Success with Center-Lining at

Towel & Tissue Wastewater Treatment Plant

January 2014

Presenters

• Shawn Holler, WW III licensed operator has over 20 years of experience at Wausau Paper and in wastewater operations.

• Patty Bradley, Utilities Asset Leader & WW III licensed operator, has 13 years experience at Wausau Paper.

Presentation Topics

• What is center-lining and process behavior charting (PBC)?

• Improved Process Control & Management• Center-lining as a communication tool with

the rest of the facility operations• Benefits of better communication

• Wausau Towel & Tissue LLC is a provider of “away from home” towel and tissue products.

• Our vision is to be The Leading provider of environmentally sensitive products to the markets we serve.

The Middletown “Big 4” Focus

Injury Free Culture Through

Improved Processes and Engagement

of all

ReliableConsistently

delivering when expected

StableProcess in control with

only common cause variation

CapableClearly meeting

customer requirements

Business Excellence

Through Reliable, Stable, Capable

Processes

16% ROCE

Fiber

SpendingOEE

16 % ROCE Through

Successful Competitive

Improvement Plans

Environmental Sustainability and Growth Aligned with the EcoSoft

Brand

Sustainability & Growth - EcoVision

EcoVisionEcoVisionWe will be the leading provider of paper based, environmentally sensitive brands and solutions to the markets we serve.

The Middletown Mill has developed a vision and 5-year plans to enhance our Green Stewardship and Sustainability.

Improvement Areas Addressed Emissions free – air emissions reductions including green house gases Natural resource reduction – best in class water, fiber, and energy use Effluent discharge improvements – effluent quality better than river Waste disposal reductions – elimination or beneficial use of waste streams Community relations and outreach

What is Center-Lining?

• We developed a list of controllable parameters (centerlines) and a list of outcome parameters (in-process) that were tracked each shift and reported each day.

• Each parameter has a range or limit to be measured against as “in compliance”.

• Each day the percent “in-centerline” and percent “in-process” are recorded and calculated by the WWTP operators.

WWTP IN-PROCESS & CENTERLINE DAILY SHEETS

Middletown Mill

Date: November 16, 2013Q:/WWTP/WWTP-7yr

IN-PROCESS for Final Effluent Process Variable Target Actual Value

1ST SHIFT 2ND Shift 3RD SHIFT CommentsHighlight all deviations

Final Effluent Flow ≤ 4.7 MGD 4.34 X X Recycle Flow ≥ 1.0 MGD 1.43 X X

pH 7 < x < 8.5 S. U. 7.84 X X

D.O. > 5.0 mg/L X X

TSS < 200 mg/L 20 X X

COD < 225 mg/L 44 X X

Front AB Temperature (average) < 32 C 22.00 X 23.60

Conveyor Cake Solids ≥ 47% 48.0% X 52.3%

% In-Process 100% 100% 100%

QSF 3.1 WWTP CENTERLINE REPORT

WWTP IN-PROCESS and CENTERLINE DAILY SHEETS - Continued

CENTERLINESComments

Process Variable Target 1ST Shift 2ND Shift 3RD SHIFT Highlight all deviations

# 1 AB D.O. - end ≥1 ppm 4.98 X 2.81

# 2 AB D.O. - end ≥1ppm 4.39 X 2.22

# 1 AB D.O. - middle (probe) ≥ 2 ppm 4.27 5.59 5.37

# 2 AB D.O. - middle (probe) ≥ 2 ppm 3.38 3.93 3.57

Nutrient addition: UREA 125 - 150 gal X X 123

Nutrient addition: H3PO4 20 - 30 gal X X 21

MLSS concentration 2600 - 4000 mg/L 3385 X 3560

RAS concentration 6000 - 8500 mg/L 8380 X 8500

# 1 AB Settleometer ≤ 600 380 X 340

# 2 AB Settleometer ≤ 600 290 X 220

# 1 AB SVI < 250 98 X 87

# 2 AB SVI < 250 99 X 69

# 1 Sec. clarifier bed depth < 5 ft 2' 6" 2' 6'' 2'6"

# 2 Sec. clarifier bed depth < 5 ft 2' 6" 2' 0'' 3'0"

F / M 0.10 - 0.25 0.17 X 0.14

PRI torque ≤ 7 0 2 0

TH torque ≤ 7 2 1 0

Total Possible In-Centerline 15 6 17 38

Actual In-Centerline 15 6 17 38

% In-Centerline 100% 100% 100% 100%

What is process behavior charting?• Process behavior charting is the statistical trending of the system

data collected for the center-lining process to look at longer term variation.

• Sigma XL (excel) is used by Wausau Paper to produce process behavior charts of the data.

• The trends produced by Sigma XL show when statistical rules (i.e., upper and lower boundaries) are violated, indicating special cause versus common cause variation in our WWTP process.

• Process behavior charts are generated from process data and are referred to as the “voice of the process”.

• Trends are utilized to determine when changes should be implemented by being able to distinguish between normal variation (common cause) and special cause variations.

WWTP PBCsFinal Effluent TSS, mg/L

1

6

2

22

2

1

1

1

2

2

2

1

1

1

11

1

11

1

2

2

11

6

6

1

6

8

22

1 1

5

5

1

55

15

1

1

1

62

2

66

2

2

2

2

6

6

22222

2

2222

2

2

2

2

22

22222

22

2

222

2

5

62

2

666 2

22

2

2 2

2

2

2

1

1

5

Mean CL: 19.81

44.20

0

20

40

60

80

08/01

/12

08/15

/12

08/29

/12

09/12

/12

09/26

/12

10/10

/12

10/24

/12

11/07

/12

11/21

/12

12/05

/12

12/19

/12

01/02

/13

01/16

/13

01/30

/13

02/13

/13

02/27

/13

03/13

/13

03/27

/13

04/10

/13

04/24

/13

05/08

/13

05/22

/13

06/05

/13

06/19

/13

07/03

/13

07/17

/13

07/31

/13

08/14

/13

08/28

/13

09/11

/13

09/25

/13

Indi

vidu

als:

FE

TSS

(PPM

)

Food to Mass Ratio

1 1

55555

5

111

1

6666

2

1

1

86

1

5622

2

1

15

666

2

2

1

222

2

222222

2

2

1

5

666

2222

2

222

22

2

2

2

6666

22

2

2

22222222

2222222

66 666

6

6666

6

666

66

666

6

6

15

66

66666

1

2

2

222

2

2

26

6

6

62

Mean CL: 0.19

0.12

0.26

0.06

0.11

0.16

0.20

0.25

0.30

08/01

/12

08/15

/12

08/29

/12

09/12

/12

09/26

/12

10/10

/12

10/24

/12

11/07

/12

11/21

/12

12/05

/12 12

/19/12

01

/02/13

01

/16/13

01

/30/13

02

/13/13

02

/27/13

03

/13/13

03

/27/13

04

/10/13

04

/24/13

05

/08/13

05/22

/13

06/05

/13

06/19

/13

07/03

/13

07/17

/13

07/31

/13

08/14

/13

08/28

/13

09/11

/13

09/25

/13

Indi

vidu

als:

F:M

Improved Process Control & Management

• We better understanding of effluent quality at the WWTP based on understanding of the causes of variation & how conditions affect our process

Final Effluent TSS, mg/L

1

2

1

Mean CL: 24.80

-10.05

59.65

-20.00

-10.00

0.00

10.00

20.00

30.00

40.00

50.00

60.00

70.00

11/01

/13 11

/02/13

11/03

/13 11

/04/13

11/05

/13 11

/06/13

11/07

/13 11

/08/13

11/09

/13 11

/10/13

11/11

/13 11

/12/13

11/13

/13 11

/14/13

11/15

/13 11

/16/13

11/17

/13 11

/18/13

11/19

/13 11

/20/13

11/21

/13 11

/22/13

11/23

/13 11

/24/13

11/25

/13 11

/26/13

11/27

/13 11

/28/13

11/29

/13 11

/30/13

Indi

vidu

als:

FE

TSS

(PPM

)

Final Effluent COD, mg/L

1

Mean CL: 55.70

11.50

99.90

0.00

20.00

40.00

60.00

80.00

100.00

120.00

11/01

/13 11

/02/13

11/03

/13 11

/04/13

11/05

/13 11

/06/13

11/07

/13 11

/08/13

11/09

/13 11

/10/13

11/11

/13 11

/12/13

11/13

/13 11

/14/13

11/15

/13 11

/16/13

11/17

/13 11

/18/13

11/19

/13 11

/20/13

11/21

/13 11

/22/13

11/23

/13 11

/24/13

11/25

/13 11

/26/13

11/27

/13 11

/28/13

11/29

/13 11

/30/13

Indi

vidu

als:

CO

D m

g/L

WWTP PBCs# 1 AB Settleometer Sept - Oct. 2011

15

1

6

5 2

2 2 2

1

22 2

2 2

2

1

11

1

11

1 11

2 2

1

56 6

1

2 22 Mean CL: 623.85

489.95

757.74

350.00

400.00

450.00

500.00

550.00

600.00

650.00

700.00

750.00

800.00

9/3/20

119/5

/2011

9/7/20

119/9

/2011

9/11/2

0119/1

3/2011

9/15/2

0119/1

7/201

19/1

9/201

19/2

1/201

19/2

3/2011

9/25/2

0119/2

7/2011

9/29/2

01110

/1/20

1110

/3/20

1110

/5/20

1110

/7/20

1110

/9/20

1110

/11/201

110

/13/201

110

/15/201

110

/17/201

110

/19/201

110

/21/201

110

/23/201

110

/25/201

110

/27/201

110

/29/201

110

/31/201

1

Indi

vidu

als:

# 1

AB

Settl

eom

eter

# 1 AB Settleometer Nov. 2011

1

6

2

6 6

Mean CL: 428.00

336.53

519.47

320.00340.00360.00380.00400.00420.00440.00460.00480.00500.00520.00540.00560.00

11/1/

2011

11/2/

2011

11/3/

2011

11/4/

2011

11/5/

2011

11/6/

2011

11/7/

2011

11/8/

2011

11/9/

2011

11/10

/2011

11/11

/2011

11/12

/2011

11/13

/2011

11/14

/2011

11/15

/2011

11/16

/2011

11/17

/2011

11/18

/2011

11/19

/2011

11/20

/2011

11/21

/2011

11/22

/2011

11/23

/2011

11/24

/2011

11/25

/2011

11/26

/2011

11/27

/2011

11/28

/2011

11/29

/2011

Indi

vidu

als:

# 1

AB

Set

tleom

eter

Nutrient Additions

UAN Usage, gpd

Mean CL: 134.21

60.28

208.14

-50.00

0.00

50.00

100.00

150.00

200.00

250.00

300.00

350.00

400.00

8/1/20

128/6

/2012

8/11/2

0128/1

6/2012

8/21/2

0128/2

6/2012

8/31/2

0129/5

/2012

9/10/2

0129/1

5/2012

9/20/2

0129/2

5/2012

9/30/2

01210

/5/20

12

10/10

/2012

10/15

/2012

10/20

/2012

10/25

/2012

10/30

/2012

11/4/

2012

11/9/

2012

11/14

/2012

11/19

/2012

11/24

/2012

11/29

/2012

12/4/

2012

12/9/

2012

12/14

/2012

12/19

/2012

12/24

/2012

12/29

/2012

1/3/20

131/8

/2013

1/13/2

0131/1

8/2013

1/23/2

0131/2

8/2013

2/2/20

132/7

/2013

2/12/2

0132/1

7/2013

2/22/2

0132/2

7/2013

3/4/20

133/9

/2013

3/14/2

0133/1

9/2013

3/24/2

0133/2

9/2013

4/3/20

134/8

/2013

4/13/2

0134/1

8/2013

4/23/2

0134/2

8/2013

5/3/20

135/8

/2013

5/13/2

0135/1

8/2013

5/23/2

0135/2

8/2013

6/2/20

136/7

/2013

6/12/2

0136/1

7/2013

6/22/2

0136/2

7/2013

7/2/20

137/7

/2013

7/12/2

0137/1

7/2013

7/22/2

0137/2

7/2013

8/1/20

138/6

/2013

8/11/2

013

Indi

vidu

als:

UA

N U

sage

gal

Nutrient Additions

PO4 Usage, gpd

15 66

555688

2 6666666152222222222

8 66 22222 62222222222222222

1155156222222222222222

8185566

815

6655556 6556662222222222222221

86 22222 66

8 666666666666 66666666666666 222226 66666622222

1

6666666688

8 665562122222221

22222661666666666666

11521222212

2212121

Mean CL: 34.9617.79

52.12

-50.00-45.00-40.00-35.00-30.00-25.00-20.00-15.00-10.00-5.000.005.0010.0015.0020.0025.0030.0035.0040.0045.0050.0055.0060.0065.0070.0075.0080.0085.0090.0095.00100.00105.00110.00115.00120.00125.00130.00135.00140.00145.00150.00155.00160.00165.00170.00175.00180.00185.00190.00195.00200.00205.00210.00215.00220.00225.00230.00235.00240.00245.00250.00255.00260.00265.00270.00275.00280.00285.00290.00295.00300.00

8/1/20

128/6

/2012

8/11/2

0128/1

6/2012

8/21/2

0128/2

6/2012

8/31/2

0129/5

/2012

9/10/2

0129/1

5/2012

9/20/2

0129/2

5/2012

9/30/2

01210

/5/20

12

10/10

/2012

10/15

/2012

10/20

/2012

10/25

/2012

10/30

/2012

11/4/

2012

11/9/

2012

11/14

/2012

11/19

/2012

11/24

/2012

11/29

/2012

12/4/

2012

12/9/

2012

12/14

/2012

12/19

/2012

12/24

/2012

12/29

/2012

1/3/20

131/8

/2013

1/13/2

0131/1

8/2013

1/23/2

0131/2

8/2013

2/2/20

132/7

/2013

2/12/2

0132/1

7/2013

2/22/2

0132/2

7/2013

3/4/20

133/9

/2013

3/14/2

0133/1

9/2013

3/24/2

0133/2

9/2013

4/3/20

134/8

/2013

4/13/2

0134/1

8/2013

4/23/2

0134/2

8/2013

5/3/20

135/8

/2013

5/13/2

0135/1

8/2013

5/23/2

0135/2

8/2013

6/2/20

136/7

/2013

6/12/2

0136/1

7/2013

6/22/2

0136/2

7/2013

7/2/20

137/7

/2013

7/12/2

0137/1

7/2013

7/22/2

0137/2

7/2013

8/1/20

138/6

/2013

8/11/2

013

Indi

vidu

als:

Pho

s. A

cid

usag

e ga

l

Center-lining as a communication tool with other departmental operations

• We learned to communicate with the rest of the of the operation using the same “language”.

• WWTP Operators attend the morning mill meetings as “step-up” employees to discuss center-line data. The Operators see the centerline and in-process data presented by the other departments and the variation in those areas.

• At times, we are able to link their variation to our process data.

Center-lining Communication• Each area of the Mill communicates the stability of their

area in the morning meeting using the “centerline and in-process” terminology

Center-lining Communication

Benefits of Improved Communication

• Communication of data can be used to prevent upsets.

• Communication of data can be used to justify projects.

• Communication of data can be used to understand how process changes in the paper mill and deinking affect the stability and costs of the WWTP operations.

• Operations are working to support each other better, relying on facts (data) rather than emotion.

Projects and Process Changes • Installation of hydrogen peroxide system to prevent low dissolved

oxygen in the final effluent.• Installation of additional flighting to sludge screw press to increase

solids.• Installation of a new polymer system following polymer trials.• Reduction of fresh water usage in deinking. • Finding alternative outlets for residual paper. The bulk of the paper

sludge is now being used in liquid solidification for non-hazardous waste streams.

• Trial to reduce VOAs in primary and thickener clarifiers to improve treatment.

• Reduction of steam usage in paper machine applications during summer months to prevent temperature impact to microorganisms.

Secondary Clarification (June 2011)

Secondary Clarification (January 2014)