THE OHIO RIVER - McALPINE POOL
*
REPORT
KENTUCKY - INDIANA
Environmental Protection Agency
Surveillance and Analysis Division
Region IV
ATHENS, GEORGIA
I JUNE 1973
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THE OHIO RIVER-McALPINE POOL REPORT
KENTUCKY-INDIANA
Environmental Protection Agency
Region IV
Surveillance and Analysis Division
Athens, Georgia
June 1973
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This report was prepared under the direction and supervision
of Dr. David W. Hill, Chief, Industrial and Special Studies Branch.
Mr. Charles A. Sweatt served as Project Engineer for the planning
and conduct of the field survey and as principal author of this
report. Participating EPA personnel are stationed in Athens,
Georgia, as part of the Surveillance and Analysis Division under
the direction of Mr. John A. Little, Region IV; and in Evansville,
Indiana, as part of Region V.
ii
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TABLE OF CONTENTS
Title Page No.
INTRODUCTION 1
SUMMARY AND CONCLUSIONS 3
RECOMMENDATIONS 9
STUDY AREA 11
DESCRIPTION OF AREA 11
WATER USES AND WATER QUALITY STANDARDS 15
WATER USES 15
WATER QUALITY STANDARDS AND USE CLASSIFICATIONS 15
STUDY METHODS 21
GENERAL 21
MUNICIPAL WASTE 21
INDUSTRIAL WASTE 22
WATER QUALITY STUDIES 22
STUDY FINDINGS 25
WASTE SOURCES 25
Oak Park Conservancy District, Indiana 25
Charlestown, Indiana 28
Hanover, Indiana 30
Madison, Indiana 32
Vevay, Indiana 34
Carrollton, Kentucky 35
Louisville (Hite Creek), Kentucky 35
Dow Corning Corporation, Carrollton, Kentucky. ... 37
M&T Chemicals, Inc., Carrollton, Kentucky 49
iii
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Table of Contents (cont'd)
Title Page No.
Kawneer, Inc., Carrollton, Kentucky 43
Indiana Army Ammunition Plant, Charlestown, Indiana. 45
Indiana-Kentucky Electric Corporation, Madison,
Indiana 46
OHIO RIVER WATER QUALITY 49
- FLOW 49
• TEMPERATURE 49
. DISSOLVED OXYGEN 50
* BIOCHEMICAL OXYGEN DEMAND 53
'TOTAL ORGANIC CARBON 54
NITROGEN 56
.PHOSPHORUS 58
« pH AND ALKALINITY 58
. SPECIFIC CONDUCTANCE 59
. TURBIDITY 59
•BACTERIOLOGICAL 59
REFERENCES 67
APPENDIX A - STATION LOCATIONS AND STUDY PLAN 69
APPENDIX B - CHEMICAL AND BACTERIOLOGICAL METHODS 83
APPENDIX C - STREAM AND WASTE QUALITY DATA 91
APPENDIX D - REGION V REPORT ON INDIANA ARMY AMMUNITION PLANT. 121
APPENDIX E - ORGANIC COMPOUNDS IDENTIFICATION 133
APPENDIX F - PERSONNEL ROSTER 135
IV
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LIST OF TABLES
Number Title Page
I MUNICIPAL AND INDUSTRIAL WASTE SOURCES 16
II MUNICIPAL AND INDUSTRIAL WATER INTAKES 17
III WATER QUALITY CONDITIONS AND SPECIFIC USE CRITERIA
APPLICABLE TO OHIO RIVER (McALPINE POOL) 19
IV MUNICIPAL & INDUSTRIAL EFFLUENT DATA SUMMARY 26
V BOD5 LOADING (LBS/DAY) TO McALPINE POOL 55
VI SUMMARY OF BACTERIAL WATER QUALITY 62
VII SUMMARY OF BACTERIAL WASTE SOURCE DATA 63
v
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LIST OF FIGURES
Figure Title Page
1 Location Map and Sampling Stations Fold-out in
back (137)
2 Ohio River Navigational Structures 12
3 Approved Ohio River Water Classification for the
McAlpine Pool Reach 20
4 Oak Park Conservancy District, IN, STP 27
5 Char lest own, IN, STP 29
6 Hanover, IN, STP 31
7 Madison, IN, STP 33
8 Carrollton, KY, STP 36
9 Kawneer and Dow Corning Discharges 39
10 M&T Chemicals Discharge 41
11 Indiana-Kentucky Power Corp. Ash Pond 48
12 Ohio River (McAlpine Pool), DO, TOC and BOD5
Concentrations 51
13 Ohio River (McAlpine Pool), River X-sectional Area,
Velocity and K2 Rate 52a
14 Ohio River (McAlpine Pool) Average Nitrogen Concentrations 57
15 Ohio River (McAlpine Pool) Total and Dissolved Phosphorus
Concentrations 60
16 Geometric Mean Total Coliform Densities 64
17 Geometric Mean Fecal Coliform Densities 65
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INTRODUCTION
Dissolved oxygen concentrations in the lower portion of the
McAlpine Pool reach of the Ohio River in violation of Federal and
State water quality standards were observed during a survey conducted
by the Environmental Protection Agency (EPA) during August and
September 1971. Results of that survey are published in the report
entitled Ohio River Waste Source and Water Quality, Louisville,
Kentucky to Wabash River Reach, Kentucky-Indiana. That report rec-
ommended that EPA investigate the causes and recommend solutions to
the low dissolved oxygen levels in McAlpine Pool.
A field study was conducted during September 18-24, 1972, with
the following objectives:
• Determine the cause of low dissolved oxygen concentra-
tions observed in the lower portion of McAlpine Pool
during the August-September 1971 EPA, Region IV, Ohio
River Study.
• Characterize the industrial and municipal wastes dis-
charged into the McAlpine Pool reach of the Ohio River.
The 1972 study was conducted by Region IV Surveillance and
Analysis Division personnel from Athens, Georgia, with the assistance
of EPA Region V personnel from the Evansville District Office.
The cooperation and assistance of the Kentucky Water Pollution
Control Commission, the Indiana Stream Pollution Control Board, the
Louisville-Jefferson County Metropolitan Sewer District, and the
various municipal and industrial entities involved in this study
are gratefully acknowledged.
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SUMMARY AND CONCLUSIONS
Wastewater discharges into the McAlpine Pool reach (River Miles
531.5 to 600.6 — from upstream to downstream) of the Ohio River are
relatively small compared to discharges from the Cincinnati and
Louisville areas. The combined effect of waste discharges into the
McAlpine Pool, however, tends to retard recovery of the river from
the effects of the Cincinnati area waste load.
1. Water quality standards submitted by Indiana and Kentucky
have been approved by the Environmental Protection Agency.
The McAlpine Pool reach is classified for recreation, aquatic
life, agricultural and industrial water supplies except in
areas where public surface water supplies are located.
These areas are classified for public water supplies by both
states. At present, the Louisville Water Company operates
the only public surface water supply in the reach. By June
1973, Kentucky is expected to classify all streams for all
uses. (The most stringent water quality criteria will apply
to all but very limited exceptions.)
2. Of the ten municipal waste sources investigated during this
survey, Madison, Indiana, is the largest. The 1.75 mgd
flow, containing approximately 20 percent industrial waste,
does not receive adequate treatment in the existing over-
loaded primary treatment facility. Stream standards for
coliform bacteria are violated by the discharge from the
plant. During the survey, the plant discharged 3,140 Ibs/day
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of BOD5, 2,770 Ibs/day of suspended solids, 9 Ibs/day of
total chromium, and total coliform concentrations from
7,300,000 to 86,000,000 per 100 ml.
The sewage treatment plants (STP) at Carrollton, Kentucky,
and Charlestown, Indiana, are both primary plants which pro-
vide inadequate waste treatment. The Carrollton STP does
not provide chlorination. Listed below is the treatment
status of all plants surveyed :
Source
Type
Treatment
Kite Cr. STP
(Louisville) Tertiary + Cl2
Oak Park
Conservancy
District STP
Primary +
Indiana Army
Ammunition Primary + Cl2
Plant STP
Indiana Army
Ammunition
Plant STP
Ind iana Army
Ammunition
Plant STP
Charlestown,
Indiana STP
Hanover,
Indiana STP
Madison,
Indiana STP
Carrollton,
Indiana STP
Vevay,
Indiana STP
Secondary +
Septic tanks
Primary + Cl2
Secondary +
Primary +
Primary
Secondary +
Impl emen ta t ion
Needs Schedule Status
None Met
Met
Secondary Secondary facility
essentially complete.
Secondary Secondary facility
under construction.
None None
Funds requested
Treatment for design and
Plant construction.
Behind
Secondary Plans Submitted.
None Met
Behind
Secondary Plans approved.
Plans almost
Secondary complete.
None Met
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3. Five industrial waste sources were investigated. The
Indiana Army Ammunition Plant, was closed by a strike and
had no discharge during the study. Information on this
source is provided in the form of a trip report prepared by
Region V personnel and contained in Appendix D. The Indiana-
Kentucky Clifty Creek Power Plant discharges approximately
960,000 gpm of cooling water with a 11°F temperature rise.
This heat load, if fully mixed, amounts to a calculated 0.42°F
temperature rise for the Ohio River flowing at a rate of
30,000 cfs. Chlorine is used for algae control in the cool-
ing system during the summer. This results in a 0.35 ppm
chlorine residual in the cooling water discharge for approx-
imately two 30-minute periods per day during the summer.
Waste samples were collected from the remaining three indus-
tries, all near Carrollton, Kentucky.
• Dow Corning,
• M&T Chemicals,
• Kawneer, Inc.
The waste samples from M&T Chemicals contained relatively
high concentrations of BODc (87.5 mg/1) and ammonia (33 mg/1)
which represent a sizable oxygen demand upon the receiving
waters. Wastes from Kawneer and Dow Corning had low oxygen
demands and probably do not contribute measurably to the low
oxygen levels in McAlpine Pool. Domestic wastes from all
industries investigated are handled adequately with the
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possible exception of Kawneer, Inc. Based on the one
effluent coliform sample which exceeded 1,600 per 100 ml,
it appears that the septic tank system now employed by the
plant may need improvement.
4. Normal waste discharges from industrial and municipal waste
sources along the study reach are not sufficiently large to
cause the previously observed low dissolved oxygen problems
in McAlpine Pool, even though waste treatment is inadequate
in several cases. Water temperatures in the river were
decreasing during the study and were slightly below the
summer peak; however, dissolved oxygen levels as low as 4.0
mg/1 were observed. Approximately 15 percent of mid-channel
observations were less than the required daily average of
5.0 mg/1. Only slight horizontal or vertical stratification
was observed. No real cause and effect relationship could be
established between any individual or group of waste dis-
charges within the study reach and observed low oxygen levels.
5. Reaeration rates in the sluggish impoundments of the Ohio
River and particularly in McAlpine Pool are low resulting
in very little reaeration. Dissolved oxygen levels at
Markland Dam are markedly depressed by upstream waste sources.
They increase steadily downstream in the first 25 miles of
the study reach but then decline downstream to McAlpine Dam.
This trend corresponds closely with factors affecting re-
aeration, namely river velocities and cross-sectional
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mg/1). DO was lower in the Ohio (5.4 vs. 6.1 mg/1) and BOD5
was higher in the Ohio (1.8 vs. 1.4 mg/1).
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RECOMMENDATIONS
1. All municipal wastes and sanitary waste discharges from industry
should receive adequate secondary treatment and disinfection.
The following sources are not meeting these criteria and/or are
not making significant progress in meeting the federal-state
implementation schedules:
• Madison, Indiana STP,
• Carrollton, Kentucky STP,
• Charlestown, Indiana STP,
• Indiana Army Ammunition Plant septic tank overflow,
• Kawneer, Inc. septic tank overflow
Agencies from the appropriate states and the EPA should review
each case and take appropriate action to assure compliance with
established implementation schedules.
2. As an immediate measure, equipment to provide adequate disinfection
should be provided at the Madison and Carrollton sewage treatment
plants.
3. Madison should determine the sources of heavy metals to its
sewers (possibly the electroplating plant) and require appropriate
pretreatment.
4. Upstream waste sources (primarily in the Cincinnati area) must
provide better waste treatment before a significant water quality
improvement will occur in the McAlpine Pool. Nitrification of
these wastes will probably be necessary.
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STUDY AREA
DESCRIPTION OF AREA
The Ohio River is formed by the junction of the Allegheny and
Monongahela Rivers at Pittsburgh, Pennsylvania. It flows south-
westerly for 981 miles to the Mississippi River near Cairo, Illinois
(Figure 1 - fold out map at rear of report). Although the river flows
through a rather narrow valley, it drains 203,910 square miles of the
middle eastern portion of the United States. The river forms portions
of the boundary between Ohio and West Virginia and separates Kentucky
from Ohio, Indiana, and Illinois.
The specific study area was the 75.3 mile reach of the Ohio
River between Markland and McAlpine Dams. The terrain is gently
rolling and is dominated by agricultural activities. The population
is dispersed in rural areas and small towns. Madison, Indiana, with
a population of 13,081 is the largest city in the study area. Indus-
trial activity along the reach is sparse.
The Ohio River is an Important navigational route serving the
eastern central United States. The river was first used for commer-
cial navigation prior to early 1800 when state and private interests
began development. Navigation was extended from the mouth to
Pittsburgh with completion of a nine-foot deep channel in 1929.
Under a modernization program inititated in 1955, the original system
of 51 locks and dams are being replaced by 19 high-lift structures
(Figure 2).
The average daily flow of the Ohio River at Louisville is
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133J Ml NOI1W313
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110,700 cfs for 41 years of record. The ten-year, seven-day low
flow of 6,140 cfs and daily average extremes are 1,110,000 and
2,100 cfs.
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WATER USES AND WATER QUALITY STANDARDS
WATER USES
Water uses within the McAlpine reach consist of public and
industrial water supplies, commercial fishing, sport fishing, recre-
ation (including swimming and water.skiing), navigation, agricultural
and municipal and industrial wastewater disposal. In contrast to
upstream and downstream reaches, the McAlpine reach receives very
little municipal or industrial waste, increasing its popularity for
recreational uses. Municipal and industrial waste discharges are
listed in Table I.
Water supplies for one municipality and three industries are taken
from this reach of the Ohio River (Table II). Most water supplies in
the area are obtained from high production wells in the river valley
alluvium. These wells, recharged from the Ohio River, typically
produce 1,000 to 2,000 gallons per minute of good quality water.
WATER QUALITY STANDARDS & USE CLASSIFICATIONS
The Federal Water Quality Act of 1965 (Public Law 89-234) pro-
vides that States, after public hearing, and prior to June 30, 1967,
may adopt water quality standards applicable to interstate waters
within the state and an implementation and enforcement plan. The act
requires that the standards will protect the public health and welfare,
enhance the quality of water, and serve the purposes of this act. In
establishing such standards, the state is required to take into con-
sideration uses for public water supplies, propagation of fish and
wildlife, recreational purposes, agricultural, industrial and all
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TABLE I
MUNICIPAL AND INDUSTRIAL WASTE SOURCES
Ohio River (HcAlpine Pool) Study
River
Mile
597.6
595.9
593.4
592.8
Municipality
Oak Park Con-
servency Dist.
- Indiana
Louisville,
Jefferson
County
Metropolitan
Sewer Dist.
Kite Cr.
Plant, KY
Indiana Army
Ammunition
Plant
Indiana Army
Ammunition
Plant
Ave.
1970 Flow
Population (MOD)
Serves 0.23
2,000
Approx. 75% 1.5
of waste
flow is from
Ford Motor
Co.'s Truck
Assembly
Plant
0.25
160 0.02(e)
Type of Treatment
Primary and
Chlorination
Tertiary and
Chlorination
Secondary and
Chlorination
Septic tanks w/no
drain field
Treatment Status and
Federal Implementation Date
Secondary facility 90% com-
plete on 6/72. Implementa-
tion date for completion -
12/73.
No needs identified.
No needs identified.
Unsatisfactory - Scheduled
to be replaced by two packaj
aeration treatment units in
Receiving Stream
Unnamed tributary
to the Ohio River.
Hite Cr., Harrods
Cr., Ohio River
Ohio River
Ohio River
iplaced by two package
i treatment units in
FY '73.
591.5 Indiana Army
Ammunition
Plant
590.5 Charlestown,
Indiana
554.7 Kawneer.Inc.
•543.5 M&T Chemicals,
Inc.
541.0 Dow Corning
Corp.
562.6 Hanover, Ind.
558.8 Madison, Ind.
5,890
3,018
13,081
0.08 Primary and
Chlorination
0.40 Primary and
Chlorination
0.45 In-plant controls
4.8 Neutralization,
floculation and
sedimentation
5.02 Sedimentation,
neutralization,
coagulation and
vacuum filtration
0.11 Secondary and
Chlorination
1.75 Primary and
Chlorination
Secondary facility now under
construction is scheduled
for completion in FY '72.
Unsatisfactory - Plans for
secondary facility submitted
to state on 9/3.6/72.
Implementation dates for
start of construction 12/72
and completion 12/73.
No needs identified
Implementation dates for
completion of stabilization
basins are 3/74. Final plans
were completed as required by
9/72.
Implementation dates for
completion of stabilization
basins are 6/74.
Jenny Lind Run to
Ohio River
Ohio River
Ohio River
Ohio River
Ohio River
545.8 Carrollton,
KY
3,218
0.28 Primary
No needs identified Ohio River
Unsatisfactory - Plans for Ohio River
secondary facility approved
by state on 4/72.
Implementation dates are
complete plans 6/71; start
construction 12/71; complete
construction 12/72
Unsatisfactory - Implementa- Knetucky River
tion dates for secondary
facility include completion
of plans by 9/72 and com-
pletion of construction by
7/74. No progress reported.
538 Vevay, Ind.
(e)-Estimate based on population served
1,463 0.12 Secondary and
Chlorination
No needs identified
Ohio River
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TABLE II
MUNICIPAL AND INDUSTRIAL WATER INTAKES
OHIO RIVER - MCALPINE POOL
(NOVEMBER 1972)
Municipalities
Louisville, Ky.
Use
Public Water Supply
Location
(River Mile)
600.6
Industries
Indiana-Kentucky Power Corp.,
Clifty Creek Plant Cooling
Colgate-Palmolive Co., Inc. Process
Louisville Gas & Electric Co. Cooling
Louisville Gas & Electric Co. Cooling
559.5
603.6
603.6
604.9
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other legitimate uses. The State of Indiana and the Commonwealth
of Kentucky have submitted and received approval on their water
quality standards. Standards submitted by the water pollution control
agericies of both states are applicable to the study reach and enforce-
able by the two states and the Federal Government. In addition to
the standards submitted by the states, the Ohio River Valley Water
Sanitation Commission (ORSANCO), a compact representing eight states
along the Ohio River, has also adopted criteria for judging the
suitability of the Ohio River water for various uses. The ORSANCO
standards, however, are not federally enforceable. Table III presents
a brief summary of the criteria applicable to the study reach.
Water use classifications for the Ohio River have been proposed
by Kentucky and Indiana and approved by EPA. A schematic representation
of the study area classifications is shown in Figure 3. A clause in
the Indiana standards provides for the classification of public water
supply to be applied at existing or future surface water supply
points. The reach of river near McAlpine Dam, now classified for
aquatic life, was planned to be upgraded in the Kentucky standards to
recreation in July 1974. However, a public hearing is scheduled by
the Department of Natural Itesources and Environmental Protection for
June 4, 1973, after which all streams are expected to be classified
for all uses. Exceptions will have to be justified by dischargers
at public hearings for their discharge permits.
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TABLE III
Water Quality Conditions and Specific Use Criteria Applicable
to Ohio River (McAlpine Pool)
Minimtn Conditions For All Haters At All Times
FT) Free from substances attributable to municipal, industrial,
agricultural or other discharges that will settle to form
putrescent or otherwise objectionable deposits.
(2) Free from floating debris, oil, scum and other floating
material attributable to municipal, industrial, agricultural
or other discharges in amounts sufficient to be unsightly
or deleterious.
13) Free from materials attributable to municipal, industrial,
agricultural or other discharges producing color, odor, or
other conditions in such degree as to create a nuisance.
(4) Free from substances attributable to municipal, industrial,
agricultural or other discharges in concentrations or
combinations which are toxic or harmful to human, animal,
plant or aquatic life.
Stream polity Criteria
Hater Use Classification
Public Water Supply (Kentucky)
and
(Indiana)
Bacteria: Monthly arithmetic mean total coliforms ±5,000/100 ml (MPN or MF); or,
£.5,000/100 ml in more than 20 percent of samples; or, ±20,000/100 ml in
more than 5 percent of samples.
Threshold Odor Number: <3 after treatment.
Dissolved Solids: ~50 mg/l at all times, monthly mean ±500 mg/l or specific
conductance & 25°C ±1,200 ^mhos/cm at all times or monthly mean
±900 vmhos/cm.
Radioactive Substances: Gross beta activity not to exceed 1,000 picocuries per
liter (pCi/l), nor shall activity from Strontium 90 exceed 10 pCi/l,
nor shall activity from dissolved alpha emitters exceed 3 pCi/l.
Recreation (Kentucky)
Recreation-Whole Body Contact
(Indiana)
-Partial Body Contact
(Indiana)
Aquatic Life (Kentucky)
and
(Indiana)
Chemical constituents:
Constituents
Arsenic
Barium
Cadmium
Chromium (Hexavalent)
Not to exceed the following at anytime:
Concentration (mg/l) Constituents Concentration (mg/l)
0.06
1.0
0.01
0.05
Cyanide
Fluoride
Lead
Selenium
Silver
0.025
1.0
O.OC
0.01
0.05
Bacteria: Total coliform monthly mean ±1,000/100 ml; daily value ±2, 400/100 ml.
If above values are exceeded, during May-October the geometric mean
fecal coliform density ±200/100 ml in ten samples per month or
±400/100 ml in 10% of monthly samples. During November-April monthly
geometric mean ±1,000/100 ml in ten monthly samples or ±2,000/100 ml
in 10% of monthly samples.
Bacteria: April-October, monthly geometric mean fecal coliform ±200/100 mi in
five samples per month or ±400/100 ml in 10% monthly samples.
Bacteria: Geometric mean fecal coliform ±1,000/100 ml or ±2,000/100 ml in 10%
of samples.
Dissolved Oxygen: (Kentucky & Indiana) Daily average >J>,0 mg/l with minimum
^4. 0 mg/l.
p_H_: "B to 9 (Ky.); 6.0-8.5 (Ind.)
Temperature: (Ky.) Max. 89°F, 5° rise in stream, 3° rise in impoundmer*ts.
(Ind.) Max. 89"F, S° rise.
Toxic Substances: (Ky. & Ind. ) ±1/10 96-hour TIM.
Taste & Odor: (Ind.) No substance which imparts unpalatable flavor to food
fish, or result in noticeable offensive odors in the vicinity of
the water.
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FIGURE
APPROVED OHIO RIVER WATER
CLASSIFICATION FOR THE
McALPINE POOL REACH.
FOURTEEN MILE
CREEK
(RM 589-3)
MADISON HWY,
BRIDGE
(RM 557. 2)
McALPiNE DAM
(RM 604.4)
BEARGRASS
CREEK
(RM 602-0)
MARKLAND DAM
(RM 531.7)
A
B
C
D
E
Key to Stream
Classif i cation
Public voter supply
Recreation
Aquatic life
Industrial water supply
Agriculture
x Scheduled for upgrading to recreation clcss ication in July 1974
xx All waters which are now used ci win be used in the future
for public or industrial wafer suoply rr\v.; ,n e et the criteria
established for those uses.
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STUDY METHODS
GENERAL
The study area was limited to the reach of the Ohio River
between River Mile 600.6 (Louisville, Kentucky) and River Mile 530.6
(lower end of Markland Pool adjacent to Craigs Creek). All waste
sources sampled on the Indiana side of the river were sampled by
personnel of the EPA, Region V, Indiana District Office, with the
assistance of personnel of EPA, Region IV, Surveillance and Analysis
Division. These samples were analyzed at the Evansville field station
laboratory. All other waste source and stream samples were analyzed
by Region IV personnel at the field laboratory located at the Louisville-
Jefferson County, Fort Southworth Sewage Treatment Plant or at the EPA
Laboratory in Athens, Georgia.
MUNICIPAL WASTE
One daily effluent composite sample was collected from each of
the municipal waste treatment plants discharging into McAlpine Pool.
The Madison, Indiana STP was the only facility where influent samples
were collected. Samples were collected and composited at hourly or
half-hour intervals with EPA automatic sampling equipment. Additional
samples requiring special preservation techniques and bacteriological
samples were collected as grab samples. All sources except the
Louisville Hite Creek STP were sampled prior to post chlorination.
Bacteriological samples, however, were collected after chlorination
if chlorination was provided. Flows were determined by in-plant
flow measuring devices or plant records. Appendix A lists the types
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22
of samples collected and the analyses performed.
INDUSTRIAL WASTE
Two daily composite samples were taken with EPA automatic
samplers from each industrial waste source discharging into the
McAlpine Pool. One grab sample was taken during each 24-hour period
for those parameters requiring special preservation. One or more
bacteriological grab sample was collected from each source. Flow
measurements were supplied by the companies based on direct measure-
ments or water usage. Appendix A lists the types of samples collected
and analyses performed.
WATER QUALITY STUDIES
Samples were collected at 17 Ohio River and tributary sampling
stations located upstream and downstream from waste sources, major
tributaries, and at intermediate river locations. Seventeen stations
were sampled at mid-channel for five consecutive days. Some cross-
sectional samples were taken below waste sources and major tributaries
to determine the amount of lateral mixing. The criteria for sampling
depth, station identification and utilization for each station are
contained in Appendix A.
For quarter point samples, each individual sample was analyzed
for dissolved oxygen, temperature and pH. For selected stations,
each quarter point sample was also analyzed for 5-day biochemical
oxygen demand, turbidity, acidity, alkalinity, nitrogen series
(NH3, N02 + N02, TKN), phosphorus (total and soluble), and specific
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23
conductance. At other stations, samples were composited across the
quarter point cross-section as outlined in Appendix A.
All stream samples analyzed for coliform bacteria were collected
immediately below the surface (approximately one foot) using a grab
technique. When quarter point bacteriological samples were collected,
individual samples were returned to the field laboratory. Any com-
positing was done by laboratory personnel using sterile glassware.
Salmonella samples were collected by suspending swabs in the river
at selected sites for two to three days. When the swabs were retrieved,
they were promptly placed in nutrient broth and analyzed for Salmonella.
Field laboratory analysis of all samples was initiated within
six to eight hours of collection. Samples for later analysis at the
Athens, Georgia, laboratory were preserved within these time limits.
Chemical and bacteriological methods used during this study are con-
tained in Appendix B.
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STUDY FINDINGS
WASTE SOURCES
Four industrial and ten municipal or domestic waste discharges
into McAlpine Pool were investigated. Other sources discharging into
the headwaters of tributary streams were not sampled since they have
very little effect upon the study objectives. Only effluent (except
Madison STP) samples were collected and no attempt was made to assess
treatment efficiencies. The locations of waste sources are shown in
Figure 1 with sample station descriptions in Appendix A. A summary
of waste source data is contained in Table IV with a complete data
summary in Appendix C. Individual waste sources are discussed in
detail.
Oak Park Conservancy District, Indiana
The Oak Park Conservancy District STP serves a residential
community of the Louisville metropolitan area. The primary treatment
plant receives an estimated flow of 230,000 gallons per day from
1,063 family units, one general store, and two service stations.
After treatment in the spiral digester (modified Imhoff Tank), the
waste is chlorinated (Figure 4) and discharged to a small unnamed
tributary which flows into the Ohio River at RM 597.6. Construction
is essentially complete on two contact stabilization units (Figure 4).
When placed in operation, the units designed to operate in parallel
should provide adequate secondary treatment for the waste.
One 24-hour composite sample was collected from the influent
of the chlorine contact chamber. Three samples for bacterial
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27
Figure 4
Old Spiral Digester Primary Unit now in Operation at
the Oak Park Conservancy District STP
One of the Two New Secondary Units Nearing Completion
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28
analysis were collected from the plant effluent. Suspended solids
and BOD5 were high at 130 mg/1 (244 Ibs/day) and 175 mg/1 (328
Ibs/day), respectively. Also, chlorination was ineffective with
total coliform densities of 16,000,000, 12,000,000, and 27,000,000/
100 ml observed in the three samples collected.
At the time of the 1972 study, the quality of the effluent was
unsatisfactory; however, the new treatment facility now under con-
struction should correct this situation. Federal, state and ORSANCO
compliance schedules require:
Completion of plans by 07/72
Start construction by 01/73
Complete construction by 12/73
The community is proceeding well ahead of schedule.
Char 1 est own, Ind iana
The city of Charlestown, with a population of 5,890, is served
by a primary treatment facility consisting of sedimentation, sludge
lagoon and chlorination (Figure 5). The average flow is 400,000
mgd. The treated waste is pumped through a three-mile force main
to the Ohio River at Mile 590.5.
A 24-hour composite sample was collected at the Parshall flume
used to measure plant discharge. The BOD5 concentration was 170
mg/1 (567 Ibs/day) and suspended solids were 60 mg/1 (200 Ibs/day) .
Bacterial samples were not collected since the force main is used
for chlorine contact and the discharge point was not readily accessible.
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29
FIGURE 5
Settling Tank and Sludge Pond at Charlestown, IN, STP
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30
Needs for Improvements and upgrading the treatment system have
been Identified. Federal, state, and ORSANCO compliance schedules
require completion of plans by 07/72 and the start of construction
by 12/72 with completion by 12/73. Final plans were submitted to the
state on 9/16/72.
Hanover, Indiana
The city of Hanover, Indiana, and Hanover College are served by
a new contact stabilization treatment facility designed for 500,000
gpd (Figure 6), but operating considerably under capacity at approx-
imately 100,000 gpd. The treated waste is chlorinated and discharged
via force main to the Ohio River near Mile 562.6.
One 24-hour composite sample was collected from the sedimentation
tank just prior to the overflow weir. Two bacteriological samples
were collected from a manhole in the discharge line after chlorination
BOD5 concentrations were 93 mg/1 (85 Ibs/day), and suspended solids
were 215 mg/1 (192 Ibs/day). These values are five to ten times
higher than would normally be expected from a plant of this type.
It must be assumed that the system was upset and that this sample was
not representative of the normal plant effluent. Total coliform con-
centrations of <100 and <1,000 per 100 ml were determined on two
effluent samples with measured chlorine residuals of 1.0 and 0.85 ppm.
Although treatment during the survey was inadequate, no addi-
tional treatment needs have been specified. The system is in com-
pliance with the implementation schedule.
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31
FIGURE 6
Secondary STP at Hanover, IN
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32
Mad iso n. Ind iana
Madison, Indiana, has a population of 13,081 and is served by
a primary sewage treatment plant which discharges into the Ohio River
at Mile 558.8 (Figure 7). Besides domestic waste, the 1,750,000 gpd
discharged from the facility contains waste from several small indus-
tries including a meat packing plant, an electroplating plant, a
shoe liner plant, a musical organ plant, and other minor industrial
discharges. The industrial waste accounts for approximately 20 per-
cent of the total flow.
Two 20-hour composite samples were collected from the chlorine
contact chamber discharge. The chlorine residual at this point was
zero when bacterial samples were collected on two different occasions.
Total coliform concentrations in the effluent were 86,000,000 and
7,300,000 per 100 ml. The plant operator stated that the chlorinator
did not have sufficient capacity to maintain a chlorine residual in
the plant effluent. The present dosage and existing chlorinator
capacity is 131 Ibs/day. BOD5 concentrations averaged 215 mg/1 (3,140
Ibs/day), suspended solids averaged 190 mg/1 (2,770 Ibs/day), total
chromium averaged 615 ug/1 (9 Ibs/day), total copper averaged 125
. ug/1 (1.8 Ibs/day), and mercury levels of 2.9 yg/1 (0.04 Ib/day) were
observed in the plant influent.
The plant effluent constitutes the largest single waste load to
the study reach of the Ohio River. It accounts for approximately 43
percent of the combined BOD5 load from waste sources surveyed. Metals
discharged from this plant are excessive and high coliform levels in
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33
FIGURE 7
Settling Tanks at Madison, IN, Primary STP. Indiana-
Kentucky Power Corp. Clifty Creek Plant in Background
Digester and Chlorine Contact Tank at the Madison STP,
The Underground Discharge is in Approximate Center of
the Picture
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34
the river below this plant discharge violate water quality
standards.
The city of Madison has been directed to upgrade the treatment
facility to provide secondary treatment. The federal and state com-
pliance schedule requires completion of plans by 06/71, start con-
struction by 12/71 and complete construction by 12/72. ORSANCO
requires a construction completion date of 12/73. Final plans were
accepted by the state on 04/72. Madison is ranked 88th on the 1973
priority list for federal grants. At the present time, the city has
indicated that no contract will be awarded until grant funds are
received. ORSANCO is pursuing enforcemement action.
V evay, Ind iana
The town of Vevay, Indiana, with a population of 1,463, is served
by an extended aeration system similar to the Hanover system shown in
Figure 6. After treatment, the 120,000 gpd average flow is chlori-
nated and discharged to the Ohio River near Mile 538. The only known
industry connection is a small shoe factory.
An 18-hour composite sample was collected at the overflow weir
from the settling unit. The effluent 6005 was less than 5 mg/1 (5
Ibs/day). Samples collected after chlorination had a total coliform
bacteria concentration of less than 1,000 per 100 ml.
No additional treatment needs have been identified and the.
system is in compliance with federal and state requirements.
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35
Carrollton, Kentucky
Carrollton, with, a population of 3,218, is served by a primary
sewage treatment system consisting of sedimentation and sludge di-
gestion (Figure 8). Waste flows average 275,000 gpd and contain
very little industrial waste. The unchlorinated effluent is dis-
charged to the Kentucky River at Mile 0.7.
A 24-hour composite sample was collected from the settling tank
at the overflow weir. The effluent 6005 concentration was 205 mg/1
(468 Ibs/day) and the suspended solids concentration was 66 mg/1
(151 Ibs/day) and the total coliform density in the effluent was
55,000,000 per 100 ml.
The federal and state compliance schedule requires that plans
for a secondary treatment facility be initiated by 2/71 and completed
by 9/72. The schedule requires construction to start by 6/73 and be
completed by 7/74.
As of April 1973, engineering plans were reported to be 90-95%
complete. A few more soil tests were needed to determine if pilings
were needed for the foundation. Completion of these plans was
anticipated with an additional 30 to 60 days.
Louisville. Kentucky - Kite Creek Plant
The Kite Creek sewage treatment plant is operated by the
Louisville and Jefferson County Metropolitan Sewer District. The
plant serves the Ford Motor Company Truck Assembly Plant as well as
the residential area in the plant vicinity. Approximately 80 per-
cent of the average daily waste flow of 1.5 mgd comes from the Ford
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36
FIGURE 8
Settling Tank at Carrollton, KY, Primary STP
Digester and Control Building at Carrollton STP
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37
Plant. The remaining 20 percent is from the surrounding residential
areas. Weekend flows, when the plant is not in operation, are ap-
proximately 0.3 mgd. The tertiary treatment facility consists of
an activated sludge secondary system followed by mixed bed filters
and chloriiiation.
The 24-hour composite sample had a BOD5 concentration of 12.6
mg/1 (159 Ibs/day) and a suspended solids concentration of 6 mg/1
(75 Ibs/day). Regular analysis performed by the Louisville-
Jefferson County Metropolitan Sewer District indicates that effluent
BODs's are normally in the 2-5 mg/1 range. Metal concentrations in
the composite sample (listed below) were low.
Element Concentration (yg/1)
• Chromium (total) <100
• Tin <1,500
• Copper 40
• Zinc 180
• Lead <100
• Cadmium 25
Dow Corning Corporation, Carrollton, Kentucky
Dow Corning Corporation produces a variety of silicone products
for industrial and domestic use. Silicones are used in mold-release
agents, rubber products, laminates, encapsulating resins, anti-
foaming agents, and water-resistant uses.( 2)
The 5.75 mgd average flow from five processing units is collected
in equalization ponds, settled, neutralized, coagulated, and discharged
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38
through an underground sewer system to the Ohio River (Figure 9).
Domestic waste from approximately 100 employees is treated in a
package treatment plant and combined with the process waste before
discharge to the river. The effluent is continuously monitored for
pH, temperature, and flow. Vacuum filters are used for sludge thick-
ening and the sludge is deposited in a land disposal area.
The combined wastewater discharge from the plant was sampled
for two consecutive 24-hour periods using automatic compositing
samplers. The average daily waste flows during this period were
determined from company flow measuring equipment to be 4,000 gpm.
The waste was an almost neutral (pH 7.4), ambient temperature (22.5°C)
discharge with low nutrient concentrations. Five-day BOD concentra-
tions averaged 3.7 mg/1 (178 Ibs/day), total nitrogen concentrations
averaged 2.7 mg/1 as N and phosphorus concentrations did not exceed
0.01 mg/1. Residue samples indicated that the waste is well settled
with an average total residue concentration of 1,924 mg/1 and a non-
filterable residue concentration of 5 mg/1. Metal concentrations
were low:
Element Concentration (ug/1)
• Chromium (total) <100
• Tin <1,500
• Copper 48
• Zinc 12
• Lead <100
• Cadmium <25
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FIGURE 9
39
Broken Discharge Flume from Kawneer, Inc., of Carrollton,
KY, at the Ohio River Edge
The Discharge from Dow Corning of Carrollton, KY, Flowing
into the Ohio River
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40
Bacteriological analysis indicated very low concentrations of total
and fecal coliform bacteria with, all results less than. 4 per 100 ml.
Two organic compounds were detected in the effluent. One,
decamethylcyclopentasiloxane, was positively identified at a concen-
tration of 0.023 mg/1. Another actomethylcyclopentasiloxane apparently
was present, hut no standard was available for verification. The low
COD and TOG values found in the waste correspond to the small number
of organic compounds found and low concentrations of each.
M & T Chemicals, Inc., Carrollton, Kentucky
M & T Chemicals, Inc., a subsidiary of American Can Company, is
the world's leading manufacturer of tin chemicals. The facility at
Carrollton produces a variety of industrial organo-tin chemicals.
These chemicals have a wide range of use including additives of PVC
and vinyl products, algicides and fungicides. Products produced for
use in PVC bottles, and films and sheets used in food containers are
sanctioned by the U. S. Food and Drug Administration.—'
The 4.8 mgd of process wastes are collected and neutralized in
sumps, flocculants are added and the waste is settled through a
series of ponds, with the treated effluent discharged to the Ohio
River at Mile 543.5 through an underground sewer (Figure 10).
Two samples, a 24-hour composite the first day and a grab the
following day, were collected from the. plant effluent. The average
daily flow of 2,260 gpm had the following concentrations:
I/ M & T Chemicals, Inc. information pamphlet.
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FIGURE 10
41
Waste Discharge from M&T Chemicals, Inc. Entering the Ohio
River. The Unstable Shoreline has Eroded
»l
A Closer View of the Eroded Sand and Gravel Shoreline
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42
• pH - 7.6
• Temperature - 20°C
• BODs - 87.5 mg/1
• TKN - 36 rag/1
• NH3 - 33 mg/1
• N02 + N03 - 1.1 mg/1
• Phosphorus - 0.68 mg/1
• Total Residue - 1,904 mg/1
• COD - 156 mg/1
• TOC - 34 mg/1
This waste source contributed an average of 2,370 Ibs/day of BOD5
or approximately 32 percent of the total measured waste load from all
sources. The ammonia load in the waste of 900 Ibs/day also represents
a large oxygen demand. The relatively low concentration of nonfilter-
able solids (20 mg/1) indicate that the waste is well settled. Metal
concentrations in the effluent are low with the exception of tin,
which averaged 3,175 yg/1.
Element Concentration (yg/1)
• Chromium (total) <100
• Tin 3,175
• Copper 40
• Zinc 20
• Lead <100
• Cadmium <25
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43
Tin, in low concentrations, improves aquatic growth and is not
toxic to humans in drinking water. CL) Therefore, tin in this dis-
charge should have no serious adverse effect upon water quality..
The total and fecal coliform concentrations were 1,263 and 4 per
100 ml, respectively.
Organic analysis revealed that the following compounds were
being discharged to the Ohio River:
mg/1 Ibs/day
• tri-n-butyl-phosphine oxide <0.1 —
• tri-butyl-phosphine oxide <0.2
• M-xylene 0.15 6.0
• 0-xylene 0.09 3.6
o 0-cresol 0.13 5.2
Xylene is reported to be toxic and causes taste and odor in water at
a concentration of 0.3 to 1.0 mg/1. Since xylene is insoluble in
water, the concentration found in the effluent indicates that M & T
Chemicals is losing considerable amounts of the chemical.
Kawneer Company, Inc., Carrollton, Kentucky
The Kawneer Company, Inc., is engaged in anodizing, rolling,
forming and finishing aluminum trim. The trim material is used
primarily in the electric appliance industry and consists of face
plates and other thin metal parts requiring special decorative
finishes.
An average of 400,000 gpd of waste including treated domestic
waste (septic tanks) from 200 shift workers, is discharged from the
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44
plant via an underground sewer to the Ohio River near Mile 554.7
(Figure 9). Plant operations are designed for maximum reuse of
water. The spent phosphoric/nitric acid solution from the anodizing
tanks is stored and resold to the supplier for use in fertilizer.
After dipping in the acid tanks, the metal passes to rinse tanks
which utilize recycled cooling water. Wastewater discharged from
the process is monitored for pH.
Composite samples were collected from the plant discharge on two
consecutive days. Chemical samples were collected before the domestic
waste enters the waste stream. Bacteriological samples were collected
on the combined waste where the waste enters the Ohio River. Average
daily waste flows based on water usage averaged 278 gpm. The indus-
trial waste contained :
• BOD5 - 3.8 mg/1
• NH3 - 0.08 mg/1
• Total N - 8.1 mg/1
• Total Phosphorus - 6.7 mg/1
• COD - 4.2 mg/1
• Total Residue - 561 mg/1
• Nonfilterable Residue - 26 mg/1
• Total Coliform - >1,600/100 ml
• Fecal Coliform - >800/100 ml
The waste contribution from this company is small. The BOD^
load of 13 Ibs/day amounts to 0.2 percent of the total waste load
measured from all study area sources. However, total coliform
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45
concentrations exceeding 1,600 per 100 ml were higher than
anticipated and indicate that some improvement may be needed in
the domestic waste treatment. Metal concentrations were low in
the effluent and are listed below:
Element Concentrations (yg/1)
• Chromium (total) <100
• Tin <1,500
• Copper 68
• Zinc 22
• Lead <100
• Cadmium <25
Indiana Army Ammunition Plant
The Indiana Army Ammunition Plant (IAAP), located near Charlestown,
Indiana, is operated under Government contract by Imperial Chemical
Industries of America, Inc. (ICI). Under the direction of the U. S.
Army, cannon and mortar propellants are loaded and single base pro-
pellants are manufactured. The facility has previously operated
with an employment of approximately 19 ,000 but is now down to near
4,500. A major portion of the 1,390 buildings are standing idle.
During the recent survey, the workers were out on strike and the
operation was shut down, making it impossible to collect waste samples.
A brief visit was made to the plant during normal operations in
August 1972 in preparation for the survey; however, no waste samples
were collected.
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46
The main potential source of industrial wastes is the
Propellant Manufacturing plant. When this plant is operating, acid
wastes from the manufacture of nitric and sulfuric acids are dis-
charged to the Jenny Lind Flume in addition to organic wastes from
the nitrocellulose line. These organic wastes include nitrocellulose,
ether, alcohol, hutylthalate, diphenyl, and a few others.
Three sources of domestic waste discharge from the site total
approximately 350,000 gpd. Approximately 250,000 gpd of this waste
is treated in a secondary treatment facility, chlorinated, and dis-
charged to the Ohio River at Mile 593.4. Eighty thousand gpd are
provided primary treatment, chlorinated, and discharged to a large
reservoir which overflows via a small stream into the Ohio River at
Mile 591.5. Secondary treatment facilities are now under contract.
The remaining estimated 16,000 gpd is overflow from septic tanks
serving 49 military housing units (160 persons). Overflow from these
units is discharged directly to the Ohio River near Mile 592.8.
Design funds and construction funds were requested in FY 71 and
FY 72, respectively, for two new package aeration treatment plants.
A trip report prepared hy the EPA, Region V, Federal Facilities
Office, resulting from a plant visit on September 30, 1971, is con-
tained in Appendix D. The report outlines in detail waste treatment
facilities and practices, proposed improvements and makes recommen-
dations for additional improvements.
Indiana-Kentucky Electric Corporation, Madison, Indiana
The Clifty Creek power plant, located about one mile west of
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47
Madison, Indiana, on the north bank of the Ohio River, produces
approximately 31 million KKH of electricity per day.
No wastewater samples were collected during the recent survey;
however, a visit to the plant was made. The main discharge is
960,000 gallons per minute of once-through, cooling water that exper-
iences a 11°F temperature rise through the system., Periodically
(twice per day in summer) , the cooling water system is chlorinated
for a 30-minute duration for algae control, producing 0.35 ppm chlorine
in the effluent during these periods. The company also has a fly ash
pond with an average inflow of 6,800 gpm (Figure 11). Water in the
lower end of this pond is very clear and appears to be extremely well
settled. Two bottom ash ponds have inflows of 2,190 gpm and 1,100
gpm. The domestic waste from the 325 employees is treated in an
extended aeration plant and chlorinated before discharge to the
r iver.
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48
FIGURE 11
Fly Ash Pond at the Indiana-Kentucky Power Corp. Cllfty
Creek Plant
Another View of the Fly Ash Pond Showing the Sediment
Deposit to the far Background of the Picture
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49
OHIO RIVER WATER QUALITY
This section contains a discussion of physical, chemical, and
microbiological data collected on the Ohio River and tributaries
during the five-day study in September 1972. A complete tabulation
of the data is contained in Appendix C.
FLOW
The Ohio River average daily flow at McAlpine Dam for 41 years
of record is 110,700 cfs. Flows during the five-day survey from
September 19-23 were 27,200; 28,100; 19,200; 33,200; and 44,600 cfs-/
respectively. These flows, which averaged 30,460 cfs, are well
below the average daily discharge for the year but about normal for
expected September flows.
TEMPERATURE
Ohio River water temperatures ranged from 24°C to 27 C with a
noticeable and consistent cooling of water temperatures occurring
during the study. No significant temperature variations were ob-
served below any waste discharges or in the lateral or vertical
cross-sections of the river. No measurable temperature change was
observed from above (Station 561.0) to below (Station 566.3) the
Indiana-Kentucky Clifty Creek Power Plant. The power company dis-
charges approximately 960,000 gpm of cooling water with an 11°F
temperature rise which would amount to a calculated 0,42°F river
I/ Flow data supplied by the U. S. Army Corps of Engineers,
Louisville, Kentucky.
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50
temperature increase based on a river flow of 30,000 cfs and fully
mixed. No variation was observed during the survey since the dial
thermometers used were sensitive only to +_ 0,5°C. Temperatures in
the Kentucky River ranged Between 24°C and 26°C.
DISSOLVED OXYGEN
Dissolved oxygen (DO) concentrations in the study reach of the
Ohio River ranged from 4.0 mg/1 to 6.6 mg/1. The lowest observed
DO was 4.0 mg/1 recorded on September 19 at RM 547.9, downstream
from the confluence of the Kentucky River, the three industrial
waste sources in Carrollton, Kentucky, and the Carrollton sewage
treatment plant effluent. Dissolved oxygen concentrations in the
Kentucky River (Station K-1.4) upstream from the Carrollton STP
effluent averaged 6.3 mg/1. Of the 176 DO observations taken from
mid-channel in the Ohio River, 27 observations or 15.3 percent were
below 5.0 mg/1. Of the 66 mid-channel observations at the five-foot
depth, eight observations or 12.1 percent were less than 5.0 mg/1.
Minimum dissolved oxygen concentrations permitted by the
Indiana and Kentucky water quality standards for "aquatic life" are
4 mg/1 with a daily average of not less than 5 mg/1. No instantaneous
DO concentrations less than 4.0 mg/1 were observed in the study
reach. Although daily averages were not determined (daily grab
samples were taken at each station), a probability of violation is
suggested at most of the nine stations where individual grab samples
of less than 5.0 mg/1 were observed (minimum DO values plotted on
Figure 12).
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51
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-------
52
Slight vertical and horizontal stratification was observed
within the study reach. Vertically, oxygen concentrations at the
five-foot depth, generally averaged 0.1 to 0.2 mg/1 higher than con-
centrations one foot from the bottom; however, at Station 600..6, the
DO observations at the five-foot and one-foot above the bottom levels
averaged exactly the same. Horizontal stratification was present
from Markland Dam down to the Carrollton area, where DO concentra-
tions were higher on the Kentucky side. These higher values prob-
ably resulted because releases from the tainter gates and locks at
Markland Dam receive different amounts of reaeration than water
passing through the generators. Variations in concentrations up to
1.1 mg/1 were observed at Station 533.8 between the quarter points.
Data collected at Station 530.0 did not show this variation; how-
ever, the water containing higher dissolved oxygen probably passed
between the quarter point and the Kentucky shore.
Oxygen levels entering the McAlpine Pool from Markland Dam were
depressed, averaging 5.0 mg/1. The level increased downstream for
the next 25 miles due to atmospheric reaeration. After reaching an
average concentration of 5.9 mg/1, the DO levels fall off steadily
downstream to McAlpine Dam. Oxygen levels in the Kentucky River
above the Carrollton waste discharge averaged 6.1 mg/1, which is
0.7 mg/1 higher than the Ohio River Immediately above the confluence.
Due to the high dilution ratio, no Increase in DO was observed below
the confluence. Figure 13 presents a graphical plot of changing
river cross-sectional area, calculated velocities and reaeration
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52a
u.
-' 70,000
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< 50,000
30.00O
O
10,000
FIGURE 13
OHIO RIVER (McALPINE POOL) STUDY
RIVER X-SECTIONAL AREA, VOLOCITY 8 K2 RATE
NOVEMBER 1972
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53
coefficients. Cross-sections were furnished by the U. S. Army Corps
of Engineers. Velocities were calculated as average velocities
through the cross-sectional area (i.e., V=Q/A) and reaeration rates
were calculated using the Churchill Method.(3) The cross-sectional
area of McAlpine Pool increases from approximately 20,000 ft below
Markland Dam to 60,000 ft2 near McAlpine Dam. The velocity and re-
aeration rate vary inversely with area as shown in Figure 14. The
high reaeration rate in the upper 20 miles of the study reach cor-
responds very closely to the break in the DO profile. Thus, in the
upper reach of McAlpine Pool, the atmospheric reaeration rate exceeds
the oxygen uptake and, as the velocity decreases with increasing
cross-sectional area downstream, a decrease of reaeration rate takes
place. Average time of travel through the reservoir was calculated
using the cross sectional areas and river flow rates of 30,000 cfs
and 13,000 cfs. The resulting times were 5.98 days at a flow rate
of 30,000 cfs and 13.80 days at a rate of 13,000 cfs.
BIOCHEMICAL OXYGEN DEMAND
A plot of average BOD5 values show a gradual decrease in con-
centration as the river flows through the study reach (Figure 12).
The high BOD^ near Markland Dam (2.2 mg/1 average) and the general
decline in concentration through the study reach to an average of
1.2 mg/1 at the Louisville water intake indicates that the stream is
recovering from upstream (Cincinnati area) waste loads., Observed
values ranged from 3.7 mg/1 recorded on September 22 at Station
0-547.9 to a low of 0.9 mg/1 at Station 0-574.0 on September 23.
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54
The 3.7 mg/1 concentration could reasonably be omitted since it
is nearly double the quarter point readings taken at the same time
as well as all other observations in the study reach., If this value
is omitted, the average BOD5 plot will appear as the. dotted line in
Figure 13 and the maximum value observed at this station is 2.2 mg/1.
BOD5 levels at Station K-1.4 (Kentucky River) averaged 1.5 mg/1.
This compares to 1.8 mg/1 in the Ohio River immediately above the
confluence.
Table V contains a listing of the major dischargers to McAlpine
Pool, their BOD5 loadings and relative contribution as a percentage
of the total waste load. Discharges from the Madison, Indiana STP
and the M & T Chemicals Plant in Carrollton, Kentucky, account for
over 75 percent of the measured BOD5 discharged into the river.
It is practically impossible to measure the singular effects of
any one of the relatively small BOD5 loads on the river. BOD5 waste
load discharged into the study reach are insignificant in comparison
with discharges to other reaches of the Ohio River such as the
Cincinnati and Louisville areas. The combined waste load of 7,350
pounds per day (population equivalent = 43,200) cannot have a very
substantial effect upon the Ohio River at the flow rates encountered
during the study. These loads, although small, do retard recovery of
the river which, in this reach, is recovering from the Cincinnati
area waste load.
TOTAL ORGANIC CARBON
All TOC concentrations for Ohio River stations fell within the
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55
TABLE V
BOD5 LOADING (LBS/DAY) TO McALPINE POOL
OHIO RIVER (McALPINE POOL) STUDY
SEPTEMBER 1972
Percent
Discharger Lbs/Day of Total
Madison, IN, STP 3,140 42.7
M&T Chemicals, Carrollton, KY 2,370 32.2
Charleston, IN, STP 567 7.7
Carrollton, KY, STP 468 6.4
Oak Park Conservancy District, IN, STP 328 4.5
Dow Corning, Carrollton, KY 178 2.4
Louisville Kite Creek STP 159 2.2
Hanover, IN, STP 78 1.1
Indiana Army Ammunition Plant 35* 0.5
Kawneer, Inc., Carrollton, KY 13 0.2
Vevay, IN, STP 5 0.1
7,341 100.0
* Estimate based on information contained in Appendix D
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56
2.8 to 6.3 mg/1 range. Figure 12 presents a profile of average
observed concentrations.. As would be expected, the TOG profile and
BOD5 profile are similar. In both cases, there is a slight increase
in concentration downstream from the confluence of the Kentucky River.
The two largest sources of TOG discharge in this immediate area are
M & T Chemicals (1,065 Ibs/day) and the Carrollton sewage treatment
plant (243 Ibs/day). The average TOC concentration of the Kentucky
River upstream from the Carrollton STP discharge averaged 4.4 mg/1
or essentially the same as the Ohio River concentrations.
NITROGEN
Total nitrogen concentrations averaged about 2.0 mg/1 for Ohio
River stations. Nitrification was actively underway as evidenced
by the reduced ammonia level from 0.2 mg/1 at the head of the reach
to 0.05 mg/1 near the lower end with a corresponding increase in the
nitrite-nitrate concentration (Figure 14). The nitrogen contribution
from individual waste sources and tributary streams within the study
reach had no measurable effect on nitrogen concentrations in the
river. The Kentucky River station (K-1.4) had an average total
nitrogen concentration of 0.84 mg/l-N.
A comparison of Figures 12 and 14 shows that the change in
ammonia concentrations is very similar to the change in BOD5 concen-
trations and inversely proportional to the nitrite-nitrate concentra-
tions. Thus, ammonia is oxidized to nitrate (nitrification) within
the reach with a corresponding uptake of oxygen. In fact, it appears
that most of the oxygen demand is due to oxidation of ammonia.
-------
57
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It has been shown that approximately 4.6 mg of oxygen are
required to oxidize 1 mg of ammonia to the nitrate form.(6) A 0.16
mg/1 reduction of ammonia was observed through the study reach, which
accounts for a theoretical oxygen, uptake of 0.16 X 4.,6 = 0.74 mg/1.
Therefore, considering the reservoir as a steady state with a five-day
flow through time, calculations show that approximately 0.74 mg/1 of
the measured 0.9 mg/1 of BOD5 can be attributed to nitrification.
PHOSPHORUS
Phosphorus concentrations were essentially constant throughout
the study reach (Figure 15). The maximum Ohio River total phosphorus
concentration was 0.13 mg/1 and the minimum value was 0.08 mg/1.
Approximately 93 percent of the phosphorus was dissolved. The average
concentration in the Kentucky River was 0.09 mg/1.
pH AND ALKALINITY
All pH values were in the 7.0 to 7.5 range, which is well within
the limits established by the state standards. The Indiana standards
specify 6.0 to 9.0 for the aquatic life classification. Average
alkalinities for the Ohio River stations ranged from 52 to 60 mg/1
with no significant trend. Alkalinity values for the station near
the mouth of the Kentucky River were slightly higher at 94 mg/1. The
pH values were also higher at 7.5. This is probably due to extensive
exposed limestone formations in the Kentucky River Valley,
-------
59
SPECIFIC CONDUCTANCE
Specific conductance averaged between 401 and 431 ymhos/cm for
all Ohio River stations.. Values decreased slightly through the reach,
being highest near Markland Dam.
Both the Indiana and Kentucky water quality standards require
that dissolved solids not exceed 500 mg/1 as a monthly average value
nor exceed 750 mg/1 at any time for Ohio River public water supply
use classifications. In lieu of actual dissolved solids measurements,
both states permit the use of specific conductance data— where 800
and 1,200 ymhos/cm are equivalent to dissolved solids concentrations
of 500 mg/1 and 750 mg/1, respectively. Dissolved solids (specific
conductance) limitations for public water supply use were not ex-
ceeded during the study.
TURBIDITY
Turbidities ranged from 3 to 15 Jackson Turbidity Units (JTU)
with average values at Ohio River stations ranging between 4 and 10.
As would be expected, there was a gradual reduction in turbidity
through the McAlpine Pool.
BACTERIOLOGICAL
The background station in the study reach was located upstream
from Markland Dam at River Mile (RM) 530.0 (Figure 1). The bacterial
2 /
quality of the river at this point was characterized by mean— total
JL/ Values referenced to 25°C.
2/ All means are geometric means.
-------
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and fecal collform densities of 980 and 82/100 ml, respectively
(Table VI)
Downstream from Station 530..0, the. first significant source of
bacterial contamination enters the river from the Carrollton, Kentucky
sewage treatment plant (Municipal Station CK — Table VII), discharging
an average of 0.28 mgd to the Kentucky River near the mouth. The mean
effluent total and fecal coliform densities were 81,000,000 and
18,000,000/100 ml, respectively. The effect of the Carrollton STP
discharge on the river was seen in quarter point samples at RM 547.9,
which showed slightly higher mean total and fecal coliform densities
of 3,500 and 200/100 ml (Table VI, Figures 16 and 17). Total and
fecal coliform densities in the Kentucky River upstream from the
Carrollton effluent were 52/100 ml and 14/100 ml, respectively.
Downstream from Carrollton, the next major waste source dis-
charging to the river is the Madison, Indiana STP, which discharged
an average of 1.75 mgd of wastes with mean total and fecal coliform
densities of 25,000,000 and 340,000/100 ml, respectively (Table VII).
The impact of this waste discharge was seen at RM 561.0 (Figures 16
and 17).
At RM 597.6, the Oak Park STP discharged to the river via a small
tributary stream an average of 0.23 mgd of waste with mean total and
fecal coliform densities of 17,000,000 and 850,000/100 ml. As shown
in Figures 16 and 17, there was little effect on the bacterial quality
of the river resulting from this discharge.
-------
62
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The bacterial quality of the river at the most downstream sampling
site in the study reach- at KM 600.6 was characterized by mean total
and fecal coliform densities of 490 and 47/100 ml, respectively-. The
densities at this station, were lower than those observed during a 1971
EPA investigation when the mean total and fecal coliform densities
were 4,500 and 140/100 ml, respectively.,
Salmonella swabs were retrieved from River Mile 530.0, 540.4,
547.9, and 561.0, but no Salmonella were isolated from these samples.
Applying the Kentucky water quality standards to the bacterial
water quality observed during the September 1972 investigation, the
following violations were noted:
• The total coliform portion of the Kentucky standard was
violated between RM 545.0 and 582.7.
• The fecal coliform portion of the Kentucky standard was
violated between RM 561.0 and 566.3.
The Indiana water quality standard for recreational waters was
violated between RM 561.0 and 566.3. These violations result from the
high coliform discharges from the Carrollton, Kentucky, and Madison,
Indiana, sewage treatment plants.
-------
67
REFERENCES
1. J. E. McKee and H. W. Wolf, Water Quality Criteria. Second Edition
(Revised 1963), California State Water Resources Control Board,
Publication No.. 3-A, Sacramento Q.971).
2. R. Norris Shreve, Chemical Process Industries, Third Edition,
Mc-Graw-Hill Book Company, 1967.
3. Tennessee Valley Authority, "The Prediction of Stream Reaeration
Rates," Chattanooga, Tennessee, July 1962.
4. U. S. Department of Health, Education, and Welfare, Public Health
Service, "Ohio River - Cincinnati Pool," Part I - 1957 Survey.
5. U. S. Department of Health, Education, and Welfare, Public Health
Service, "Ohio River - Cincinnati Pool," Part II - 1960 Survey.
6. U. S. Department of Health, Education, and Welfare, Public Health
Service, "Oxygen Relationships in Streams," Robert A. Taft
Sanitary Engineering Center, Cincinnati, 26, Ohio, March 1958.
-------
APPENDIX A
STATION LOCATIONS AND
STUDY PLAN
OHIO RIVER-McALPINE POOL
69
-------
70
OHIO RIVER (McALPINE POOL) STUDY
STATION LOCATIONS
Industrial
DC The effluent from Dow Corning Corporation of Carrollton, Kentucky.
Samples were collected from a manhole in the effluent discharge
pipe between the Company parking lot and Hwy. 42. The discharge
flows into the Ohio River near R.M. 541.0.
M&T The effluent from M&T Chemicals, Inc. of Carrollton, Kentucky.
Samples were collected from the waste discharge pipe on the bank
of the Ohio River. The waste flows into the river near R.M. 543.5.
KG The effluent from Kawneer Co., Inc. of Carrollton, Kentucky. Samples
were collected from the waste sump inside the plant. The waste flows
into the river near R.M. 554.7.
Municipal
CK The effluent from the Carrollton, Kentucky, primary sewage treatment
plant. The waste flows into the Kentucky River at mile 0.7.
LK The effluent from the Louisville Jefferson County Sewer District's
Kite Creek tertiary sewage treatment plant. This waste flows into
Hite Creek tributary to Herrods Creek tributary to the Ohio River
near mile 595.9.
OP* Effluent from the Oak Park Conservency District's primary sewage
treatment plant. The waste flows into a small stream which flows
into the Ohio River near mile 597.6.
CH* Effluent from Charlestown, Indiana, primary sewage treatment plant.
The waste is piped to the Ohio River near R.M. 590.5.
HA* Effluent from the Hanover, Indiana, secondary sewage treatment
plant. The waste is piped to the Ohio River near R.M. 562.6.
MA* Effluent from the Madison, Indiana, primary sewage treatment plant.
The effluent is piped to the Ohio River at R.M. 558.8.
VE* Effluent from the Vevay secondary sewage treatment plant. The
waste flows into the Ohio River near R.M. 538.
Stream
0-530.0 Ohio River 1.5 miles upstream of Markland Lock and Dam.
0-532.3 Ohio River 0.8 mile downstream of Markland Lock and Dam.
-------
71
0-533.8 Ohio River 1.0 mile downstream of Markland Lock and Dam and
adjacent to Lindenburn day mark.
0-540-4 Ohio River 0.6 mile upstream of Dow Corning waste outfall and
adjacent to Minnet run light.
0-542.0 Ohio River upstream of M&T Chemicals and downstream of Dow
Corning waste outfalls.
0-545.0 Ohio River 1.5 miles downstream of M&T Chemicals outfall.
0-547.9 Ohio River 2.2 miles below confluence with the Kentucky River
adjacent to Notch Lick light.
0-555.6 Ohio River 2.2 miles upstream of Madison, Indiana, STP effluent
and 0.9 mile downstream of Kawneer Company outfall. Adjacent
to the Richwood light.
0-561.0 Ohio River 3 miles downstream of the Madison, Indiana, STP
effluent and adjacent to the Clifty Creek light.
0-566.3 Ohio River downstream of Hanover STP and Clifty Creek Power
Company effluents and adjacent to Spring Creek light.
0-574.0 Ohio River adjacent to Bethlehem Reach light.
0-582.7 Ohio River adjacent to Oldham C.ounty's water district municipal
intake.
0-587.7 Ohio River 1.7 miles upstream of Fourteen Mile Creek.
0-595.0 Ohio River below outfalls from the Indiana Army Ammunition
Plant and above the confluence of Harrods Creek.
0-600.6 Ohio River adjacent to the Louisville, Kentucky, municipal
water intake.
K-1.4 Kentucky River upstream of the Carrollton, Kentucky, STP
effluent and 1.4 miles above the confluence of the Ohio River.
H-1.6 Harrods Creek at U.S. Hwy. # 42 bridge 1.6 miles above the mouth.
* Samples analyzed by EPA, Evansville, Indiana, office.
Note: Ohio River mileage and station location descriptions are based on
the Ohio River Navigation Charts produced by the U.S. Army Crops
of Engineers.
-------
72
STUDY PLAN
OHIO RIVER-MCALPINE POOL
OBJECTIVES
• To determine the cause of low dissolved oxygen concentrations
observed in the lower portion of McAlpine Pool during the
August-September 1971 EPA, Region IV, Ohio River Study.
• To characterize the industrial and municipal waste discharges
into the study reach of the Ohio River.
SCOPE
The study area will be limited to the reach of Ohio River between
Louisville, Kentucky (RM 600), and Markland Pool adjacent to Craigs
Creek at RM 530.
AUTHORITY
Authority for the study is granted in the Federal Water Pollution
Control Act as amended. The work will be performed under the direction
and supervision of the Environmental Protection Agency, Surveillance
and Analysis Division, Athens, Georgia.
TIME SCHEDULE
• Field study - September 18-25, 1972
• Complete lab analysis - October 31, 1972
• Finished report - November 30, 1972
GENERAL FIELD ACTIVITIES
The principal effort in this study will be directed toward the
collection of stream quality data. The relatively few sources of
-------
73
municipal and industrial waste discharged into the study reach will
be sampled to determine possible effects upon Ohio River water quality.
The Louisville-Jefferson County Metropolitan District will
provide laboratory space for the study at the Fort Southworth sewage
treatment plant. Samples will be collected, packed in ice, and delivered
to the Fort Southworth lab for a portion of the required analysis. The
samples will be forwarded to the Environmental Protection Agency lab
in Athens, Georgia, for completion of the analysis.
WATER QUALITY STUDIES
Samples will be collected for five consecutive days at the 17
stream sampling stations listed in Table 1. Field analysis will consist
of:
• DO (Field titration)
• pH (Field meter)
• Temperature
Other chemical analyses:
• BOD 5
• Turbidity
• Acidity and Alkalinity
• Nitrogen series (NH3, N02-N03, TKN)
• Phosphorus - Total and Soluble
• Specific Conductance
Bacteriological analyses:
• Total and Fecal Coliform
• Salmonella Isolation
-------
74
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Samples will be collected at the following depths:
• Field Analysis (DO, pH, Temperature)
1) Stream depth <10 feet mid depth.
2) Stream depth 10 to 15 feet - 5 feet from surface
- 1 foot from bottom
3) Stream depth >15 feet - 5 feet from surface
- mid depth
- 1 foot from bottom
• Chemical Analysis - mid depth in stream <10 feet deep and at
5 feet in stream = 10 feet deep.
• Bacteriological - immediately below surface (approximately 1
foot) .
MUNICIPAL WASTE
Samples will be collected at the nine waste treatment facilities
listed in Table 2. Composite samples will be collected proportional
to flow where possible. Grab samples will be collected from the
septic tank overflow. The following analyses will be made:
• Flow (field measurement or plant equipment)
• pH (field meter)
• TOC
• Total Solids
• Nitrogen Series (TKN, NH3, N02-N03)
• Total Phosphorus
-------
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• Total Suspended Solids
• Volatile Suspended Solids
Samples will be collected prior to chlorination with the excep-
tion of bacteriological samples which will be collected after the
chlorine contact chamber where possible.
INDUSTRIAL WASTES
Two 24-hour composite samples will be collected on the industrial
waste discharges listed in Table 3. Flow rates will be determined
by:
• Company flow measuring equipment
• Flow measurement by EPA personnel
• Company water records
• Company estimate
One grab sample for coliform analysis will be collected at each
effluent. Standard analyses will be:
• Temperature (beginning and end of composite)
• pH (beginning and end of composite)
• Alkalinity and Acidity
• BOD5
• COD
• TOC
• Nitrogen Series (TKN, N02-N03,
• Total Phosphorus
• Total Solids
• Suspended Solids
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These additional analyses may be required on industrial samples:
• Metals -- chromium, tin, copper, zinc, lead
• Organics
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• Cyanide
• Detergent
-------
81
APPENDIX A
PERSONNEL ROSTER AND TIME SCHEDULE
OHIO RIVER (MCALPINE POOL) STUDY
Study Director - David W. Hill
Personnel
Project Engineer Charles Sweatt
Microbiologist Herbert Barden
Chemist Tom Bennett
Chemist Aide Tom Sack
Aide Wayne Bent ley
Field Personnel Rod Davis
Hugh Vick
Ray Wilkerson
Eddie Shollenberger
-------
82
TENTATIVE TIME SCHEDULE
No. Samples
Daily Activity chem Bacti
• Drive from Athens to Louisville
9/19 • Make boat run upstream 25 17
• Set up automatic samplers at:
1) Ammunition Plant Primary
2) Ammunition Plant Secondary
3) Ammunition Plant Laundry Waste
Ammunition Plant Septic Tank (Grab) _1 1
26 18
9/20 • Make boat run downstream 25 17
• Collect composite samples 3 3
• Set up automatic samplers at:
1) Oak Park Primary
2) Charlestown Primary
3) Hanover Secondary -- —
28 20
9/21 • Make boat run downstream 25 17
• Collect composite samples 3 3
• Set up automatic samplers at:
1) Dow Corning Corporation
2) M&T Chemicals, Inc. --
3) Kawneer Company, Inc. -- --
28 20
9/22 • Make boat run upstream 25 17
• Collect composite samples 3 3
28 20
9/23 • Make boat run upstream 25 17
• Collect composite samples 3 3
• Set up automatic samplers at:
1) Madison Primary
2) Carrollton Primary
3) Louisville Tertiary -- --
28 20
9/24 • Collect composite samples 3 3
• Collect any missed or lost samples; <6 <6
collect samples on Bear Grass and Goose
Creeks if time permits
<9 <9
-------
83
APPENDIX B
CHEMICAL AND BACTERIOLOGICAL METHODS
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87
BACTERIOLOGICAL METHODS
Total Coliform Enumeration; The membrane filter procedure out-
lined in Standard Methods (1) was used. The method employs M-Endo
Broth with an incubation at 35 + 0.5°C for 22-24 hours.
Fecal Coliform Enumeration; The membrane filter procedure out-
lined in Standard Methods (1) was used. The method employs M-FC
Broth with an incubation temperature of 44.5 +_ 0.2°C for 24 hours.
Salmonella Isolation and Identification: Swabs used for isola-
tion purposes were placed into wide-mouthed jars containing approxi-
mately 200 ml of 1-1/2 strength Tetrathionate Broth with brilliant
green added (1:100,000 w/v). The inoculated enrichment was incubated
for 24-48 hours at 41.5°C according to the procedure of Spino (2).
Some of the primary enrichments were subcultured again to Tetrathionate
Broth with brilliant green for 18-24 hours at 41.5°C.
After either primary or subculture enrichment, an inoculum from
each enrichment was streaked onto Hekton Enteric Agar and Xylose-
Lysine-Desoxycholate Agar (XLD) and incubated for 18-24 hours at
35 +_ 0.5°C. Suspect Salmonella colonies were picked from the
respected plates and subjected to the identification scheme outlined
in Table I.
The methods and media outlined in Table I are described by
Ewing (3) with the exception of the cytochrome oxidase procedure.
Oxidase was determined using Patho-Tec-CO— reagent impregnated
paper strips.
JL/ Does not imply endorsement of this product
-------
TABLE B-4
IDENTIFICATION SCHEME FOR SALMONELLA SUSPECTS
Suspect colony
Lysme Iron Agor (LIA)
i I
Alkaline slant and alkaline or Acid slant and butt; Alkaline
neutral butt with or without H2S slant and acid butt-DISCARD
Urease Production
I 1
Positive Negative
DISCARD I
Cytochrome Oxidase
Positive Negative
DISCARD I
Lactose,Sodium Maionate, Indole
Positive Negative
DISCARD I
Lysme decarboxylOM, Citrate, Motility, HZS
Positive Negative
| DISCARD
Poly Q" Antisera
Positive Negative
I DISCARD
Complete Serological Identification
I
Confirmation of identification by National
Center For Disease Control
-------
89
REFERENCES
1. American Public Health Association, Standard Methods for the
Examination of Water and Wastewater, 13th Edition, 1971.
2. Spino, D. V., "Elevated-temperature Technique for the Isolation
of Salmonella from Streams," Appl. Microbiol., 14, No. 4, 1966.
3. Ewing, W. H., "Enterobacteriaceae, Biochemical Methods for Group
Differentiation," Public Health Service Publication No. 734,
Revised 1962.
-------
91
APPENDIX C
STREAM AND WASTE QUALITY DATA
-------
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121
APPENDIX D
REGION V REPORT ON
INDIANA ARMY AMMUNITION PLANT
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122
REPORT ON WASTE DISPOSAL FACILITIES
AT FEDERAL INSTALLATIONS
DEPARTMENT OF THE ARMY
INDIANA ARMY AMMUNITION PLANT
DATE OF REPORT: January 6, 1972
ENVIRONMENTAL PROTECTION AGENCY
REGION V
1 NORTH WACKER DRIVE
CHICAGO, ILLINOIS 60606
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A visit was made to the Indiana Army Ammunition Plant,
Charlestown, Indiana, on September 30, 1971, by Messrs. Harry
Maroney, and Irving Bernstein, of the U. S. Environmental Protection
Agency, Region V, Chicago, Illinois, to inspect previously recom-
mended improvements contained in "Report on Waste Disposal Practices
at Indiana Army Ammunition Plant", dated May 1, 1969, conducted by
the Federal Water Pollution Control Administration, Ohio Basin Region,
and to observe current operations. The following persons were in
attendance:
1. Indiana Army Ammunition Plant:
Lt. Col. W. F. Crews Commanding Officer
Mr. Maurice Mennen Executive Assistant
Mr. W. W. Struck Operations Review
Mr. T. R. Owen Industrial Specialist
2, Olin Inc.
Mr. B. C. Baldridge Resident Manager
Mr, W, Rice Director, Engineering
Mr. E. L. Allen Engineer
Mr. H. D. Foster Engineer
I. General Description;
The Indiana Army Ammunition Plant is located in Clark County,
Indiana, approximately 1/4 mile south of Charlestown. The instal-
lation consists of 1,390 buildings located on approximately 10,600
acres, the terrain being flat to slightly rolling, and situated on
bluffs above the Ohio River. The major portion of the drainage
flows to three minor tributaries of the Ohio River, namely, Jenny
Lind Run, Battle Creek, and Lentzier Creek.
The present population numbers approximately 4,500 employees.
The manufacturing plant has been reduced to five hundred (500)
employees, and the present employment at the loading plant is 4,000.
The population figure includes approximately 60 persons living in
housing areas on the plant site.
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Subject: Report on Waste Disposal Facilities at Indiana
Army Ammunition Plant
The primary mission of IAAP is the manufacture of single base
propellants and the loading of cannon and mortar propellants.
Formerly, Indiana Army Ammunition Plant was operated as two separate
plants, designated as Indiana Ordnance Works (the propellaht manu-
facturing plant), and Hoosier Ordnance Plant (the loading plant).
A. Responsible Agency:
The installation is Government Owned(Army) Contractor Operated,
(Olin Corporation), and is directly under control of the U. S.
Army Ammunition Procurement and Supply Agency, Joliet, Illinois.
B. Dates of Visit:
September 30, October 1, 1971
C. Background Data:
1. Receiving Waters: Industrial wastes are discharged to
Jenny Lind Run, then to the Ohio River. Sanitary wastes are dis-
charged to the Jenny Lind Flume, and then Jenny Lind Run? or to
the Ohio River directly. Storm, waters drain to Jenny Lind Run,
tributary to the Ohio River, or to Lentzier Creek,
2, Waste discharge flows: Present, 333,OQOGPD Sanitary
wastes (253,000 HOP and 80,000 IOW), The average flow of the
industrial waste is approximately 1,287,000 GPD, which includes
an unknown quantity of springwater infiltration. The major
portion of the industrial waste is generated in the HOP production,
since IOW activities have been curtailed.
II. Waste Treatment Facilities and Practices;
A. Separate storm, sanitary and industrial waste sewer
systems are installed.
1. Storm Sewer: Storm water drainage in the IOW area is in
most part from roof surfaces, either directly, or via gutters, and
downspouts, parking areas, surface roads, unimproved land, etc.,
by natural runoff to two parallel 48" diameter storm sewers, then
to the Jenny Lind Run, tributary to the Ohio River, Storm water
drainage in the HOP area is by natural runoff, and a series of
ditches to Lentzier Creek.
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Subject: Report on Waste Disposal Facilities at Indiana
Army Ammunition Plant
2. Sanitary Wastes: All sewage generated at IAAP is treated
at the IOW and HOP sewage treatment plants and numerous septic tank
facilities, as follows:
a. IOW sewage treatment plant. This primary treatment
plant serves the entire propellant manufacturing area and is
currently operating at a reduced level, since the production of
single base propellant has ceased. The plant has been designed
for a population equivalent of 10,000, and the sanitary waste is
generated in the administrative and shop areas.
Performance of all equipment is satisfactory and no appreciable
odor prevailed. The plant consists of the following equipment:
Bar screen, two primary settling tanks with mechanical scrapers,
two anaerobic digesters (one heated with fixed cover, and the
other open), and four sludge drying beds. The plant effluent
flow is monitored by utilizing a flow recorder and V-notch weir,
and is discharged to Jenny Lind Lagoon without benefit of chlorine
contact chamber or plant effluent chlorination. However, the
sewage in the primary tank is dosed with hypochlorite. Jenny Lind
Lagoon is elevated and diked, and the spillover is aerated in
flowing to a lower level lagoon. The two lagoons are known as
Jenny Lind Run, tributary to the Ohio River» The plant effluent
discharged was observed to be clear, colorless,odorless, and
exhibited no signs of floating oil, grease or scum.
A typical plant effluent analysis is listed below:
November 1971
Monthly Average
BOD 7.7 PPM
pH 8.0
Dissolved Oxygen 11.0 PPM*
*Stream Analysis
The BOD concentration of 7.7 PPM is at a minimum of 25% of
that to be expected from a primary treatment plant. The low
concentration could be due to infiltration and dilution of the
waste waters from the vehicle wash rack. The BOD discharged from
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Subject: Report on Waste Disposal Facilities at Indiana
Army Ammunition Plant
the plant is not degrading the waters of the lagoon, since the
dissolved oxygen in the stream approaches saturation.
b. HOP Sewage Treatment Plant. This secondary sewage
treatment plant provides services for the loading area. The plant
was designed for a population equivalent of 9,000, and an average
flow of 1.25 MGD, and consists of a "Bio-Activation Process",
combining a trickling filter and activated sludge treatment.
Components include lift station, comminutor, bar screen, Parshall
flume, two primary tanks, dosing chamber, high rate rotary trick-
ling filter (no mercury seal), aeration tank, intermediate and
final settling tanks, aerobic digester, six (6) sludge drying beds,
three plant effluent pumps, and an eight-inch force main to the
Ohio River. There are two streams of raw sewage influent to the
sewage treatment plant. The one originating in the bag manufacturing
area flows by gravity, and the other is pumped to the sewage treat-
ment plant. The lift station and final settling tanks have by-
passing facilities to the Lenzier Creeks. There is no chlorine
contact chamber. Chlorination is provided in the effluent lift
station wet well and a pipe three miles long is utilized to
obtain the required detention time. The plant effluent discharged
was observed to be clear, colorless, odorless, and exhibited no
signs of floating oil, grease or scum. There is no recording in-
strumentation, Flow is calibrated from the height on V-notch weir.
A typical plant effluent analysis is listed below for
November 1971:
Monthly Average
BOD 2.2 PPM
pH 7.4
Dissolved Oxygen 12.0
The BOD concentration is too low for the degree of treatment provided,
which could signify that infiltration is affecting the results.
c. Septic Tanks: Domestic wastes from the military
housing River Ridge Area (49 houses - 160 persons) are discharged
to three septic tanks. These tanks do not have terminal drain-
fields, and the effluent is discharged directly to the Ohio
River, without disinfection or other treatment. Approximately
100 additional septic tanks exist at Indiana Army Ammunition Plant,
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Subject: Report on Waste Disposal Facilities at Indiana Army
Ammunition Plant
the major portion of which have been replaced by sanitary sewer
connection to the treatment plant.
d. Cafeteria: Currently, the cafeteria cooking facil-
ities are not being utilized. Food is delivered by a Louisville
caterer, and only dishes are washed. Solid wastes are disposed
of in a container and removed and disposed of by the caterer with
his facilities. The building is fitted with grease traps.
e. Automobile Service Station: All crankcase oil from
the servicing operation is recovered and disposed of by sale.
Motor oil is reprocessed.
f. Vehicle Maintenance Area: The locomotive repair
shop, Building 718, has floor drains in the service pits which
lead to the sanitary sewer. The building is equipped with traps
to intercept grease and oil. There are two wash racks in
Building 2552, the effluent from which (emulsified oil and grease)
is also discharged to the sanitary sewer. Traps have been
installed to intercept any oil before discharge to the sewer.
g. Laundry wastes from Building 1021 are discharged to
a baffled settling tank, which overflows into the sanitary sewer
system. The waste contains detergent and some lint.
3. Industrial Wastes:
a. Bag Loading: The bag loading plant (HOP) is currently
active. The operations consist of the fabrication of a cloth bag,
and the loading of mortar and cannon propellant into these bags.
The latter are manufactured from purchased cloth and made to
various bag sizes by sewing machine operators at the plant. Also,
paper tubes are manufactured for the packaging of the propellant
bags, before inserting them into a box for shipment to an ammuni-
tion loading plant. Also, titanium dioxide is purchased and
blended with a wax compound. This material is utilized for gun
tube protection. No appreciable amounts of industrial waste are
generated from the above operations.
b. Propellant Manufacturing: (IOW). The plant is
currently in an inactive status, but when operative, includes
the manufacture of smokeless cannon and mortar propellants and
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Subject: Report on Waste Disposal Facilities at Indiana Army
Ammunition Plant
support acids (nitric and sulfuric), which are as follows:
1. Nitrocellulose is produced by the interaction of wood
pulp and/or cotton linters and nitric acid. In this process
sulfuric acid is used as a dehydrating agent.
2. In the next step, ether and alcohol are used as a drying
agent to remove water from the nitrocellulose. The dry, lumpy
material formed is extruded through a die, forming strands approxi-
mately 4 feet long, which are then cut to grain size about 3/4
inch long.
3. Nitric acid is manufactured by the oxidation of ammonia
gas (AOP process), and sulfuric acid by the burning of sulfur to
sulphur dioxide, and subsequent oxidation to sulfur trioxide in
the presence of a vanadium pentoxide catalyst. The sulfuric
trioxide is collected in water to form sulfuric acid.
The wastes from the propellant lines, and sulfuric and nitric
acid plants are discharged to the industrial waste sewer system,
which leads to the Jenny Lind Flume. The acid wastes include
sulfuric and nitric acids. Other wastes which enter Jenny Lind
Flume include nitrocellulose and other organic materials from
the propellant lines (ether and alcohol, butylthalate, diphenyl,
etc.). Lime is added to both lines for neutralization (controlled
manually), based on pH readings taken near the junction of Jenny
Lind Run and the Ohio River.
c. Cooling towers are used in the loading plant to
condition air. A closed loop system is used with a minimum of
blowdown. Copper piping is used in the system, and consequently
no corrosion inhibitors or fungicides are required.
d. Indiana Army Ammonition Plant has two powerhouses
(in an inactive status) which contain boilers, air compressors
electrical generators and other supporting equipment. Each power-
house is operated in conjunction with a cooling tower and reservoir,
The water reaching the boiler room receives treatment with ferric
sulfate, and the coagulated solids are removed in a precipitator.
The effluent is then discharged to an anthrafelt filter, and then
a clear well. The boiler make up water (clear well effluent)
then receives additional treatment in a zeolite softener,
Backwash from the zeolite softener (calcium and
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Subject: Report on Waste Disposal Facilities at Indiana Army
Ammunition Plant
magnesium chloride) , and anthrafelt filter, precipitator sludge
(ferric hydroxide), coal ash, and boiler blow down are discharged
to a suinp which overflows to the lagoon. There are numerous other
package steam and hot water boiler plants scattered over Indiana
Army Ammunition Plant. The make up water for these boiler plants
is treated with a chelating agent, and receives subsequent condition-
ing in a zeolite softener. The boiler blowdown, and softener
regeneration x^stes are discharged to an impervious clay bottom,
land locked settling basin.
III. Storage of Hazardous Material
There are two 18,000 gallon fuel oil storage tanks which do
not have sufficient diked capacity to contain the full content of
each tank in the event of a major spill. The fuel oil storage tank
farm is also diked. Numerous other oil storage tanks are either
diked or installed underground. The acid tanks (sulfuric, nitric
and mixed acid)are not diked, but any spillage would be discharged
into the process sewer lines, receive subsequent neutralization,
and sulfate precipitation treatment, before discharge to the
receiving streoin. Ether, alcohol, and ammonia tanks are not diked.
There are numerous above ground storage magazines for storage of
loaded propellant bags at ambient temperature. Any spillage in
these magazines would be on a dry basis. In the event of a spill,
the powder could be swept up and taken to the disposal ground.
IV. Improvements Proposed by Indiana Army Ammunition Plant:
The following improvements will be, or have been, made
consistent with the recommendations contained in the May 1, 1969
FWPCA Report, and the U. S. Army Environmental Hygiene Agency,
Edgewood Arsenal, Maryland, Sanitary Engineering Survey,
Indiana Army Ammunition Plant, Charlestown, Indiana:
1. Improved ventilation in chlorine cylinder storage room
Building 403-2.
2. Provided Bureau of Mines - approved respiratory
protective masks in the chlorine cylinder storage room, Build-
ing 403-2, cooling tower chlorinatio, room and Building 6001
(HOP well water chlorination facilities).
3. Installation of Standard Methods, (OTA) procedure to
determine free avaJ" able chlorine residual in progress.
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Subject: Report on Waste Disposal Facilities at Indiana Army
Ammunition Plant
4. Completed 65% of a survey to establish the points where
storm waters could enter the sanitary sewer system and other
sources of infiltration.
5. Provided multiplication factors for calculating flow
from the continuous recorder at HOP Sewage Treatment Plant.
The factors have been placed on the instrument.
6. Conducted a study as to the best approach to provide the
degree of treatment required (secondary) in the River Ridge septic
tank area. The conclusion reached is that the only method to cope
with the problem is the construction of two new package aeration
treatment plants. Accordingly, FY'72 funds have been requested
to construct these facilities. Completion is expected in FY '73.
7. FY '71 funds ($5,000) were requested for the design of
the package type aeration treatment facilities to replace septic
tanks. FY '72 (MCA) funds ($89,000) have been requested to
construct these facilities.
8. Provided chlorination facilities for the HOP Sewage Treatment
Plant.
9. The dried sludge disposal area has been relocated from
a position where it could be a source of water pollution,
especially during heavy and prolonged rainfall.
10. FY '72 - '74 Funds have been requested for integrating
and totalizing flow recorders for both sewage treatment plants.
Included also is the purchase and installation of an automatic
(Technicon) sampler. The monitor will be located between the
lower settling pond and the Ohio River.
11. FY '74 funds will be requested to reroute the HOP
Sewage Treatment Plant lift station and final settling tank by
pass lines, and sludge bed effluent piping to a new lift station.
The latter will pump any sanitary wastes from these sources to
the head of the sewage treatment plant. The pumps will be driven
by a liquified petroleum internal combustion engine, and. serve
in a stand by capacity for use during a power failure.
12. The updating of the IOW sewage treatment plant from
primary to secondary treatment is scheduled for completion during
FY '72. Included in the new facilities are a trickling filter,
final settling tanks and chlorination facilities.
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Subject: Report on Waste Disposal Facilities at Indiana Army
Ammunition Plant
13. Grease traps have been installed in Buildings 401-2,
718, and 2552.
14. The settling tank baffles at the laundry, Building 1021,
have been repaired.
15. Upon resumption of manufacturing operation, an industrial
waste monitoring program will be provided.
16. Funds have been requested to enlarge the dike capacity
for the 18,000 gallon fuel oil storage tanks to hold at least
the contents of each tank.
17. Replaced septic tank at Building 2558 with line to
sewage treatment plant.
V. Recommendations:
1. The existing practice of neutralizing industrial wastes
with lime be augmented with facilities for removing the nitrate ion.
Under present conditions industrial wastes are neutralized with
lime before discharge to the Ohio River. Most of the sulfate is
removed by precipitation, but the nitrate ion is discharged to
the river unaffected by treatment. This project should be initi-
ated if and when the production of cannon and mortar propellant
is resumed.
2. Consideration be given to diking of the ether, alcohol
and ammonia tank at the IOW plant, upon resumption of operation.
3. The raw and treated sanitary and industrial waste be
monitored on a regular basis.
4. A testing program be established which should include
5 day BOD, suspended and settleable solids, pH and chlorine
residual. For the HOP sewage treatment plant, in addition to
the above tests, sludge index and colorimetric dissolved oxygen
should be run. BOD of the raw wastes and final effluent be
determined at least once a week, preferably twice a week,
(3 hour composites) taken at 11:00 A.M., 12:00 Noon, and IrOOP.M.,
suspended solids of raw waste and final effluent at least once
a week at the same hours, settleable solids once or twice a week
at representative flows.
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Subject: Report on Waste Disposal Facilities at Indiana Army
Ammunition Plant
Chlorine residual of the effluent daily, Monday through Friday,
twice daily when stream conditions require, sludge index and
colorimetric dissolved oxygen test weekly.
Daily monitoring be conducted on the combined effluent at
the junction of Jenny Lind Run and the Ohio River for flow,
BOD, COD, pH, suspended solids, dissolved solids, and nitrates.
5. The discharge of septic tank effluent to the Ohio River
be curtailed as expeditiously as possible.
6. The overflow line from the boiler plant water treatment
sump be diverted from the lagoon to the sanitary sewer. It is
conceivable that during heavy rainfall there could be a discharge
to the lagoon.
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APPENDIX E
ORGANIC COMPOUNDS IDENTIFICATION
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APPENDIX F
PERSONNEL ROSTER
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APPENDIX F
Personnel Roster
Ohio River (McAlpine Pool) Study
David W. Hill - Study Director
Charles Sweatt - Project Engineer (Field)
\
Tom Bennett - Project Chemist (Lab)
Herbert Barden - Project Microbiologist (Lab)
Tom Sack - Physical Science Technician (Lab)
W. R. Davis - Chemist (Field)
Hugh Vick - Chemist (Field)
Ray Wilkerson - Hydraulics Engineering Technician (Field)
Eddie Shollenberger - Engineering Technician (Field)
E. Chaudoir - Hydrologist (Evansville)
S. Paulson - Engineering Technician (Evansville)
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FIGURE I
INO. f~
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ALA I GA.
Indiana - Kentucky
Clactric Corporation
Cl.lly Cr«k Powar Plant
LOCATION MAP
Indiana
Indiana Army ,
Ammunition Plant /*•
5404
V
Corning Wait* \
M8T Chamicalf Wont \
•Iftftuetf Hirtr
McAlplna L*
LOUISVILLE
US. ENVIRONMENTAL PROTECTION AGENCY
REGION
LOCATION MAP
AND SAMPLING STATIONS
SURVEILLANCE AND ANALYSIS DIVISION
ATHENS GEORGIA
* U.S. GOVERNMENT PRINTING OFFICE : 1973 748—252/3203 Region 4
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