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Union Carbide Corporation, Ferroalloys Division, Alloy (RM 89.7R)
Union Carbide Corporation operates a ferroalloy plant at Alloy
on the north bank of the Kanawha River [Figure 5]. The plant has
been in operation since 1934 with significant expansions in 1941 and
1951. Plant modernization has continued during the past 10 years.
Employment was about 1,250 persons in 1972 with about 1,450 required
for full production. Production capacity was in the range of 145,000
to 170,000 m. tons (160,000 to 190,000 tons) of alloys per year.
In 1972, the plant had 15 electric arc furnaces for alloy pro-
duction. Electric power was obtained from hydroelectric plants on
the New River and an on-site, coal-fireci power plant. Raw materials
were batch loaded into the furnaces, smelted, and the molten metal
cast in molds for sale to customers.
Raw materials included coal, coke, charcoal, dolemite, lime,
limestone, mi 11 scale, silicate of soda, produced metals, produced
slags, chrome ore (Kefdag Turkish, Yassitepe, Russian and Transval),
manganese ore (El Paso, Amopa, Comilog, Mamativan, Chilean and Turkish),
sand (silica and Zirconium), North Carolina gravel and Winona quartz.
By-products were several "throw away" slags including ferro-
chrome silicon, silicomanganese, ferrochrome and ferromanganese slags.
Finished products included the following: silicon metal, ferrosili-
cons, ferromanganese, silicomanganese, ferromanganese silicon, cal-
cium silicon, SMZ (silicon manganese zirconium), 35-40% zirconium,
strontium silicon, calcium barium silicon, low carbon ferrochrome,
ferrochrome silicon, silicon titanium and hypercal.
3
Water use at the plant was reported as about 378,000 m /day
(100 mgd) in April 1977, of which 257,000 m3/day (68 mgd) was power
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#*:A^
Figure 5 . Location Map - Alloy & Boomer Areas
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57
plant cooling water. Most of the remaining flow was furnace cooling
water. Other water uses were for an air pollution scrubber on one
furnace, tap washing on another furnace, bottom ash sluicing at the
power plant and sanitary purposes.
In 1972, scrubber and tap washing waters were treated in a
series of two small settling ponds. Settled sludge was diposed of in
a landfill. Bottom ash was sluiced to another series of three set-
tling ponds with solids removed to a landfill. Sanitary wastewaters
were treated in a small biological treatment plant. Cooling waters
were not treated. Aerial photographs of the plant recorded in Octo-
ber 1977 showed the two series of settling ponds to still be in use
[Figure 6]. An additional long rectang'ular pond had been constructed
at the north end of the plant [Figure 7]. This was apparently part
of additional treatment facilities to be constructed in 1977.
Emissions from all but one of the furnaces were controlled by
dry bag dust collector systems. The one furnace was controlled by a
scrubber, as previously discussed. In 1972, reuse of the collected
dust was being investigated, indicating a probable high metal con-
tent. Actual disposal was not reported. Fly ash from the power plant
was controlled by electrostatic precipitators with disposal to land-
fill (location undefined).
In addition to the materials discussed above that were disposed
of in landfills, the "throw away" slags were also sent to landfill.
Some of these materials have reportedly been landfilled along Jarret
Branch for years. This is a small stream entering the plant site
from the east and flowing under the southeast corner of the plant
[Figure 5]. The 1977 aerial photographs showed a delta of deposited
solids at the mouth of the creek [Figure 6]. Reportedly, metals are
leached from the landfill or washed with solids into Jarrett Branch
resulting in elevated metals concentrations in the stream discharge
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to the Kanawha River. Ownership of the landfill area was not
defined. •
Solid wastes have also been landfilled along the river edge, •
most noticeably at the northwest corner of the plant site where the
fill extends into the river [Figure 7]. This could allow metal bear- •
ing solids to be washed into the river. Surface runoff from ore ™
stockpiles is another potential source of heavy metals. •
Effluents from six outfalls were sampled in 1972. Outfall 007
was not yet constructed. It apparently serves the new pond. Outfall •
008, Jarret Branch, also was not sampled. The only toxic substance
present in significant amounts was chromium which was discharged at •
21 kg (47 lb)/day. Bioassays detected no toxicity in plant effluents.
As part of their NPDES permit requirements, Union Carbide must ™
periodically monitor for As, Ba, Cd, Cr, Hg, Ni , Pb and Zn. In April «
1977, the plant reported an average chromium discharge of 22 kg (48 |
lb)/day.
Toxic substances present in air emissions include SO^ in the
power plant combustion gases and heavy metals in particulate matter I
passing furnace control equipment. The amount of furnace emissions
is not defined. Power plant S0? emissions were reported as 225 ppm •
in 207,000 ACFM in 1974. •
I
In summary, toxic substances released to the environment from
the Union Carbide facility at Alloy are known to include chromium
discharged in plant wastewaters (22 kg/day), SOp emissions from power •
plant boilers and heavy metals leached or washed from the Jarret Branch
landfill. Additional heavy metals may be released from landfills on •
other portions of the plant site. Chromium is an NRDC priority pollutant.
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59
JARRETT
BRANCH
Figure 6.
Union Carbide Ferroa//oys Plant - South Half
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60
mm.
Figure 7.
Union Carbid* Ferroalloys Plant-North Half
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61
Appalachian Power Companyt Kanawha River Plant, Glasgow, RM 78.3R
This is a 430 MW coal-fired thermal electric power plant. The
plant operates continuously. It began operation in 1953.
Condenser cooling is provided by once-through use of Kanawha
River water. Water use was 1,590,000 m /day (420 mgd) in 1972 of
o
which only 5,300 m /day (1.4 mgd) was treated for boiler feed, bear-
ing cooling and sanitary uses.
Bottom ash was sluiced to storage ponds north of the plant
3
[Figure 8]. Overflow averaging 265 m /day (0.07 mgd) was discharged
to the river. The bulk of the bottom ash was hauled away for fill.
Fly ash was collected dry and hauled to a storage area east of the
plant.
Drainage from the coal storage area was pumped to the river. It
averaged only 6 gpm.
Analysis of the ash pond effluent in 1972 showed low levels of
copper, chromium, lead, nickel and zinc to be present. Higher levels
of these metals were present in the coal storage drainage but dis-
charge loads were small. Less than 2 kg (5 lb)/day of heavy metals
were discharged by the power plant.
Combustion of coal in the plant boilers releases large volumes
of SOp to the atmosphere. The amount was not determined in this
study.
In summary, except for SO,, emissions, the Kanawha River power
plant is not a significant source of toxic substances.
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Figure 8 ., Location Map - Glasgow Area
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63
Appalachian Power Company, Cabin Creek Plant, Cabin Creek, RM 74.31
This coal-fired power plant was originally built in 1913. It
was modified to its present type of operation with six generating
units in 1942. Operations were reduced to a peaking basis in 1962.
In 1972, only two units with a capacity of 180 MW were operated. The
other units were shut down because they were not equipped with air
pollution control equipment.
Water use at the plant was 738,000 m3/day (195 mgd) in 1972.
The plant had 18 outfalls of which 4 were deactivated when the four
3
units were shut down. Bottom ash was sluiced in about 1,500 m /day
(0.39 mgd) of water to a small pit. Th'e overflow was discharged to
Cabin Creek near its mouth. Bottom ash was hauled to a coal refuse
dump in 1972 but reportedly was to be pumped to the fly ash ponds
shortly thereafter. Fly ash was sluiced to ponds located west across
Cabin Creek [Figure 9]. One of the two ponds was being filled while
fly ash from the other was hauled by truck to a fill site downstream.
The pond o'
the river.
The pond overflow of about 230 m /day (0.06 mgd) was discharged to
Sampling of the two ash system discharges in 1972 showed the
same results as for the Kanawha River Plant, low levels of heavy
metals present. The Cabin Creek Plant does not appear to be a sig-
nificant source of toxic substances except for S0? emissions from the
boilers. The plant reportedly burns 0.75% sulfur coal.
Diamond Shamrock Chemical Company, Belle, RM 69.3R
Diamond Shamrock Chemical Company operates an organic chemical
plant at Belle adjacent to the duPont chemical plant [Figure 10].
The plant was initially operated by Belle Alkali as a chlorine caus-
tic plant in 1920. Facilities for chlorination of methane to methyl
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T'i R.
upont-City
AEROBIC POND
Du PONT
DIAMOND SHAMROCK
KER MACHINERY
Figure 10. Location Map - Belle Area
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chloride and methylene were added in 1932. After World War II,
production of chlorine and caustic was stopped. The plant was con- •
verted to a methanol starting point in 1969.
Raw materials in 1972 were chlorine, brought in by barge, and
methanol piped directly from the duPont plant. Products manufactured •
include methylene chloride, chloroform, carbon tetrachloride, muriatic ™
acid and an intermediate product of methyl chloride. Production was _
estimated to beMn'the range of 180 to 230 m. tons (200 to 250 tons)/day |
in 1976. Carbon tetrachloride production was about 1.4 to 2.3 m. ton
(1.5 to 2.5 tons)/day. |
About 30,000 m /day (7.9 mgd) was "withdrawn from the Kanawha Ij
River in 1972 and used for once-through, non-contact cooling. Only
3
about 8 m /day (0.002 mgd) was used in the process in the liquid phase
of a caustic scrubber used to neutralize the methyl chloride gas stream
containing small amounts of hydrogen chloride. This waste stream was _
not treated in 1972. The 1977 aerial photographs [Figures 11 and 12] |
showed a small pond at the northeast corner of the plant; its function
was unknown. I
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Analysis of the Diamond Shamrock effluents in 1972 detected no •
heavy metals other than a low level of zinc. No organic analyses
were run. In late 1976, testing for carbon tetrachloride detected a
discharge of 3.6 kg (8 lb)/day. No chloroform data were reported.
Analyses of samples obtained from the two effluents in February 1977 _
during an investigation of carbon tetrachloride discharges to the |
Kanawha River detected low levels of carbon tetrachloride, chloro-
form, trichloroethylene, 1,1,2-trichloroethane, tetrachloroethylene, •
1,2-dichloroethane, 1,1,2,2-tetrachloroethane, and dichlorobenzene
isomers. All of these compounds are priority pollutants as are the •
final products, methylene chloride and methyl chloride.
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Figure jj.
DuPonf and Diamond Shamrock - North Side
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DUPONT WWTP
-&l-< AM ROCK
Figure 12,
DuPonf and Diamond Shamrock - South Side
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Organic residues from the process are primarily recovered and
used in the process. Residues not used are sent to a disposal con-
tractor. All residues containing carbon tetrachloride collected be-
tween 1968 and January 1975 (33 tons), were sent to a contractor in
early 1975. Ultimate disposal locations were not defined.
Available data indicate that the plant has discharged at least
eight priority pollutants with known toxicity. Three raw materials
and final products are also toxic. However, the data show only low
levels of releases of these toxic substances to the environment. The
potential for major releases in the event of an accident or spill
does exist.
E. I. duPont de Nemours and Company, Inc., Belle, RM 68.5R
The duPont plant is a large chemical production facility situated
on about 42 hectares (104 acres) along about 1.6 km (1 mi) of the
Kanawha River [Figure 10]. The plant began operation in 1926 with
the only product being ammonia. Various products have been added
through plant expansions and more than 30 organic and inorganic chem-
icals are now produced. Peak employment reached about 5,000 about
1945. Current employment is 1,600. Plant operations are continuous
and relatively uniform.
In July 1976, substances identified by duPont as handled, used
as raw materials or produced as final product, intermediate or by-
product at the Belle plant and present on an EPA proposed hazardous
substance list included the following:
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A list of products submitted to EPA in late 1977 is presented in
Table 3.
incineration.
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Acetic Acid Hydrochloric Acid
Acetic Anhydride Hydrogen Cyanide •
Acetone Cyanhydrin . Methyl Mercaptan |
Aluminum Sulfate Methyl Methacrylate
Ammonia Monomethylamine ^
Ammonium Chloride Phosphoric Acid •
Ammonium Hydroxide Potassium Hydroxide *
Aniline Propyl Alcohol
Antimony Potassium Tartrate Sodium Hydroxide I
Antimony Trioxide ' Sodium Hypochlorite I
Calcium Hypochlorite Sodium Methyl ate
Chlorine Sodium Nitrite •
Cupric Formate Styrene |
Cyclohexane Sulfuric Acid
Dimethyl amine Triethyl amine
Formaldehyde ' Trimethyl amine •
VansrHnm Ppnt.nvirlp •
Vanadium Pentoxide
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Water use in early 1977 was averaging about 435,000 m /day •
3
(115 mgd), a substantial reduction from 662,000 m /day (175 mgd) in
1972. The reduction is due to process changes. Treated wastewater •
is discharged to the Kanawha River through four outfalls. There are
an additional 51 "non-contact water" outfalls. •
mid-1972 included a biological (activated sludge) wastewater treat- *
Waste disposal facilities and practices in use at Belle in
>at-
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ment plant, an anaerobic pond, incineration, burning of liquid organic
wastes in the powerhouse, barging of fly ash to a local landfill,
barging of brines to the Gulf of Mexico and on-site deep well disposal of
brine and organic wastes. In late 1977, barging of fly ash and brines |
had been discontinued. In addition to incineration and wastewater
treatment, some deep well disposal was continuing. Various waste •
materials were disposed of by contractors. These were transported
out of state by truck, rail and barge for disposal by landfill or •
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Table 3
PRODUCTS LIST
E. I. DU PONT DE NEMOURS AND CO.
Belle, West Virginia
Agricutlure Chemical Intermediate F-3259, F-3455
Ammonia
Benlate
Benomyl
Bis-para-aminocyclohexyl-methane
Carbon Monoxide
Dimethylacetamide
Dimethylether
Di methylformami de
Dimethylsulfate
Ethylene glycol
Formaldehyde
Formamide
Hydrogen
Hydroxyacetic Acid
Methacrylate:
Methyl Methacrylate
n-Butyl Methacrylate
2-Ethyl Hexyl Methacrylate
Methacrylic Acid
Ethyl Methacrylate
Methyl amines
Monomethylamines
Dimethyl amines
Trimethyl amines
Methylenedianaline
Methyl Formate
Small Lots Manufacturing Products
Sodium Styrene Sulfonate
Vazo
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Most process wastewater streams are discharged to the biological
plant for treatment. Treated flows are in the range of 7,600 to g
2
11,400 m /day (2 to 3 mgd). Treatment units include neutralization,
three isolation tanks for storage of spills, a large equalization •
tank, a cooling tower, phosphorous feed, five aeration units and five
final clarifiers [Figure 12]. Waste activated sludge is pumped to •
the anaerobic pond. A 65% increase in treatment capacity was com-
pleted in 1977.
•
The 3 hectare (7 acre) anaerobic pond is in a side valley of
Simmons Creek, about 1 km (0.6 mi) north of the main plant site [Fig- |
ures 13 and 14]. Originally built for fly ash disposal, the pond was
converted to treatment of organic waste's. It now is used for dis- I
posal of waste activated sludge. In 1972, some process wastes were
also pumped to the pond. •
The pond was formed by construction of a dam from cinders and
from clay and rock fill. A cinder keyway through the dam allows the
pond contents to continuously seep through the dam where they are
collected in a sump and piped to the biological treatment plant. I
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Areas adjacent to the pond appeared, in aerial photographs taken •
in October 1977, to be used for disposal of various solid and liquid
wastes. An apparently active disposal area was located north (up- •
hill) of the pond [Figure 14]. Black 55-gal drums were neatly stacked ™
beside three upright cylindrical tanks at the north edge of the disposal M
area. A pile of randomly dumped drums were at the south edge of the I
area. Unknown solid wastes were dumped in the area. Near the north
end of the pond, rusting containers had been dumped down the hillside. |
A diversion ditch has been constructed around the pond to pre- •
vent surface runoff from adjacent hillsides from reaching the pond.
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73
Figure 13.
DuPonf Anaerobic Pond
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Figure M.
DuPon/ Disposal Area
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Near the west end of the dam forming the anaerobic pond, a small
pond was diked off on the hillside [Figure 13]. It contained a red-
dish brown liquid in contrast to the black anaerobic pond contents.
Unknown solid wastes had been dumped into the pond on the west side.
A 1973 duPont drawing labeled the pond as a "waste retention" pond.
An active landfill operation was present south of the dam. A
white material had been placed against the toe of the dam. Gray ma-
terial with the^appearance of bottom ash and/or fly ash was being
deposited downstream from the dam. It is not documented in file ma-
terials if this is the present fly ash disposal area.
There were no data in the file to "define what wastes are land-
filled in this area, what control measures are employed or if there
are any linings or other protective barriers to prevent contamination
of groundwater. There did not appear to be a lining under the anaero-
bic pond.
Solid wastes from the plant are disposed of by various contrac-
tors.
Two deep wells, 460 and 1,610 m (1,500 and 5,300 ft) deep, respec-
tively, were previously used for waste disposal. Injected wastes
were primarily brines but included soluble organic materials such as
aniline, aromatic ami no compounds, and chlorinated and brominated
derivatives of benzene. A 1972 State permit limited the total volume
to be injected to 518,000 m3 (137 million gal)/year. In late 1977,
the deepest well (No. 2) was still in use. Materials and volumes
discharged to the well were not documented. It is thus not known if
the same substances are still injected. It is probable that process
changes and diversion of wastes to biological treatment have occurred.
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A source of nitrosamine emissions was discovered at the Belle
plant by EPA in early 1976. These emissions are now flared. Nitros-
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Materials barged to the Gulf were wastes from spent glycol re-
covery and from production of Benlate benomyl fungicide and sodium I
styrene sulfonate (SSS). The wastes contained sodium terephthalate,
ethylene glycol, SSS, chlorides, sulfates, other organics, antimony I
and low levels of cadmium and mercury. Current disposal of these
wastes was not documented. • •
Antimony, copper and phenol are the only priority pollutants «
monitored in the wastewater discharges. Discharge monitoring reports |
showed copper loads averaged 43 kg (95 lb)/day in 1975 and 34 kg (74
lb)/day in 1976 with a maximum discharge of 113 kg (250 lb)/day. I
Both antimony and phenol discharges were nil. In 1973, about 14,500
kg (32,000 lb)/month of antimony were barged to ocean disposal. I
amines were also present in the anaerobic pond. • _
In late 1977, duPont reported that 49 hydrocarbon compounds were
emitted to the atmosphere from the Belle plant. Ten of these com- I
pounds (analine, butyl isocyanate, carbon monoxide, dimethyl sulfate,
ethyl chloroformate, HCN, methyl chloroformate, methylene chloride, I
methylene dianiline and mono methyl amine) are considered by duPont to
have serious toxicity. •
Data showed that NO,, emissions from the three boilers were more _
than 380 kg (850 lb)/hr. Carbon monoxide emissions from several sources |
totaled more than 620 kg (1,370 lb)/hr. Methylene chloride emissions
were about 14 kg (30 lb)/hr. J
A total of 35 spills of chemicals, acids and oils were reported I
to the EPA between August 1975 and August 1977. Copper liquor was
one toxic chemical spilled. •
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In summary, the duPont Belle plant handles large quantities of
chemicals, some of which are known toxic substances. Known dis-
charges of toxic substances to the Kanawha River are small except for
copper. The potential for larger releases is present, however, and
monitoring data on toxic substances are very limited. Large emis-
sions of carbon monoxide and nitrogen oxides are reported. Emissions
of other toxic substances to the atmosphere are reportedly small.
MINOR INDUSTRIAL SOURCES
There are six known minor industrial sources of wastewater dis-
charges with NPDES permits in the Upper Kanawha Valley. In addition,
aerial photographs recorded in October 1977 showed several potential
sources of water pollution. None of these sources appear to be sig-
nificant sources of toxic substances.
Exxon Corporation, Boomer Terminal, RM 88.9R
This is a small terminal engaged in the wholesale distribution
of petroleum and petroleum products [Figure 5]. Originally con-
structed about 55 years ago, the terminal was remodeled in 1966.
3
Sales volume is about 114,000 m (30 million gal)/year.
Surface runoff and water drained from the storage tanks are treat-
ed in an oil separator with a capacity of 11,000 liters (3,000 gal).
Any recovered petroleum is used off-site. Sludge is removed from the
oil separator annually by a tank cleaning contractor for off-site
disposal.
There appears to be no significant potential for release of toxic
substances to the environment from this facility.
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West Virginia Water Company, Montgomery Plant, RM 85.6
This small water treatment plant has been in operation since
1927. Water withdrawn from the Kanawha River is mixed with alum and
chlorine, clarified and passed through pressure sand filters. In
1972, an average of about 2,200 m3 (578,000 gal)/day was treated.
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Sanitary wastes, filter backwash and clarifier sludge were _
scheduled to be connected to the Montgomery sewerage system in 1972. |
Thus, there may no longer be a direct surface discharge at this
facility. I
Except for the minor potential of chlorine releases, this •
facility is not a source of toxic substances.
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Chesapeake and Ohio Railway Co., Handley, RM 83.6L
This terminal facility includes a yard office, a locomotive car
building, a car department building, a fueling station, and a turn- •
table and roundhouse [Figure 15]. It has been in existence about 100 •
years. •
Most buildings are served by septic tanks; the YMCA is served by
a small package aerobic digestion plant. An oil separator is used to •
3
treat drainage from the fueling station. Flow averages about 15 m
(4,000 gal)/day. Oil is salvaged and shipped off-site. Sludge is I
periodically removed by a septic tank contractor.
This facility is not a significant source of toxic substances. *
Analysis of an effluent sample for heavy metals in 1972 detected none
present.
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TTil* \ £" \\ U VV ^S^^V* b^-'Sm S.
Figure 15. Location Map - Handley & Hugheston Areas
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Texaco, Inc., Hugheston (Montgomery) Terminal, RM 81.6R
This small terminal receives, stores and distributes petroleum
products !Figure 151. There was no industrial use of water in 1972. I
Storm runoff and water drained from the tanks were discharged un-
treated. An oil separator was to be installed in 1972. This termin- •
al is not a source of toxic substances. *
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Valley Camp Coal Co., Shrewsbury, RM 74.5R
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This facility consists of a mine and a coal preparation plant
3
[Figure 9]. Mine infiltration water averaging 190 m (50,000 gal)/day
is discharged untreated to the Kanawha River.
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At the preparation plant, coal is crushed, washed, screened, |
graded to size, and stockpiled for shipment. Wastewaters are col-
lected in a sludge tank and then passed through sieves and centri- I
fugal driers. Collected solids are returned to a coal storage pile.
Effluents from the driers are sent to thickeners, given chemical and I
coagulation treatment and vacuum filtered to recover coal and mineral
solids. All water is then recycled, except for irregular discharges •
to lagoons used for drying beds. Overflows from the lagoons averag- "
•3
ing 4 m /day (1,000 gpd) are discharged to the Kanawha River. _
Sampling of the two effluents from the mine and preparation plant
in 1972 detected low levels of several heavy metals and a zinc load •
of about 14 kg (30 lb)/day. Except for zinc, this facility does not
appear to discharge toxic substances. I
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Cecil I. Walker Machinery Co., Belle, RM 70.4R
This facility is located in Belle just upstream of the Diamond
Shamrock-duPont complex [Figure 10]. The Company is engaged in the
sale, maintenance, overhaul and repair of earth-moving equipment.
The plant was constructed in 1959. In 1972, the plant operated.
two shifts/day, five days/week, and employed about 280 persons.
Water supply is obtained from the Belle water system. In 1972,
3
about 9 m /day (7,500 gpd) were used in the wash room to wash equip-
ment, and in the dynometer room to cool motors. Sanitary wastewaters
were discharged to the municipal system. Wash and cooling water were
discharged to three long, narrow lagoons operated in series. Most of
the sediment in the wash water was earth, which was settled out in
the first lagoon. Sediments were periodically removed by a back hoe
and used for landfill on Company property.
Aerial photographs recorded in October 1977 showed the three
ponds were still in use [Figure 16]. The first pond in series appear-
ed to contain either very turbid water or to be nearly filled with
sediment. More than one-third of the surface area was covered with
oil. The other two pond surfaces were bright yellow, the same color
as the paint on the refinished equipment. Apparently, some type of
paint waste was being discharged to the lagoons. Piles of solid waste,
probably sediments dredged from the first pond, were adjacent to the
pond system.
Grab samples of the final pond effluent taken in 1971 and 1972
showed the effluent to have high COD and solids. Low levels of chrome,
copper, lead, and zinc were detected.
It would appear that paint wastes not present in 1972 are now
being discharged from this facility. This could increase the dis-
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Other Minor Industrial Sources
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charge of heavy metals. No data were available on organic chemicals
or on air emissions, disposal of contaminated sediments on-site I
could result in surface runoff of heavy metals. However, this plant
does not appear to be a significant source of toxic substances. I
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Aerial photographs of the Upper Kanawha Valley taken in October I
1977 detected several additional possible sources of water pollution
[Figures 9 and 17]. West of Chelyan on the south bank of the river I
was a small facility with three storage tanks identified on the navi-
gation charts as the Pure Oil Company. „ Several trucks that appeared •
to have hauled asphalt or heavy crude oil were parked at the site. I
No NPDES permit exists for this facility.
A stockpile of what appeared to be a chemical substance was adja-
cent to the west side of the Pure Oil facility. The stockpile con- I
tained alternating bands of white and light blue substances. A drag-
line was actively unloading a white substance from a barge. Material I
was being dumped into a hopper that fed a conveyor that moved the
material to the stockpile. Spillage around the hopper was reaching •
the river. Surface runoff from the pile could easily move material •
into the river. The nature or ownership of the stockpile was unknown.
A dredging operation was active in the river near the stockpile
[Figure 17]. A clamshell or dragline was dredging material from the •
river bottom for processing in a floating-washing facility. Coal re-
covered from the sediments was then conveyed to an adjacent barge. •
The washing operation produced a long, black plume in the river.
Across the river at Diamond, a waste pond was observed next to a •
large building [Figure 9]. The nature of the operation and disposal _
of effluent, if any, could not be determined. |
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it-
16.
Cecil Walker Machinery Company -Belle
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Figure 17.
Materials Stockpile West of Che/yon
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MUNICIPAL SOURCES OF TOXIC SUBSTANCES
There are 12 communities in the Upper Kanawha Valley that have
NPDES permits to discharge municipal wastewaters to the Kanawha River.
Wastewater volumes and levels of treatment for these discharges are
listed in Table 4.
Known industrial facilities in Upper Valley communities were
previously listed in Table 2 in Section VI. Except for major indus-
tries with known direct discharges to the Kanawha River, there are no
significant industrial sources of toxic substances in these communi-
ties. Therefore, toxic substances present in the municipal discharges
would be primarily from normal domestic-wastes.
Because the population of the Upper Valley is relatively small,
no significant discharges of toxic substances from municipal sources
should be present. Disposal of sludge from the various treatment
facilities could be a minor potential source of toxic substances in-
cluding heavy metals.
SOLID AND HAZARDOUS WASTE DISPOSAL
Large volumes of solid and hazardous wastes are generated by
major industrial facilities in the Upper Kanawha Valley. Disposal
practices at the Union Carbide plant at Alloy, the Diamond Shamrock
and duPont plants at Belle, and the two Appalachian Power Company
power plants were previously discussed. Some solid wastes potentially
containing minor amounts of toxic subtances are generated by minor
industries and by municipalities. These are not considered to be
significant sources of toxic substances. Municipal solid waste dis-
posal practices were not defined.
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Table 4
MUNICIPAL SOURCES OF WASTEWATER DISCHARGES
UPPER KANAWHA VALLEY
Community
Belle
Cedar Grove
Chelyan Public
Service Dist.
Chesapeake
Glasgow
Handley
Kanawha Falls PSD
(Boomer Village,
Charlton Heights
Population
Served
2,000
5,000
3,000
5,000
1,000
200
7,000
Village,
Flow
3
m /day
760
1,890
1,140
1,890
490
76
2,650
,
mgd
0.2
0.5
0.3
0.5
0.13
0.02
0.7
Level of
Treatment
Secondary
None
None
Primary
Primary
None
None .
Falls View Village,
Glen Ferris Vill
Montgomery
Pratt
TOTALS
age)
5,000
1 ,000
29,200
1,890
450
11,236
0.5
0.12
2.97
Primary
None
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DuPont and Diamond Shamrock dispose of wastes off-site by con-
tractor. Movement of these wastes by truck, train and barge presents
the potential for spills and for inadequate disposal practices at
other locations.
NON-POINT SOURCES
There is much,coal mining activity in the Upper Kanawha Valley
vicinity, both surface and underground. Runoff from surface mines
and drainage pumped from underground mines can contain acids and heavy
metals. Data were not available to define the potential contribution
of toxic substances from these sources.,.
Populated areas are concentrated along valley floors adjacent to
water courses. Surface runoff and indiscriminant dumping in these
areas would contribute small amounts of toxic substances.
Mobil sources including automobiles, trucks, trains and boats
emit toxic substances including carbon monoxide, nitrogen oxides and
variuos hydrocarbons. Because of the small population, the amount of
these toxics emitted would be relatively low, but would be in close
proximity to populated areas.
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VIII. SOURCES OF TOXIC SUBSTANCES — CENTRAL KANAWHA VALLEY
For purposes of this report, the Central Kanawha Valley is defined
as the developed valley of the Kanawha River between Marmet Dam at
Marmet (River Mile 67.7) and St. Albans (River Mile 46) [Figure 18].
This 35 km (22 mi) reach of the valley is wider and less winding than
the Upper Kanawha Valley but is still relatively narrow with a maximum
valley floor width of about 1.6 km (1 mi). Flanking mountains decrease
in height above the valley floor moving downstream. Average mountain
heights are less than 200 m in the Charleston vicinity.
A large majority of the Kanawha Valley population is concen-
trated in this central area. The cities of Charleston, South Charles-
ton, Dunbar, Institute and St. Albans have a combined population of
about 115,000. Urban and industrial developments are concentrated
along the valley floor with residential areas divided between the
valley and adjacent hillside and tributary valley suburbs.
Major industrial facilities are located along the Kanawha River
at South Charleston and Institute. Several small industrial plants
are scattered up and down the valley.
The municipal water supply for most of the area is provided by
the West Virginia Water Company. Raw water is obtained from the Elk
River. Most industrial water is obtained from the Kanawha River.
This valley reach encompasses the upper half of the Winfield Dam navi-
gation pool.
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91
MAJOR INDUSTRIAL SOURCES
There are three major industrial plants and a major municipal
wastewater treatment facility primarily treating industrial waste-
waters in the central valley. Union Carbide's South Charleston Plant
is one of the largest petrochemical plants in the world. The adja-
cent South Charleston Sewage Treatment Company facility treats Union
Carbide's process wastewaters along with South Charleston municipal
wastewaters and can be considered an industrial source of toxic sub-
stances. FMC Corp. operates a large inorganic chemicals plant at
South Charleston just downstream from Union Carbide. A few kilome-
ters downstream, Union Carbide operates a major organic chemicals
plant at Institute.
The following sections discuss the raw materials, products, water
uses, wastewater treatment, wastewater discharge characteristics, air
emissions and hazardous waste disposal practices at each of the four
facilities as they effect releases of toxic substances to the environment.
Union Carbide Corp., Chemicals and Plastics Div.,
South Charleston, RM 54.6-56.2
Union Carbide's Chemicals and Plastics Division operates two
facilities in South Charleston, the South Charleston Plant and the
Technical Center. The South Charleston Plant is one of the largest
petrochemical plants in the world. It produces more than 500 different
chemicals, plastics and fibers from derivatives of natural gas and
petroleum. Most products are intermediates that are either used in
other processes or are sold to customers for use in finished products.
The plant occupies an area of about 93 hectares (230 acres).
Production facilities are on 2 km (1.25 mi) long Blaine Island and
about a 1.6 km (1 mi) reach of the south bank of the Kanawha River
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The Center occupies an area of about 255 hectares (630 acres).
This includes the large Ward Hollow and Holz waste disposal ponds.
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[Figure 19]. Two storage facilities occupy about 0.8 km (0.5 mi) of «
the north river bank. |
Production at the plant is continuous. An average of about I
3,630,000 kg (8,000,000 Ib) of intermediates and products were re-
portedly used in the processes or produced for sale to customers each •
day in 1971. Current employment is about 1,700. Production at this
location began in 1929. •
' • I
To the southwest is the large Technical Center [Figure 19]. _
This research, development and engineering center employed about . |
2,800 in 1971. No products as such are manufactured at the Center.
However, various pilot plants are operated as part of the research •
and development activities. Most union Carbide products were devel-
oped at this Center. • 9
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The Center has a low potential for release of toxic substances |
to the environment relative to the major production facility. The
following discussion will concentrate on releases from the South Charles- I
ton Plant.
The list of raw materials, intermediates and final products used
or produced at the South Charleston plant is voluminous. A partial
listing including products of both the South Charleston and Institute
plants is given in Table 5. .
More than 450 raw materials are received at South Charleston
including the following priority pollutants: acrylonitrile, benzene, I
ethylene dichloride, isophorone, nickel, vinyl chloride and zinc chloride.
In late 1976, Union Carbide estimated that about 65 of 300 compounds I
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1
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3£w/- Jkr ^;1 rfi--\^x ;\*-- s<^s^^'^f\) • •./^i?
S/Sr,!8ksS*«SSS XfOi*5& ',1:,'
•• .
' J
•lj- -t,T^«V^"°S
5?^*; to
m ^.A^X^
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TABLE 5
Products List - Union Carbide Corp
Institute and South Charleston Plants
Acetaldehyde
Acetone
Acids, Patty and Higher Synthetic
Fatty Acids - Chemically Specified Group
Hexanoic
Synthetic Group
2-Methylpentanoic acid
2-Ethylbutanoic
2-Ethylhexanoic
Alcohols, Fatly and Higher Synthetic
4-Methyl-2-pentano!
5-Elhyl-2-nonanol
Aldol
Alkylate, linear
Alkylpyridme
2-(2-Butoxyethoxy) ethyl acelate
n-Butyl acetate
Butyraldol
n-Butyric acid
Carbon monoxide
1-Chlorobutane
Chlorodifluorome thane
2-Chloroethanol
Crotonaldehyde
3-Cyclohexene-1-carboxaldehyde
Dichlorodifluoromethane
Diethyl maleate
2.6-Dimethylmorpholine
N.N-Dimethyl-1,3-propanediamine
2.4-Dinitrotoluene
2.4- (and 2.6)-Dmitrotoluene
1,4-Dioxane
3,4-Epoxycyclohexylmethyl-3.4-epoxycyclohexane carboxyla'e
2-Ethoxyethanol
2-(2-[2-Ethoxyethoxyl ethoxy) ethanol
Ethyl acetate
2-Ethylbutyraldehyde
Ethylene glycol diacetate
Ethyl ether
2-Ethyl-1,3-hexanediol
2-Ethylhexyl tallate
5-Ethyhdenenorbornene
Etnyi silicate
Ethyl vinyl ether
flavor and Fragrance Chemicals
Oiethyl succmate
Isobutyl acetate
F.jO'OCarbons
G'jtaraldehyde
G jtsnc anhydride
Hydrochloric acid
r-yO'ogen
Mfd'Oxyethyl cellulose
\ 2 Hydroxyethyldiethylenetriamme
M2-Hydroxyethyl) ethyleneimine
^yo'oxyethylpiperazine
4 riydroxy-4-methyl-2-pentanono
l.r-lminodi-2-propanol
isobutoxyethanol
liobutyl vinyl ether
iiocyanates. Organic
Methyl isocyanate
Toluene dusocyanate
Isopenianoic acid
isophorone
isopropyl acetate
Kovalerone
Vedicmals
Piperazme, base
Piperazme derivatives
Mesityl oxide
2-Methoxyethyl acetate
Meihoxypolyethylene glycol
l-Methoxy-2-propanol
3-(3-Methoxypropoxy)-1-propanol
Methyl acetate
Methyl chloride
2-Methyl-5-ethylpyridine
Methyl isobutyl ketone
2-Methyl-2,4-pentanediol
2-Methyt-2,4-pentanediol diacetate
N-Methylpiperazme
2-Methylvaleraldehyde
Methyl vinyl ether
1-Naphthol
t .1'. 1 "-Nitnlotri-2-propanol
Oxo chemicals
Paraldehyde
2.4-Pentanedione
2-Pentanone
Pesticides
Aldicarb
2-Ethyl-1.3-hexanediol
Sevin®
Phosgene
2-Picoline
4-Picplino
Plasticizers
Tetraethyleno glycol di (2-ethylhexanoate)
Tnethylene glycol di-(2-ethylbutyrate)
Tn (2-ethylhexyl) phosphate
Plastics and Resins
Acrylic resins
Ethylene-vinyl acetate copolymer resins
Polyurethane surface coating resins
Polyvmyl acetate resins
Polyvinyl butyral resins
Polyvinyl phloride-acetate copolymer resins
Polyether polyols for urethane applications
Polyethor polyols for non-urethane applications
Polyethylene glycol
Polyethylene oxide
"olypropoxy ethers
Polypropylene glycol
P'Opionic anhydride
n-Propy| acetate
"-Propyl alcohol
Pfopylene glycol
Surface-Active Agents
Alcohols, mixed linear, ethoxylated and sulfated.
sodium salt
Nonylphenol. ethoxylated
n-Octylamme
Phenol, ethoxylated
Poly (mixed ethylene/propylene) glycol
Tetraethylene glycol
1,2,3,4-Tetrahydronaphthalene
Tetralol
Tetralone
N.N.N',N'-Tetramethyl-1.3-butanediamine
Toluene-2.4-diamme
Triacetm
Tnethylene glycol diacetate
2.6,8-Tnmethyl-4-nonanone
Tripropylene glycol
Valeric acid
4-Vmyl-1-cyclohexene
5-Vinyl norbornene
General and Compounded Products
Phenyl alkanes
UCAR Fiimer 351
UCON Hydrolubes (H8 series. LB series, and WC series)
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listed in an EPA proposed Hazardous Substance List were handled at
South Charleston. At the same time, a preliminary review of the 65
priority pollutants by Union Carbide indicated that only four (acryl-
onitrile, haloethers, isophorone and vinyl chloride) were known or
believed to be present in wastewater discharges.
3
In 1976, water use at the plant averaged 540,000 m /day (143
mgd), down from 840,000 m3/day (222 mgd) in 1972. Only 15,000 m3/day
(4 mgd) of the 1976 flow was used for contact process purposes. At
one time the plant had 91 active wastewater outfalls. This was reduced
to 20 in 1977. Only cooling waters are discharged directly to the
Kanawha River. Various pollutants are present in the cooling waters
because of leaks, spills, etc. Process" wastewaters are collected in
a redwood flume for transport to the South Charleston Sewage Treat-
ment Company for treatment and disposal (see discussion in the follow-
ing section).
Phenol and vinyl chloride are the only priority pollutants required
to be monitored in the cooling water discharges by the NPDES permit.
In 1976, an average of 10 kg (22 lb)/day of phenol was reportedly
discharged. No vinyl chloride discharge was reported. Bioassays are
required periodically on several outfalls. A TLm of 4.7% was reported
for one outfall (025) indicating the effluent was strongly toxic.
Union Carbide periodically monitored its cooling water outfalls
for organic chemicals during the last half of 1976. Gas chromato-
graph analysis detected 29 specific organic chemicals. The frequency
of detection ranged from 1 to 23 times during the 180-day period.
Observed concentrations ranged from 1 to 385 ppm. Acetone was the
most frequently detected and the highest concentration. None of the
chemicals detected were priority pollutants.
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Union Carbide also monitors the process wastewaters discharged «
to the South Charleston Sewage Treatment Company. Gas chromatograph X
analyses detected 44 specific organic chemicals in average concentra-
tions ranging from 2 to 954 ppm. Acrylonitrile, a priority pollutant, I
was discharged at an average concentration of 192 ppm.
Various outfalls were sampled for phenols and heavy metals during
the 1972 EPA survey. Concentrations were either below detection limits •
or at low levels. In 1975, several samples were collected from South •
Charleston Plant outfalls for organic analyses. No organics were _
detected in measurable quantities. . |
Numerous organic compounds are emitted to the atmosphere from 19 •
source areas with numerous emission points. More than 50 of these
compounds have known toxicities ranging from slightly toxic to carcino- • I
genie. Compounds of special concern include acrylonitrile (3 kg/hr),
benzene, dioxane, isophorone, and vinyl chloride. The most hazardous •
emission is vinyl chloride monomer. This substance is covered by •
NESHAPS regulations. The vinyl chloride operations at this location ^
have a waiver of compliance until 1978. Prior to 1977, vinyl chlor- |
ide emissions were about 14 kg (30 lb)/hr. These were reduced to
about 1.4 kg (3 lb)/hr in 1977 by a process change. Also, vinyl chlor- •
ide vents are now incinerated at the steam plants. Three reported
accidental releases of vinyl chloride totalling 2,700 kg (5,900 Ib) fl|
occurred during March-August 1977. The largest, a release of 1,700
kg (3,800 Ib), occurred on March 20. •
There are two power plants at this facility. The Island Power _
House has nine boilers ranging in design capacity from 95 to 330 million H
Btu. Various fuels including coal, natural gas, liquid waste and
3 tt
waste gases can be used. In 1975, an average of 57 to 95 m (15,000 •
to 25,000 gal)/day of miscellaneous hydrocarbon residues were inciner-
ated. ' Combustion of waste gases and liquids and of coal releases SO^ B
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and NO to the atmosphere along with other possible toxic substances.
/^
No data were available in the Region III air files to define the quantity
or characteristics of possible emissions of toxic substances from the
boilers. About 450 kg (1,000 lb)/hr of NO are emitted with all boilers
X
in operation.
The Mainland Power Station has two boilers rated at 200 million
Btu each. They can burn natural gas or coal. Combustion of coal
releases S09 and NO to the atmosphere. Emissions of NO are about
£- J\ /\
200 kg (440 lb)/hr.
Fly ash slurry from the power plants containing about 45,400 kg
(100,000 lb)/day of solids is pumped to" a disposal pond south of the
Technical Center [Figure 19]. Prior to 1973, the pond used was the
Ward Hollow Pond. This pond also received industrial sludges from
the South Charleston Sewage Treatment Company containing 9,000 kg
(20,000 lb)/day of solids and possibly some wastewaters from the Techni-
cal Center. Effluent from the pond was initially discharged to Ward
Hollow and thence to the Kanawha River by way of Davis Creek. Because
of the high oxygen demand of the pond effluent, it was piped to the
South Charleston Sewage Treatment Company in 1972.
Use of the Ward Hollow Pond was discontinued about 1973 and use
of the Holz Pond to the west initiated [Figure 19]. Holz Pond effluent
is piped to the treatment plant. File information does not indicate
if the Ward Hollow Pond still discharges to the treatment plant. No
information was available to define the potential for seepage from
the ponds into ground and surface waters.
The 1972 EPA survey sampled the Ward Hollow effluent, then dis-
charged to the river. Its main constituents were high levels of cal-
cium chloride. Low levels of cyanide, phenols, cadmium, chromium,
copper and nickel were detected. No organic analyses were performed.
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Aerial photographs of the ponds taken in December 1977, showed M
that the Ward Hollow Pond was still partially covered by water. Two m
large tank trucks were discharging liquids to the upper end of the
Holz Pond. This could have been sludge from sludge storage ponds at I
Union Carbide's Institute Plant. Sludge from the Institute plant
containing 13,600 kg (30,000 lb)/day of solids is also piped to the I
Holz Pond. These sludge discharges began in late 1977.
Chemical wastes (apparently both solid and liquid) are trans- ™
ported to the Goff Mountain Landfill adjacent to the Union Carbide ^
Institute Plant (see later section on this plant). Non-chemical solid I
wastes (lumber, paper, scrap polymer) are landfilled in the "Fill-
mont" area between the Technical Center and the FMC Inorganic Chemicals I
Division's fly ash pond [Figure 19] or are sent to an undefined land-
fill operated by Kanawha County. Aerial photographs taken in October •
1977 showed two fill areas bisected by the Interstate Highway [Fig-
ures 20 and 21]. Both areas showed recent use. ' •
In summary, the Union Carbide South Charleston Plant is a major
petrochemical facility that handles numerous hazardous and/or toxic
substances. Available information indicates that direct discharges
of toxic substances to the Kanawha River in plant wastewaters are a
relatively small. Only a few priority pollutants are discharged.
The potential for spills of toxic substances exists. Air emissions •
also contain toxic substances. Vinyl chloride emissions have been
recently reduced but three accidental releases occurred during 1977. •
Emissions from incineration of organic pollutants have not been defined. *
The plant disposes of large volumes of solid wastes in disposal ponds ^
and landfills. The current environmental impact of these disposal V
practices is undefined.
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Figure 20.
Fast Landfill A rea
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Figure 21.
West Landfill Area
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South Charleston Sewage Treatment Company,
South Charleston, RM 56.2L
South Charleston Sewage Treatment Company (STC), a subsidiary of
Union Carbide, operates a wastewater treatment plant owned by the
City of South Charleston. The facility is a joint venture between
Union Carbide and the City to treat process wastewaters from Union
Carbide's South Charleston Plant and municipal wastewaters from the
City and is adjacent to the South Charleston Plant [Figure 19].
The plant began operation in 1963. It provided primary treat-
ment of both industrial and municipal wastewaters and secondary treat-
ment of about one-third of the effluent. Facilities to provide secon-
dary treatment of all flows were completed in 1968. Additional facili-
ties were completed in 1977.
The plant is designed for separate primary treatment of municipal •
and industrial wastes. The two primary effluents could then be mixed
for secondary treatment or handled separately. In 1977, the two effluents
received separate secondary treatment. Treated effluents were combined
before discharge.
Municipal primary treatment units include a grit chamber, two
primary clarifiers, a sludge thickener and vacuum sludge filters.
Both pre- and post-chlorination are provided. Primary sludge is thick-
ened and then dewatered on the filters. Filter cake is hauled to a
South Charleston landfill. The location was not given in the file.
There is no sludge digestion.
Chlorinated primary effluent receives secondary treatment (acti-
vated sludge process) in the Aero Accelators. These units provide
both aeration and secondary clarification. Waste activated sludge is
pumped to the industrial influent. Effluent from the Aero Accelators
is discharged to the plant outfall.
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No data were present in the file on toxic substances in the muni- ^
cipal wastewaters. There were no reported Major Contributing Industries JQ
on the municipal system. The manufacturing directory did not list
any significant potential industrial sources of toxic substances with •
South Charleston addresses other than plants with known direct surface
fj
discharges. Municipal flow was about 7,600 m /day (2 mgd) in September fl
1976. The South Charleston population is about 16,000. There thus
appears to be no significant industrial flow in the municipal system.
•
Existing municipal flow is about one-third of design flow. Appar- ^
ently, the municipal system is usually operated with only one primary |
clarifier and one Aero Accelator in use at one time. Aerial photographs
taken in late September and mid-October showed the No. 2 clarifier •
and accelator were not in operation [Figure 22].
Process wastewaters from Union Carbide's South Charleston Plant
are conveyed to the treatment plant in a redwood flume. These waste- •
waters can be pumped to one of the four large holding tanks for spill m
containment or for emergency storage during power outages.
Process wastewaters from the redwood flume are pumped to a grit
chamber and then to two primary clarifiers operated in parallel. •
Grit is landfilled in Union Carbide's "Fillmont" area. Primary indus-
trial sludge (including municipal and industrial waste activated sludge) jft
containing about 9,000 kg (20,000 lb)/day of solids is pumped to the *
Holz Pond near Union Carbide's Technical Center [Figure 19]. No sludge
thickening is provided. Return supernatant from Holz Pond is discharged
to the treatment plant influent. _
w
Primary effluent is neutralized by chemical additions and conveyed
to the equalization tanks. It is then released to the large, rectangular •
aeration basin. Basin effluent flows through three final clarifiers
operated in parallel. Clarified effluent goes to the plant outfall. •
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Figure 22.
Ch«r/««ton S«wog« Tr««fm.nf Company
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Figure 23.
FMC South Charleston - East P/anf Are,
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Activated sludge is returned to the aeration basin with waste sludge
combined with primary industrial sludge for pumping to Holz Pond.
In 1977, the average industrial flow treated was in the range of
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15,000 to 23,000 m /day (4 to 6 mgd). Phenol and vinyl chloride monomer
are the only priority pollutants limited by the NPDES permit. Phenol
loads must average less than 1.4 kg (3 lb)/day. A vinyl chloride
concentration of 0.58 ppm was measured in the effluent in December
1977. During the 1972 EPA survey, no heavy metals, cyanide or phenol
were measured in the plant effluent. However, a 96-hour TLm of 26%
indicated that effluent toxicity was higher than would be expected
following this treatment. In July 1977, a 96-hr LC50 of 38% was measured.
The 1975 organics sampling detected low" levels of only two compounds
in the effluent.
As discussed in the previous section, numerous organic compounds
including acrylonitrile, a priority pollutant, have been detected in
the Union Carbide process wastewaters discharged to the treatment
plant. Current data is inadequate to assess the removal of these
substances in the treatment process.
Because of the presence of toxic substances in the process waste-
waters treated by the plant, any bypassing would result in the discharge
of toxic substances to the Kanawha River. Industrial sludges currently
landfilled would also contain toxic substances.
FMC Corp., Industrial Chemical Division, South Charleston, RM 54-55L
FMC Corp. operates this major chemical plant occupying three
production areas in South Carolina [Figure 19]. The main production
area is the east plant adjacent to Union Carbide's South Charleston
plant [Figure 23]. The two other production areas are adjacent to
the converted Naval Ordnance Center [Figures 24 and 25].
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Completed in 1915, this plant was the first major chemical plant
in the Kanawha Valley. Production is continuous with little seasonal
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variation. Current employment is about 1,250.
A 1977 list of products included ammonia, carbon disulfide, car-
bon tetrachloride, chlorine, cyanuric acid, hydrogen peroxide, sodium •
hydroxide, dichloro-5-triazine-2,4,6-(!H, 3H, 5H) trione, sodium salt
and 1, 3, 5-trichloro-s-triazine-2,4,6-(lH, 3H, 5H) trione. Most •
products are manufactured at the east plant. Chlorinated dry bleach *
is made at the central plant and hydrogen peroxide at the west plant. •
Principal raw materials are salt brine, coal, urea, sulfur and natural •
gas.
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An annual average of 360,000 m /day (95 mgd) of cooling water is
withdrawn from the Kanawha River through intakes at the east end and •
central production areas. The only treatment is coarse screening and
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chlorination. About 11,000 m /day (3 mgd) of process, sanitary and
drinking water is obtained from the West Virginia Water Company.
Cooling water intakes are downstream of wastewater discharges from _
Union Carbide's South Charleston Plant and the South Charleston Sew- •
age Treatment Company.
In early 1977, wastewaters were discharged through 26 outfalls,
25 of which discharged to the Kanawaha River and one to Davis Creek •
about 0.8 km (0.5 mi) above its confluence with the river. Eight
outfalls were considered to be major with the remainder discharging £
non-contact cooling water, condensates or surface runoff. Very little ™
wastewater treatment was provided. As noted during the 1972 EPA survey, ^
the potential for spills was high at the plant. •
A large discharge of carbon tetrachloride detected in the Kanawha m
River in February 1977 allegedly originated at the FMC Plant. As a
result and because of requirements for reductions of pollutants •
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Figure 24.
P/MC Soufh Charleston - Central Pfanf Area
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£.?C'~; ' " ''
Figure 25.
FMC Soufh Charfesfon - W«sf Plant Ar*a
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discharged by July 1977, various wastewater treatment and control
measures were implemented in 1977. These included consolidation of
minor discharges, construction of a neutralization facility at the
east plant and installation of spill control facilities. The current
status of these improvements was not defined.
A 16 hectare (40 acre) flyash pond provides settling and partial
neutralization of some plant wastes including (in early 1977) flyash
from plant boilers, calcium and magnesium carbonate slurry from brine
purification and some process wastes from hydrogen peroxide and chlorin-
ated bleach production [Figure 26]. The pond discharges to Davis
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Creek. Treated flow was about 5,700 m /day (1.5 mgd) in 1976.
Toxic substance limited by the NPDES permit include arsenic,
hexavalent chromium, lead and chlorine. Discharges of the first three
totalled less than one kg per day on the average in 1976. Chlorine
discharged averaged 2,970 kg (6,540 Ib) per day, about half the 1975
discharge. The 1972 survey detected 7 kg (16 lb)/day of chromium in
the flyash pond effluent.
During the investigation of the February 1977 carbon tetrachloride
discharge samples were obtained from the FMC cooling water intake and
seven outfalls for organic analysis. Organic compounds detected in
the wastewater discharges that were not detected in the intake included
di-m-butyl ether, carbon tetrachloride, chloroform, dichlorobenzene,
methyl methacrylate, 2-methyl-2-pentenal, benzene, napthalene, 4-me-2-pen-
tanone and numerous other unidentified aromatic compounds. Five of
these compounds are priority pollutants. Concentrations were not
determined.
Air pollution data in the file were limited. Sources of S0? in-
cluded the carbon disulfide plant, a sulfur recovery plant, the carbon
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landfill. Bottom ash, waste asbestos and other plant solid wastes
were landfilled. The location was not given. An active landfill
Union Carbide, Chemicals and Plastics Division,
Institute Plant, RM 48.1-49.6R
Union Carbide operates this large chemicals plant about 13 km (8
mi) downriver from their South Charleston Plant. Production facilities
occupy most of the southeastern portion of the 314 hectare (775 acre)
plant site [Figure 27]. Wastewater treatment facilities are to the
west and a chemical landfill to the north.
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tetrachloride plant, a sulfur purification plant and the four plant M
boilers. Emission rates were not indicated. The chlor-alkali plant Q
is under NESHAPS regulations for asbestos. Asbestos is handled in
the wet state. In mid-1977 filter press cake was being sent to a I
landfill in New York.
The report of the 1972 study indicated that FMC then operated a
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area adjacent to the west plant was detected in the October 1977 —
aerial photographs. This area [Figure 20] or a landfill west across V
the Interstate Highway [Figure 21] could have been used by FMC and/or
Union Carbide. • •
New bottom ash and flyash handling facilities were reportedly it
under construction in 1977. Ultimate disposal was not specified. '
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In summary, the FMC South Charleston Plant produces only one
priority pollutant, carbon tetrachloride. However, seven additional _
priority pollutants have been detected in its effluents. Although j[
reduced from past levels, chlorine discharges are large. Spills of
toxic substances have occurred in the past. Waste asbestos could •
have been disposed of in a local landfill. Air emissions of toxic
substances are not defined. V
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Figure 26.
FMC Fly Ash Pond
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'A/I o r^mm^^mm
iOwfcss^P«
nr**i=J/;J-' Ib^^^i^I 'V\.f-.'-.'.g-.'t?^h
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The Institute plant was originally built for the U.S. Government —
during World War II to produce butadiene and styrene. Union Carbide |
purchased the plant in 1947 to make other chemicals. Various processes
have been added over the years. In 1972, annual production was about •
1.5 million tons of basic and intermediate materials. The products
included chemical additives for gasoline, jet fuels, water based paints, B
cheese, baked goods, and other foods. More than 100 chemicals were
made for the textile finishing industry and more than 90 for pharma- •
ceutical companies. Several agricultural chemicals were produced »
including the insecticide SEVIN. —
A listing of raw materials, intermediates, and final products
provided by Union Carbide in early 1978" included more than 350 com- •
pounds. The principal raw materials were natural gas, chlorine, caustic,
ethylene oxide, naphthalene, alcohols, amines and air. Priority pollu- A
tants among the 350 compounds were acrylonitrile, benzo(a) pyrene,
benzene, carbon tetrachloride, chlorobenzene, chloroform, chlorophenol; •*
chrome, copper, dichlorobenzene, dichlorophenol, dicyclopentadiene, •
isophorone, methyl chloride, methylene chloride, naphthalene, nickel, _
silver, toluene and trichlorophenol. |
The South Charleston and Institute plants apparently interchange •
various chemicals. A 1977 listing of combined products of the two
plants is presented in Table 5 in the South Charleston Plant section. V
An undated listing of hazardous materials stored at South Charleston
and Institute contained more than 600 substances. Many of these were •
identified by trade names or mixture numbers. Their actual chemical »
makeup was not defined. The hazardous material listing also indicated ^
that the materials were moved by various combinations of tank truck, Q
tank car and barge. Some materials were purchased, some moved between
the two plants and some transported to customers. For the priority I
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pollutants, storage tanks were reported as less than 380 m (100,000
gal) in size except for vinyl chloride which was stored in tanks in
the 380 to 1,900 m3 (100,000 to 500,000 gal) volume range.
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The Institute Plant operates continuously with little production
variation. Current employment is about 1,800.
Water use at the plant in 1977 was about 1,100,000 m /day (290
mgd). Except for 3,800 m /day (1 mgd) purchased from the municipal
supply, all water was withdrawn from the Kanawha River. Two in-plant
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water treatment facilities provided about 23,000 m /day (5.8 mgd) for
process water and boiler feed. Cooling water use averaged about
1,060,000 m3/day (280 mgd).
The plant has 11 active outfalls; six discharge directly to the
Kanawha River and five to Goff Branch, a small tributary draining the
chemical landfill area. Outfall 001 is" the effluent from the waste-
water treatment plant. One outfall is water screen backwash water
and the remaining nine are classified as non-contact cooling water
discharges. These discharges have some contamination, however, from
leaks, spills and undetected process connections.
The wastewater treatment plant has been expanded and modified
several times since it was placed iii operation in 1963. In 1972,
treatment units included an equalization basin, three aeration basins
(activated sludge process), two final clarifiers and a sludge storage
basin. Primary sludge from the equalization basin and waste acti-
vated sludge were pumped to the sludge holding basin, then to nearby
sludge drying beds. Dried sludge was landfilled at an adjacent site.
It is not clear if this was immediately adjacent to the wastewater
treatment plant or at the Goff Mountain chemical landfill. All of
the 1972 units are shown on the topographical map [Figure 27].
Major modifications in the treatment system were completed in
1977. Two primary clarifiers, an emergency holding pond, a neutral-
ization capability, a sludge thickener and a third final clarifier
were constructed. Three sludge ponds had previously been added north-
east of the treatment plant since 1972. In late 1977, primary sludge
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3
During the 1972 survey, an average of 22,000 m /day (5.8 mgd) of
of the substances had known toxic effects.
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and waste activated sludge were thickened and pumped via pipeline to ^
Union Carbide's South Charleston Plant for pumping to the Holz Pond |
in South Charleston. Aerial photographs taken in October 1977 showed
all new treatment units in place and apparently operational [Figure •
28]. In January 1978, Union Carbide reported that about 26,500 m3 (7
million gal) of activated sludge were stored in two sludge ponds north- B
east of the treatment facility. This sludge was being trucked to the
Holz Pond for disposal.
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treated process wastewaters were discharged. These contained daily (
loads of about 45 kg (100 Ib) of phenols, 150 kg (330 Ib) of cadmium,
6 kg (14 Ib) of zinc, 5 kg (12 Ib) of copper and small amounts of I
lead, nickel and chromium. A bioassay yielded a 96-hr TLm of 9% indi-
cating the effluent was highly toxic. . •
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Phenol is the only priority pollutant limited by the NPDES permit
and this limit was effective July 1, 1977. Wasteload reports submitted
to the State indicated average phenol loads discharged have been reduced
to less than 4 kg (10 lb)/day. Quarterly bioassays in 1977 showed J
TLm's of 16 to 35% indicating the effluent is still moderately to
highly toxic. •
Sampling of the cooling water discharges in 1972 detected a phenol fl|
load of 19 kg (42 lb)/day. DMR data indicated phenol loads were reduced
to average and maximum daily loads of 4 and 27 kg (8 and 60 Ib), respec-
tively, in 1976.
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Sampling of the Institute Plant effluents in 1975 resulted in |
the detection of 37 organic compounds including the priority pollutants
dichlorobenzene, dinitrololuene, and bis (2-chloroethyl) ether. Ten I
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Figure 28.
Union Carbide Institute Plant - Wasf.wafer Treafmenf P/Onf
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-»i V * *'*%*^ I*
on^iji ,.-* i^.
Figure 29.
Union Carbide Institute Plant- Fly Ash Pond
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Figure 30.
Cunningham ft* a Ity Company - fly Ash Pond
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?•*• 'HE*
f «£/ t 4&s*
Figure 31.
Union Carbide Institute Plant •• Ash Pond
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121
Analysis of the treatment plant effluent in March 1977 detected
13 specific organic compounds. Bis (2-chloroethyl) ether, carbon
tetrachloride, ethyl benzene and toluene, all priority pollutants,
were present in low levels. Dichlorobenzene isomers were present at
higher levels. Concentrations were not determined.
A 1977 emissions inventory listed about 80 organic compounds
that are emitted to the atmosphere from various sources at the Insti-
tute plant. Fifty-nine of these have toxicity ratings ranging from
slightly toxic to highly toxic. Five are suspected carcinogens. Ten
are priority pollutants.
The Institute Plant has two boiler" houses with eight boilers
each. All units can burn process residue. Various methods of bottom
and fly ash disposal have apparently been used. At some time in the
last few years, a rectangular settling pond was constructed on the
north side of Goff Branch in the northeast portion of the plant [Fig-
ure 29]. Bottom and flyash were pumped to this pond. Supernatant
was discharged to Goff Branch. Aerial photographs and thermal imagery
recorded in October 1977 indicated the pond was not active.
During the 1972 EPA study, fly ash was slurried and pumped to
disposal ponds on Finney Branch east of the plant [Figure 30] (see
discussion of Cunningham Realty Co. in the minor industrial source
section). The flow discharged to this contract disposal facility was
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about 11,000 m /day (2.9 mgd). Aerial photographs and thermal imagery
recorded in October 1977 indicated this operation was continuing.
The photographs also showed a small pond on the river bank just east
of Outfall 002 [Figure 31]. The pond could have been used for settling
bottom and/or fly ash. The thermal imagery indicated the pond was at
ambient temperature and thus probably not in current use. However, a
dragline or clamshell unit was parked at the pond and solid waste
that appeared to have been dredged from the pond was piled along the
west edge.
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Union Carbide operates a State licensed chemical landfill in the
Goff Branch drainage area on the north side of the Institute Plant.
Class I chemicals from both the Institute and South Charleston Plants
are disposed of there. In 1972, about 3 out of 16 hectares (7 out of |
40 acres) of the site were actively used for disposal. An applica-
tion was submitted to the State in March 1977 to upgrade the facility •
and extend its life to the year 2004.
The landfill uses the wet process. A clay blanket has been placed *
below active fill areas. Peripheral drainage controls keep surface M
runoff from adjacent hillsides from entering the fill areas. Wastes m
are blended with soil with the location in the fill and blending ratios
dependent upon the waste characteristics. Leachate is collected in a •
pond(s) and piped to the wastewater treatment plant.
The 1977 application indicated that more than 50 different waste
materials are disposed of in the landfill with a weight more than 54 ' •
m. tons (60 tons)/day. Toxic substances included in the wastes were *
dicyclopentadiene, Sevin insecticide and naphthalene. _
Aerial photographs taken in October 1977 [Figures 32 and 33]
showed that materials were being disposed of at several locations in I
the valley. Two small diked ponds were present along the west side
of Goff Branch [Figure 32]. The north pond contained a liquid various •
shades of brown. The south pond contained a green/brown liquid.
Various materials had been dumped uphill of the south pond. Near the •
northeast corner of the disturbed area was a stack of black drums "
that appeared to be leaking [Figure 33]. Most of the area around the M
ponds and the leaking drums had been disturbed indicating that materials w
have probably been buried there.
It is not clear where leachate from the area is intercepted for
conveyance to the treatment plant. The two ponds could not catch all •
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f i g u r e 32.
Union Carbide Chemicaf Land fill • Wesf Side
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Figure 33.
Union Carbide Chemical landfill - East Side
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Figure 34.
Union Carbide fnsfifufe Plant - Norfh Process Area
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•&'
Figure 35.
Union Carbide Institute Plant - Land Fill Area
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127
such leachate. It appeared that several concrete drop structures
(stair-stepped conduits) were being actively constructed in the bed
of Goff Branch. This would allow the stream flow during wet weather
to pass through the disturbed area with less erosion potential. It
appeared that interception of the entire runoff from the valley would
be necessary to treat all leachate.
One group of process units was east of the south edge of the
landfill area [Figure 34], Two small ponds, one probably unlined,
were associated with these units.
Solid wastes from the plant have also been disposed of at other
on-site locations. A 6 hectare (15 acre) site west of the wastewater
treatment plant was reportedly used for disposal of inert (non-chemi-
cal) wastes in 1972. Some sludge could also have been disposed of in
the vicinity of the treatment plant in the past. At the treatment
plant site, construction of the third final clarifier was delayed in
1976 by unstable soil conditions. Ashes, waste oil and other materials
were reportedly dumped in the area in the past. The potential for
contamination of groundwater with toxic substances in the vicinity of
the treatment plant is high. Aerial photographs showed that some
solid wastes of unknown makeup had been dumped in the area between
the wastewater treatment plant and the production facilities [Figure
35].
In 1977, undefined solid wastes were disposed of by contract at
two off-site landfills operated by the Kanawha County Regional Develop-
ment Authority (Cross Lanes) and by the City of Huntington.
There was no documentation in the file concerning the use of
contractors for disposal of toxic substances.
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In addition to Union Carbide wastewaters, the treatment plant
reportedly received wastewaters from an independent tank truck/tank I
car cleaning facility west of the plant in late 1976. A 1976 Union
Carbide map labeled this facility the Kanawha Valley tank car and •
tank truck cleaning facilities. Wastewaters received primary treat-
ment before batch discharge to the treatment facility. No data on •
flow volume or characteristics were reported. Apparently the facil- •
ity primarily serviced units transporting Union Carbide materials.
October 1977 aerial photographs showed a small unlined pond on the p
east of the cleaning facility. Its temperature was warmer than ambient.
The Chemical-Leaman Tank Lines, Inc. tank cleaning facility (see dis- •
cussion under minor sources) is north of the wastewater treatment
plant [Figure 27]. Its treatment plant, discharge apparently flows to •
the Kanawha River in the vicinity of the independent tank cleaning *
facility. M
In summary, Union Carbide's Institute Plant is a major producer
and handler of organic chemicals. At least 20 chemical substances I
handled or produced by the Institute Plant are priority pollutants
and a number of other chemicals have known toxic effects. Low levels •
of most of the priority pollutants present at the plant have been
detected in wastewater discharges. The potential for larger spills •
exists. More than 50 toxic substances are released to the atmosphere *
including three suspected carcinogens. The disposal of chemical wastes M
at the Goff Mountain landfill creates a potential for release of toxic •
substances to the atmosphere and to ground and surface waters. Toxic
substances could also be present in old landfills in the vicinity of p
the wastewater treatment plant. Contamination of groundwater with
toxic substances in that area is possible. •
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129
MINOR INDUSTRIAL SOURCES
There are nine minor industrial facilities in the Central Valley
that have or had, direct discharges of wastewaters to the Kanawha
River that required NPDES permits. There are numerous additional
small industrial plants located in urban areas of the Valley. These
would be expected to be serviced by municipal sewerage systems. The
potential for releases of toxic substances to the environment from
these small plants was summarized in Table 2 in Section VI.
Libby-Owens-Ford Company, Charleston, RM 63.4L
A flat sheet (window) glass plant is operated by LOF in the
Kanawha City area of Charleston [Figure 36]. Plant operations began
in 1916 with plant expansions occurring in 1920, 1923 and 1960. The
plant had 12 glass furnaces in operation at its peak. In 1972, four
gas-fired units were in operation producing an average of 428 m. ton
(472 ton)/day of glass. Employment has been as high as 2,200 but was
reported as 957 in 1972 and 475 in 1976.
Potable water is obtained from the municipal supply and sanitary
wastewaters are discharged to the municipal sewerage system. The
plant uses Kanawha River water for furnace cooling and for dust inhibi-
3
tion when preparing furnace charges. In 1972, about 700 m /day (0.195
mgd) of river water was treated (settling with alum and soda ash additions,
filtration and chlorination), and used for make-up water for the closed
cooling system. A low chromate preparation called Hagatreat 168 was
added for scale prevention and algae control. There was no cooling
system blowdown. Filter backwash (every two days) was discharged to
the river. The settling basin was cleaned annually with sludge dis-
charged to the river.
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Figure 36 . Location Map - Kanawha City Area
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In 1972 all combustible wastes were incinerated at the plant
site. Waste glass and rejected batch materials were hauled to a land-
fill.
Emission sources are the four gas-fired glass furnaces.
Aerial photographs of the plant site in October 1977 did not
reveal any potential sources of toxic substances not reported.
•>. .
This plant is not considered a significant source of toxic sub-
stances.
American Oil Company, Charleston, RM 62.OR
American Oil Company operates a small bulk petroleum products
distribution facility across the Kanawha River from Kanawha City
[Figure 36]. The facility does not have an NPDES permit. From the
size and type of operation, it is probable this is not a significant
source of toxic substances.
Exxon Company, Charleston, RM 57.81
The Exxon Company operates a bulk petroleum products terminal on
the south bank of the Kanawha River across from downtown Charleston
[Figure 37]. The terminal was built over 50 years ago and was re-
3
modeled in 1966. In 1972, annual sales volume averaged 284,000 m
(75 million gal). The plant employed 39 persons.
Petroleum products are received by barge or railroad tank car.
Both tank cars and tank trucks can be loaded for product distribution.