation
Consequence
Current Control
Recommendations
heating and
subsequent explosion
during hot days.
Responsibility
HAZOP Ref #
46. Consider the bunding
requirements for the
peroxide day tank
123. Bug growth within DIP area tanks 1. Production of hydrogen and other
combustibles leading to ignition.
51. Review Fairfield
operations and tank
cleaning procedures,
maintenance access,
operating procedures,
venting, clean out of
tanks and equipment.
HAZ.1.2.123
50. Investigate when to
flush the system, how
to handle pulp with a
higher biological
content. Check hot
work requirements and
are they any different
to normal pulp.
3. CONFINED
EXPLOSION
(INSIDE BUILDING
STRUCTURE)
(flammables, dusts,
mists, oxygen
enrichment, unstable
compounds)
4. EXPLOSIVE
DECOMP/
DETONATION
(Ammonium Nitrate
solid/solutions)
(chemical
incompatibility, dead
heading, low pH,
119. Peroxide
120. Caustic soda 10%, biocides and
fungicides
1. Internal explosion
1. Piping relief valves
47. Ensure that the AP
peroxide piping
standard is followed
during the project.
2. Vents
48. Source, review and
possibly implement the
NPI FaS technical
standard.
3. Temperature in day tank
49. Source and review the
AMCOR FaS technical
standard.
1. ISO containers
8 of 15
HAZ.1.3.119
HAZ.1.4.120
25/05/2012
Areas: HS 2 Areas
HAZOP:
Node: 1. DIP
Deviation
high volatiles)
Consequence
Current Control
Recommendations
Responsibility
HAZOP Ref #
5. PHYSICAL
OVER/UNDER
PRESSURE
(flammables,
combustibles,
oxygen, halogen,
unstable compound,
polymerization, loss
of ignition / re
ignition)
6. TOXIC / HARMFUL
EXPOSURE
(toxic gases, mists,
liquids, dusts, acids,
alkalis, biological,
wastes, combustion
products,
carcinogens,
dermatitis, irritants
sensitizers)
121. Caustic soda
1. Current site procedures in place
PPE
HAZ.1.6.121
122. Biocide & fungicide
1. PPE & Bunding of tanks
HAZ.1.6.122
7. VIOLENT RELEASE
OF ENERGY
(potential, electrical,
kinetic)
104. No issues identified
HAZ.1.7.104
8. EXPOSURE TO
DAMAGING
ENERGY
kinetic, potential)
104. No issues identified
HAZ.1.8.104
9 of 15
25/05/2012
Areas: HS 2 Areas
HAZOP:
Node: 2. Wetlap
Deviation
Consequence
Current Control
Recommendations
Responsibility
HAZOP Ref #
1. EXTERNAL FIRE / 125. Fungicide added to the stock going 1. No real consequence
EXPLOSION
to the machines
(flammables,
combustibles,
wastes, pyrophoric,
dusts, unstable
compounds)
HAZ.2.1.125
2. INTERNAL FIRE / 126. Same as current arrangement
1. No real consequence
EXPLOSION
(flammables, mists, 127. Damage to fire protection system 1. Contamination near bails
(4 years old) due to poor ventilation
combustibles,
pyrophoric,
dusts, oxygen,
unstable
compounds)
HAZ.2.2.126
53. Review when the fire
protection system
piping is to be replaced
in the future due to
rapid corrosion.
3. CONFINED
128. No real cause open warehouse
EXPLOSION
(INSIDE BUILDING
STRUCTURE)
(flammables, dusts,
mists, oxygen
enrichment, unstable
compounds)
4. EXPLOSIVE
154. Bug growth within wetlap area
DECOMP/DETONA
tanks
TION
(Ammonium Nitrate
solid/solutions)
(chemical
incompatibility, dead
heading, low pH,
high volatiles)
HAZ.2.2.127
HAZ.2.3.128
1. Production of hydrogen and other
combustibles leading to ignition.
5. PHYSICAL
128. No real cause open warehouse
OVER/UNDER
PRESSURE
(flammables,
combustibles,
oxygen, halogen,
unstable compound,
50. Investigate when to
flush the system, how
to handle pulp with a
higher biological
content. Check hot
work requirements and
are they any different
to normal pulp.
HAZ.2.4.154
HAZ.2.5.128
10 of 15
25/05/2012
Areas: HS 2 Areas
HAZOP:
Node: 2. Wetlap
Deviation
polymerization, loss
of ignition / re
ignition)
Consequence
Current Control
6. TOXIC / HARMFUL 129. Biocide & fungicide
EXPOSURE
(toxic gases, mists,
liquids, dusts, acids,
alkalis, biological,
wastes, combustion
products,
carcinogens,
dermatitis, irritants
sensitizers)
1. PPE & Bunding of tanks
Recommendations
54. Ensure that the
Fungicide operation
goes through the new
chemical use
procedure.
7. VIOLENT RELEASE 155. No real cause
OF ENERGY
kinetic)
HAZOP Ref #
HAZ.2.6.129
HAZ.2.7.155
8. EXPOSURE TO
124. Layout creates traffic management 1. Increased likelihood of personnel
DAMAGING
issue
injury
ENERGY
kinetic, potential)
52. Traffic management
concerns in the wetlap
area are being covered
as of the part layout
review. Consider an
alternative layout
arrangement to avoid
the traffic issues.
130. Mobile equipment operation similar
to current practice
131. Equipment
Responsibility
HAZ.2.8.124
HAZ.2.8.130
1. Personnel injury / death
55. Review guarding of the
equipment in the
wetlap area including
the bail dewiring, nips
and rotating
equipment.
11 of 15
HAZ.2.8.131
25/05/2012
Areas: HS 2 Areas
HAZOP:
Node: 3. Overview
Deviation
1. Environment
132. Waste paper litter becoming
airborne
Consequence
Current Control
Recommendations
1. Fire hazard elsewhere in the plant
1. Waste paper to be covered by a 56. Discuss providing
tarp configuration
waste paper litter
containment to prevent
fire hazard,
contamination and
housekeeping issues.
2. Housekeeping issue
2. Fencing on the boundary
3. Contamination of near bails
4. Contamination of neighbouring
areas
133. Open drain running past buildings 1. Waste paper contamination in drain 1. DIP building bunded
and subsequent wetlands
2. Effluent from DIP piped to the
clarifier
2. Materials and
Hazards
58. Resolve how storm
water is collected from
the outside concrete
pad. Resolve how to
avoid waste paper
contamination of storm
water release.
HAZ.3.1.133
59. Investigate adequate
protection measures
for the "Far Western"
drain.
HAZ.3.1.134
1. Smell
60. Check the ambient air
quality in this area
156. No issues identified outside of what
previously discussed
3. Major Risk Factors 136. Large lifts
HAZOP Ref #
HAZ.3.1.132
57. Resolve how site
generated clean waste
paper is to be
processed.
134. DARS plant used to be in this area 1. No real consequence identified
unsure of any contaminated
grounds
135. DIP is near NSSC dam
Responsibility
HAZ.3.1.135
HAZ.3.2.156
1. Injury
1. Covered under normal
construction procedures
2. Damage to plant and equipment
2. Project risk study completed
HAZ.3.3.136
3. HAZOP study of PIDs to be
completed
4. Electrical Hazards 137. Relocation of power line
1. Injury
2. Disruption of power
1. Part of the plan is to install it
underground
12 of 15
61. Check with regulator
and AMCOR if there is
a trigger for the
hazardous area
HAZ.3.4.137
25/05/2012
Areas: HS 2 Areas
HAZOP:
Node: 3. Overview
Deviation
Consequence
Current Control
5. Structural Issues
138. Expansion of back access road
1. Traffic congestion
1. To be covered under the project
scope.
6. Waste Disposal
139. Significant volume of waste to be
removed
1. Significant handling requirements
1. Possible compacting of waste
Recommendations
electrical compliance
regulations due to the
relocation of the power
lines.
Responsibility
HAZOP Ref #
HAZ.3.5.138
62. Review waste removal
logistics. Compaction
now or in the future
should be considered.
Consider location to
avoid existing traffic
management issues in
this area.
HAZ.3.6.139
63. Develop operations
and manning plan for
the DIP and wetlap
areas, including solid
waste disposal
7. Risk to Existing
Facilities
140. Reverse beepers on mobile
equipment
1. Disturbance to neighbours
1. Closest neighbour located over 64. Noise of mobile
the hill
equipment in this area
needs to be
considered as part of
the environmental
impact study.
HAZ.3.7.140
65. Resolve pedestrian
access in the DIP area
especially
surrounding the
maintenance staff
workshop and carpark.
HAZ.3.8.141
67. Consider impact on
process of
contamination from
NSSC liquor when it
blows through the
vents.
HAZ.3.8.143
68. Consider how after
hours maintenance
requirements will be
HAZ.3.9.144
8. Risk from Existing 141. Pedestrian access for maintenance 1. Relocation of main pedestrian traffic
Facilities
staff workshop to carpark
around new plant
143. Contamination from the NSSC
when blows safety vents. Occurs
potentially once every 2 years
9. Health and
Toxicology
1. Black liquor on the DIP
2. Cover cars with black liquor
144. Manual handling of bail, dewiring of 1. Personnel injury
bails, waste paper
13 of 15
25/05/2012
Areas: HS 2 Areas
HAZOP:
Node: 3. Overview
Deviation
10. Transport and
Siting
Consequence
Current Control
145. Equipment operating within
unloading area building
1. Ventilation in the unloading area
142. Transport management around
existing carpark
1. Traffic congestion
1. Community engagement
strategy lead by Shaun focus
of recycling, plan to have an
open house forum in the town
centre
Recommendations
done around elevated
equipment.
HAZOP Ref #
69. Include adequate
ventilation for buildings
where equipment will
be operating inside.
HAZ.3.9.145
66. As part of the traffic
management plan
consider access with
existing carpark and
potential weighbridge.
HAZ.3.10.142
11. Consultation with 146. Covered under multiple
External
consultations
Authorities
12. Management
Arrangement
Responsibility
HAZ.3.11.146
147. Construction works interfering with 1. Disruption to both construction and
ongoing operations
operations.
70. Part of the construction
review consider lay
down areas, site
offices, emergency
planning etc.
HAZ.3.12.147
71. Minimize impact on
site operations and
consider separate
facility (cafeteria,
toilets etc.) during
construction.
13. Safety Criteria
148. Excavations during construction
1. Dust emissions on to the existing
site
14. Emergency
Facilities
149. Mill alarms
1. Construction area to respond to mill
alarms
HAZ.3.13.148
72. Develop a response
strategy for mill alarms
during the construction
and DIP operation.
HAZ.3.14.149
150. Facilities for construction service
need to be independent of the mill
HAZ.3.14.150
15. Technical
Standards
151. Areas of the mill that don't comply
with current mill standards
HAZ.3.15.151
16. Staff
156. No issues identified outside of what
previously discussed
HAZ.3.16.156
17. Recommended
Studies
152. Compliance with plant regulations
73. Source vibration
database for historical
14 of 15
HAZ.3.17.152
25/05/2012
Areas: HS 2 Areas
HAZOP:
Node: 3. Overview
Deviation
Consequence
Current Control
Recommendations
data from AMCOR
Responsibility
HAZOP Ref #
74. Ensure compliance
with plant regulations
due to the purchase of
second hand
equipment
18. Quality
Management
153. Compliance with site quality
system. ISO14000 plant risk
assessments, operation task risk
assessments, and maintenance
task assessments.
75. Ensure compliance
with site quality
system. ISO14000
plant risk
assessments,
operation task risk
assessments and
maintenance task
assessments.
15 of 15
HAZ.3.18.153
25/05/2012

Works Approval

Transcription

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