Project Challenge: Effluent Compliance for a Northern Ontario Pulp Mill

A major pulp and paper facility in Northern Ontario was facing significant challenges in meeting the stringent provincial discharge limits for Total Suspended Solids (TSS) and Biochemical Oxygen Demand (BOD) in its final effluent. Their existing clarifier and sand filtration system was underperforming, especially during seasonal high-flow periods and process upsets, leading to non-compliance notices and potential fines. The mill required a robust, high-capacity filtration solution that could handle variable feed conditions and provide consistent, high-quality effluent to protect the local watershed.

Our Engineered Solution

NettyMarie proposed a turnkey solution centered on our NM-Series High-Throughput Membrane Filtration System. The design incorporated a multi-stage approach:

• Primary Screening: Installation of heavy-duty duplex basket strainers to protect downstream equipment from large debris and fiber clumps.
• Core Filtration: A skid-mounted array of our proprietary ceramic-coated tubular membranes, selected for their exceptional abrasion resistance and chemical tolerance in the harsh mill environment.
• Automated Control: A fully integrated PLC-based control system for automated back-pulsing, chemical cleaning-in-place (CIP), and real-time monitoring of transmembrane pressure and flow rates.
• Sludge Handling: Integration with the mill's existing sludge dewatering system to manage concentrated solids.

The system was engineered for a peak flow rate of 1,200 m³/day, with redundancy built into the membrane trains to allow for maintenance without process shutdown.

Implementation & Process

The project was executed in a phased 14-week timeline to minimize disruption to mill operations. Our team worked closely with the mill's engineering staff throughout the process.

• Weeks 1-4: Detailed site survey, final design approval, and prefabrication of the main filtration skid at our facility.
• Weeks 5-8: Site preparation, including concrete pad construction and utility tie-ins (power, water, compressed air).
• Weeks 9-12: Delivery and installation of the main filtration unit and ancillary equipment. This was synchronized with a planned mill maintenance outage.
• Weeks 13-14: Commissioning, operator training, and performance validation testing under real operating conditions.

Close collaboration ensured all safety protocols and mill-specific operational procedures were integrated into the system's controls.

Measurable Results & Impact

The installation of the NettyMarie filtration system delivered transformative results for the mill's environmental performance.

• Effluent Quality: Achieved a consistent effluent TSS of less than 10 mg/L and BOD reduction of over 85%, well within provincial compliance limits.
• Operational Reliability: The system has operated continuously for over 18 months with 99.7% uptime, handling process fluctuations seamlessly.
• Cost Savings: Elimination of potential non-compliance fines estimated at $150,000 annually. Reduced chemical consumption for downstream polishing by approximately 20%.
• Water Reuse Potential: The high-quality filtrate has opened opportunities for internal water reuse within the mill's processes, reducing fresh water intake.

The project has solidified the mill's reputation as an environmental leader in the region and provided a scalable model for other facilities.