-------
The effluent from the waste treatment plant had a dissolved
oxygen range of 4.8 to 7.2 mg/1, a pH of 6.7 to 6.9, and a
temperature of 23 to 27 degrees C. The median tolerance limit (TL
50) was 34 percent at 24 hours, 30 percent at 48 hours, and 26
percent at 96 hours. (The TL50 is the concentration of effluent that
would be lethal to 50 percent of the fish held in it for the
specified time period, i.e., 24, 48, or 96 hours. Thus, the lower
the TL50, the higher the toxicity of the effluent.) The indicated
toxicity of this nominal 10 mgd discharge was higher than would be
expected of a treated effluent.
The 17.83 mgd flow from outfall No. 025 (the vinyl resins and
plasticizers area) and the 17.15 mgd discharge from outfall No. 074
(the miscellaenous chemicals area) were also tested for toxicity by
means of static bioassays. Test conditions were: dissolved oxygen
4.9 to 6.8 mg/1, pH 3.3 to 6.0, and temperature 23 to 27 degrees C.
The TL50 for outfall No. 025 was 14 percent at 24 hours, 10 percent
at 48 hours, and 9.2 percent at 96 hours. The test fish died
immediately in a 100 percent discharge solution. There was less than
50 percent mortality in 100 percent wastewater shown in the 24-hour
exploratory bioassay of the wastewater stream from outfall No. 074.
Further bioassays are undertaken only when the mortality rate in
undiluted effluent exceeds 50 percent.
It should be noted that these two outfalls represented only 29
percent of the total untreated wastewater flow from the plant.
Summary and Conclusions
1. Pollution abatement programs which have been undertaken have
markedly reduced the plant's pollutional loads to the Kanawha River.
2. To meet established future use criteria for the Kanawha
River, additional improvements will be required in waste treatment
and other abatement efforts.
3. The wastewater treatment facilities had been operated with
good efficiency but the need for a higher level of sustained
efficiency is evident. Better biological treatment suspended solids
removal, and minimizing the effects of peaks in organic loadings are
areas for improvement.
4. The largest sources of pollutional loads to the Kanawha at
the time of the survey were the Ward Hollow stream — 6,400 pounds
per day of BOD (5), the waste treatment plant — 4,000 pounds per day,
and the so-called cooling waters — 3,200 pounds per day. (Since the
Ward Hollow stream was routed to the waste treatment plant beginning
in late 1972, future abatement efforts must be directed at the waste
treatment plant and the untreated cooling water sources.)
B-32
-------
5. A number of the plant's outfalls had been properly
classified as cooling water streams on the basis of the analytical
results of this study.
6. The time lag for the detection and correction of spills or
similar upsets in cooling waters was excessive. Daily analyses of
composite samples from each cooling water discharge provided the only
routine checks.
7. The flume replacement scheduled for completion by late 1973
will bring a needed reduction in discharge of untreated industrial
wastewater caused by river flooding, but discharges will still occur
during certain extreme conditions.
8. Toxicity levels were high in two of the three outfalls
selected for bioassay checks. The possibility exists that the other
untested discharges were also toxic.
Recommendations
General
It is recommended that:
1. The combined total Union Carbide-South Charleston Waste
Treatment Plant BOD(5) load to the river be reduced to no more than
3,500 pounds per day and the total nitrogen load to no more than
1,400 pounds per day. These numbers are based on the maintenance of
4 mg/1 DO at the Kanawha River sag point at a seven-day, once-in-10-
year low flow of 1930 cfs at Charleston.
2. The toxicity of effluents be reduced at least to the point
that no discharge exceeds 1/20 of the 96-hour TL50.
Waste Treatment Works
It is recommended that:
1. Coagulants be added to the wastewater or that other
physical-chemical treatment methods be developed and applied to
maintain the primary industrial effluent suspended solids
concentration below 30 mg/1.
2. Tests of advanced methods be undertaken to reduce and smooth
out organic loadings in the primary system and to improve organic
removal in the secondary system.
B-33
-------
Union Carbide Plant
It is recommended that:
1. Separation of process wastes from cooling waters be
effected, priority efforts being directed toward identification of
the pollutants, determination of the sources, and abatement of
pollution in the following untreated wastewater discharges:
Outfall
074
039
025
023
032
Process Area
Miscellaneous chemicals
Acetaldehyde
Vinyl resins and plasticizers
Fine chemicals and vinylite
Aldehyde and power house
Flow
17.15
6.14
17.83
13.40
2.77
The above are listed in the recommended order of priority based on
the calculated pollutional loads discharged to the Kanawha River.
The sum of the BOD(5) loads from these sources is approximately 2,600
pounds per day, over three-fourths of the total load from the 21
cooling water discharges sampled.
2. The untreated wastewater discharge be routed from the Dynel
Tow area to the industrial wastewater flume, then to the waste
treatment plant.
3. Engineering studies be undertaken to determine the best
method for improving the monitoring of untreated wastewater streams
and that an improved monitoring system be implemented. The possible
use of on-line total carbon analyzers programmed to selectively
sample wastewaters from various sources on a timed cycle is
suggested.
4. Plant personnel be required to keep an accurate and detailed
log of raw wastewater discharged from the flume into the river and to
report same to regulatory authorities.
B-34
-------
UNION CARBIDE CORPORATION
CHEMICALS AND PLASTICS DIVISION
INSTITUTE PLANT
INSTITUTE, WEST VIRGINIA
General Plant Description
Union Carbide's plant at Institute, West Virginia is located at
Mile Point 48.9 on the Kanawha River, about six miles downstream from
Charleston on the right side of the river (facing downstream) . It
occupies just over one mile of shoreline in two stretches, one of
which fronts the chemical plant and the other the wastewater
treatment plant (Figure C-l) .
The plant is bounded on the southeast by West Virginia State
College and on the northwest and northeast by largely undeveloped
land. The company owns 775 acres, of which 550 had been developed.
The plant was originally built for the United States Government
during World War II to produce butadiene and styrene, materials
needed to manufacture Buna-S rubber. In April, 1943 styrene
production began, and the entire plant was practically complete and
in full production.
In 1947, Union Carbide purchased the plant from the Government,
not to produce butadiene but other chemicals, such as acetone and
butanol. Gas-producing operation began in December 1950, and other
additions followed — the SEVIN complex, the fluorocarbons and
CELLOSIZE units, another steam and power plant, and an expanded
laboratory.
In early 1970, Union Carbide acquired the West Virginia
properties of Ameripol, Inc., a subsidiary of the B. F. Goodrich
Company. The principal property consisted of a 36.2-acre parcel of
land, including buildings and storage facilities, surrounded on three
sides by the Union Carbide plant.
From an initial staff of 147 employees, employment rose to almost
3,000. In February 1972, it stood at about 1,900. The plant was
operating 24 hours a day, 365 days a year.
Annual production was about 1.5 million tons of basic and
intermediate materials. The products included chemical additives for
gasoline, jet fuels, waterbased paints, cheese, baked goods, and
other foods. Over 100 chemicals were made for the textile finish
industry and over 90 for pharmaceutical companies. The insecticide
SEVIN was one of several agricultural chemicals being produced.
Products being manufactured in February 1972 and their general uses
C-l
-------
31V1S VINIOHIA 1S3M
nvdino
isvagns soo
nvdino
isva
C-2
-------
are listed in Table C-l. Production units and associated products
are listed in Table C-2.
The principal raw material used by the Institute Plant was
natural gas. (With the closing of the olefins units in mid-1972, the
plant was to import ethylene and propylene.) Other major raw
materials included chlorine and caustic, napthalene, isopropanol,
ethanol, ammonia, and air.
Water Usage
The plant purchased an average of 1.7 million gallons a day (mgd)
of water from the Nitro municipal system and withdrew an average of
300 mgd from the Kanawha River. The latter figure ranged from 240
mgd in winter to 350 mgd in summer.
The average amounts of water used within the plant were:
Cooling water 288.0 mgd
Process water 5.6 mgd
Sanitary system 1.7 mgd
Other 0.7 mgd
Fly ash disposal 2.9 mgd
Evaporation 0.4 mgd
The plant processed about 6.0 mgd through its two in-house raw
water treatment plants complete with Zeolite exchange. Water
purchased from the City of Nitro was used for in-plant domestic
purposes and in some process applications.
The volume of cooling water used had been reduced about 47
percent during the period 1962-1972; (it dropped further when the
olefins complex was shut down in mid-1972.) Other water uses had not
changed materially in recent years. An average of 5.6 mgd of
wastewater, including process and sanitary wastes, was treated at the
company's wastewater treatment plant. It was discharged into the
Kanawha River.
Wastewater Discharges and Waste Sources
The plant had five major outfalls on the Kanawha River; one was
connected to the waste treatment plant, and four discharged cooling
water. The plant also discharsed wastes to Goff Branch, a small
stream to the southeast, which drained into the Kanawha. Figure C-2
C-3
-------
TABLE C-l
PRODUCTS MANUFACTURED AT THE UNION CARBIDE INSTITUTE PLANT
Products
Aldehydes
Ketones
Alcohols
Glycols
Phthalate esters
Alkylbenzene
Ethylene oxide adducts
Anhydride
Fluorocarbons
Polyethylene glycol
Esters
Acrylates
Polyols
Ethylene oxide polymers
Isocyanates
Polymers
Fibers
Hydroxyethyl cellulose
Glutaraldehyde
Mixed oxide adducts
Aryls
Ethers
Pyridines
Oxides
Carbamates
Uses
Intermediates for acids,
alcohols, amines
Solvents for lacquers, Pharma-
ceuticals
Solvents; intermediates for
aldehydes, ketones
Solvents; automobile anti-
freeze
Plasticizers
Soft detergents
Detergents, surfactants
Intermediates
Propellants for aerosols,
refrigerants
Pharmaceuticals, cosmetics
Solvents
Plastics
Urethane foams for upholstery
mattresses
Water thickener, water soluble
extruded and molded shapes
Rigid foams
Oil additives
Synthetic yarn
Paint thickener
Tanning agent for leather,
makes leather washable
UCC Brand Name
PRESTONE
FLEXOL
UCANE
TERGITOL
UCON
CAEBOWAX
NIAX
POLYOX
NIAX
UCAR
CELLOS IZE
UCAR
UCON
Brake fluids, lubricants
Intermediates, dye carriers
Extractants
Pharmaceutical intermediates
Sterilizers, fumigents, intermediates
Insecticides, pesticides SEVIN
C-4
-------
TABLE C-2
Units
PRODUCTION UNITS AND ASSOCIATED PRODUCTS
Union Carbide - Institute Plant
Product or Use
Olefins
High pressure hydrogenation
Alkylbenzene
Ketones
Misc. recovery
Butanol
UCAR improvers
CELLOS IZE
Catalyst
Plasticizers
Ethylene oxidation
2
Ethylene glycol
Air separation
Acrolein derivatives
Fluorocarbons
SEVTN
SPANDEX3
POLYOX
Oxide derivatives
Rigid polyols
Isocyanates
DNT
Phthalic anhydride
Ethylene, propylene, acetylene, butadiene,
dripolene - from natural gas
Intermediate for weather resistant rubber
Intermediate for biodegradable detergents
Isopropanol, miscellaneous ketones
Miscellaneous chemicals processing
Butanol and intermediates for other alcohols
Oil additives
Hydroxyethyl cellulose
Miscellaneous catalysts
Phthalate esters - plasticizers
Pyridines pharmaceutical intermediates
Ethylene oxide, ethylene glycol
Nitrogen, oxygen
Acrolein derivatives, glutaraldehyde
Fluorocarbons
SEVIN insecticide
SPANDEX - yarn for elastic wearing apparel
POLYOX
IERGITOL, TEMIK, CARBOWAX, acrylates
Polyalcohols for urethane foams
TDI- foam insulation ingredient
DNT - an intermediate
Phthalic anhydride, FLEXOL DOP
1 - The operation of the Olefins Unit discontinued in 1972.
2 - The production of ethylene oxide discontinued in 1972.
3 - The production of SPANDEX was discontinued in 1972.
k - The POLYOX Unit is operated a maximum of six months per year.
5 - The production of TEMIK discontinued in 1972.
C-5
-------
is a flow diagram of the sources of cooling water, and Figure C-3
shows the wastewaters directed to the wastewater treatment plant.
The wastewater treatment outfall (001) was submerged and usually
created a surface roil in the river. Three cooling water outfalls
(002, 003, 004) were above water, while the fourth (005) was
submerged and also created a surface roil.
Even though the discharges from outfalls 002, 003, 004, and 005
were primarily cooling waters, they contained significant quantities
of pollutants. Company officials stated that they separated as much
as possible all direct, continuous, and intermittent process
discharges to the cooling water sewers.
Direct discharges into the river occurred from traveling screen
backwashes at the three raw water intake pumphouses. Some accidental
discharges into Goff Branch had occurred in the past from production
areas and a hydrochloric acid neutralization process.
Waste Treatment Program
Historical Development
Information on waste control efforts prior to the initiation in
1958 of the State's phased program was not obtained from the company.
At the beginning of the phased cleanup program, the plant was
apportioned about 130,000 pounds per day of BOD(5) as its average
contribution to the Kanawha. Figure C-4 is a company graph of raw
BOD(5) loads, permit limits, and loads discharged from 1958 through
1971. Thirty to 40 percent of the BOD(5) load imposed on the river
had been discharged into it via cooling waters, which had been
Increasing while the total load had been increasing.
The State's Phase I program required that the 1958 BOD(5) load be
reduced by 40 percent to 78,000 pounds per day by mid-1963. As the
final step in meeting the Phase I requirements, the company
constructed an aerated stabilization facility capable of removing
50,000 pounds per day. The facility came on line in 1963.
Preliminary work to reduce the wasteload to the waste treatment plant
included source eliminations, tighter housekeeping practices, and
incineration in the powerhouse.
When Phase I ended in mid-1972 and the State's water quality
objectives for the river had not been met, it launched Phase II. The
plant was required to achieve a 70 percent reduction of the 1958
BOD(5) load by mid-1966. This limit of 39,000 pounds per day was
attained by converting an aerated lagoon into an activated sludge
system, improving source controls, and installing an elaborate in-
C-6
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plant monitoring and control system. These improvements were
completed in 1966.
The dissolved oxygen (DO) level in the Kanawha was still below
3.0 mg/1 at the sag point when Phase II ended, therefore the State
initiated Phase III in 1969. The plant was then required to achieve
an 85 percent reduction in the 1958 BOD(5) load and as large a
reduction of its nitrogenous load as practical by the end of 1972.
The allowable BOD(5) discharge was reduced to 19,500 pounds per day.
To attain these reductions, six additional 100-horsepower
aerators were installed. This increased the BOD(5) reduction
capacity of the biological system to about 97,000 pounds per day.
Source control measures included stripping, decanting, and
incineration. Additional low-flow waste streams were diverted from
the cooling water sewer system to the wastewater treatment plant.
Production unit shutdowns also lowered waste discharge loadings. The
retirement of the acrylic esters unit resulted in 65 percent
reduction in the oxidizable nitrogen load and a drop of 15,000 pounds
per day in the BOD(5) load sent to the biological system.
The company indicated the improved operation of the final
clarifiers and the removal of TERGITOL detergents had resulted in a
75 percent reduction of suspended solids and a decrease of 6,000
pounds per day BOD(5) discharge to the river from the wastewater
treatment plant. Expansion of the cooling water monitoring system
and installation of carbon analyzers on the major outfalls had
minimized the duration of accidental spills, condenser leaks, etc.
The company;s records indicated that the Phase III BOD(5) goal was
attained during only eight months on 1971. The Phase III program was
scheduled to end in December 1972.
Waste Disposal Facilities
One of two powerhouses had been modified to burn liquid organic
wastes, and in 1971, the average amount incinerated was the
equivalent of 600,000 pounds of BOD(5) per day. An average of 2.9
mgd of fly ash slurry was handled by a private contractor and pumped
to its landfill about 1.5 miles east of the plant. The overflow from
the site discharged into Finney Creek, which in turn empties into the
Kanawha.
The plant's Environmental Department operated a State-licensed
chemical landfill (Goff Mountain Landfill) in a 40-acre mountain
valley site just north of the plant. About seven acres were being
utilized. Solid organic chemical wastes consisting of filter cakes,
rejected products, etc,, were handled in a managed disposal pattern.
The solid materials were retained by a leaky earth dam. Liquid run-
C-10
-------
off was directed through the dam, collected, and sent through the
wastewater treatment plant.
A 15-acre site west of the wastewater treatment plant was used to
dispose of inert (non-chemical) materials.
Wastewater Treatment Plant
Process and sanitary waterborne wastes, drainage from tank truck
loading racks and runoff from the Goff Mountain landfill were sent to
the wastewater treatment plant. The BOD(5) loading to the plant
averaged about 110,000 pounds per day. The figure varied by 30 to 40
percent, principally because wastes from the CELLOSIZE unit were
either burned or routed to the treatment plant.
The wastewater treatment plant was located on a 15-acre site 0.8
mile downstream from the production site; there was room for
expansion.
The wastewater treatment plant included:
1. A collection and pumping system
Process wastes from the plant were collected in two sump
areas (Figure C-3). One sump collected wastewater from the eastern
and nearby western plant areas, and the other did so from the far
western plant area wastes. An operator in the control room at the
treatment plant mormally monitored the pH of the intake and requested
that acid or base from various production units be added.
The wastes were transferred approximately one mile to the
wastewater treatment plant via a 20-inch diameter fiberglass-
reinforced polyester pipe.
2. Primary System - Equalization Basin (Figure C-5)
Wastewater from the transfer line entered a 1 million-gallon
equalization basin which had a 4-hour retention time at the normal
waste flow of 5.6 mgd. The resulting sludge was transferred to the
adjacent sludge storage basin, and floating organic chemicals and
solids were removed by mechanical means. Automated measurements of
flow, pH, temperature, total carbon, and specific organic chemicals
were recorded for the effluent (the influent to the aeration basins.)
3. Secondary System - Biological Aeration Basins (Figure C-5)
This system consisted of three 5 million-gallon, one-acre
aeration basins which contained a total of fifteen 75-horsepower and
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C-12
-------
fifteen 100 horsepower aerators and two 316,000-gallon final
clarifiers.
During non-recycling periods, the aeration basins and the final
clarifiers had retention times of 62 and 2.5 hours, respectively, at
the average plant wastewater flow of 5.6 mgd. When return sludge
flow was underway, retention time was reduced to 40 hours. The three
aeration basins had been designed so they could be operated in
parallel or in series.
The effluent from the aeration basins was transported to the two
final clarifiers where the liquid overflow was discharged into the
river through the submerged outfall No. 001. Two sludge pumps moved
the settled materials from the bottom of the clarifiers to be
recycled to the aeration basin or wasted to the 12 million-gallon
sludge-holding basin. Sludge was pumped from the holding basin to
nearby sludge-drying beds. The dried sludge was landfilled at the
adjacent site.
Cooling Water
On an average, 275 mgd of water were needed for cooling purposes
in summer and 238 mgd in winter. The summer average discharge
quantity (in mgd) for each outfall was:
002, 90; 003, 105; 004, 15; and 005, 65.
Monitoring
An extensive monitoring program was followed at the plant,
including in-plant process waters, cooling waters, river water,
outfalls, and wastewater treatment unit evaluations. The sewer
sampling schedule for the plant is illustrated in Table c-3, and the
on-stream analyzers or monitors are listed in Table C-4. In all, 26
in-plant process wastewater samplers and 43 cooling water samplers
were utilized daily.
Efficiency of Waste Treatment
Prior to 1963, few waterborne waste loads were treated, and any
load reductions achieved resulted primarily from increased process
control. Figure C-6, however, Illustrates how progress in treatment
after 1963 reduced the BOD(5) loads imposed on the river; the table
is based on data provided by plant officials. In the table', the
difference between the total raw load and the amount discharged into
the river represents the quantity removed in the wastewater treatment
plant.
C-13
-------
TABLE C-3
SEWER SAMPLING SCHEDULE
Union Carbide Corporation - Institute Plant
Chemicals and Plastics Environmental Protection Dept.
Dissolved Oxygen
Biobasin Oxygen Uptake
Temperature
Carbonate Carbon
Organic Carbon
BQD20
Gas Chromatography
Acidity
Alkalinity
COD
Chlorides
Color
PH
Ortho Phosphate
Total phosphorus
Phenolics
Ammonia Nitrogen
Kjeloahl Nitrogen
Nitrate nitrogen
Total Volatile Solids
Suspended Solids
Soluble Solids
Fecal Coliform
Total Coliform
Fecal Strep
Oil & Grease
Specific Conductivity
Sulfide
Sulfite
Surfactants
Turbidity
Sulfates
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C-16
-------
During Phase I, the initial wastewater treatment plant's BOD(5)
remjval efficiency ranged between 50 and 60 percent. After it was
expanded in 1966, efficiency increased to 70 percent until tha end of
1967. Since then, the level has varied widely — from 40 percent in
December 1969 to more than 90 percent in mid-1971. The average for
the entire year of 1969 was about 60 percent.
The BOD(5) loading data for cooling water and the wastewater
treatment unit discharges from the plant since 1963 are summarized in
Table C-5. There was a continuous reduction in cooling water BOD(5)
loads until 1966; they then leveled off until 1970 and dropped again
in 1971. In 1971, the cooling water BOD(5) load averaged 39.2
percent of the 1963 load. Treatment plant influent BOD(5) loadings
were erratic until 1970 when an 18.6 percent reduction occurred. In
1971, the influent load was 72.2 percent of that for 1963.
The waste treatment plant's ability to remove BOD(5) increased
steadily from 1963 through 1966, then rose sharply after it was
expanded in 1966. The average annual efficiency level dropped,
however, in 1969 and 1970. In 1971, the annual efficiency reached 80
percent, the highest level observed. Efficiency fell off badly in
the winter of 1971-72. Company officials said that an imbalance in
pH control killed organisms in the aeration basins. (Sludge from the
south Charleston treatment plant was used to reseed the activated
sludge but recovery took several months.)
Kjeldahl nitrogen loads from the wastewater treatment plant
varied widely from 1968 through 1970, but the average load dropped
from 30,000 pounds per day in 1968 to 25,000 pounds per day in 1970.
The average decreased to about 5,000 pounds per day in early 1971
(and has remained there), primarily as a result of source control;
the treatment plant itself does not remove nitrogen effectively. The
large decrease in early 1971 resulted from the closedown of the
acrylic esters unit.
Future Plans
Project Purposes
1. Tie east field storage tanks Divert surface drainage wastes
to process sewer. from cooling water.
2. Install specific organic Rapid identification and cor-
chemical analyzer on outfall rection at source of spills.
005.
3. Install new pump and modify Increased reliability; elimi-
two others at center sumps; nate overflow to cooling water.
modify control instrumen-
tation.
C-17
-------
ITN
9
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C-18
-------
4. Install a parallel transfer Insurance against break.
line from plant to wastewater
treatment facility.
5. Add two new sludge recycle Provide reliability and increase
pumps at treatment facility, sludge recycling capacity.
6. Lay a second line to trans- Prevent backup of flow in bio-
fer effluent from biobasins basins.
to the secondary clarifiers.
7. Reduce BOD load to cooling Collect and recover or burn
water by 2,200 pounds per wastes.
day.
8. Install interceptor process Serve plant river bank-dock
sewer. area.
9. Install sludge drying basin The mix will be used as the
and mix dried sludge with blending agent at the Goff
soil. chemical landfill.
Spill Potential
The plant had an inherent design weakness in that the old cooling
water drainage system was so positioned that spillages drained into
it unless they were pumped directly to the process waste line. This
situation resulted in the direct discharge of most production unit
upsets, pond drainage, leaky glands, and spills resulting from
negligence and mechanical failure.
Recent notable spills included one that occurred when a barge was
overfilled and 46,000 gallons of methyl iosbutyl ketone (MIBK) were
lost on January 20, 1972. Thirty six hundred gallons of
dicyclopentadiene were discharged through a spill into a cooling
water sewer on February 15, 1972.
Based on experience, the potential for significant chemical
spills is relatively high. Plant personnel recognized this problem
and had installed a monitoring system to detect spills to cooling
water.
NFIC-Cincinnati Field Survey
Sampling
To confirm and/or ascertain the magnitude of wastewater discharge
loadings and sources, NFIC-C conducted a 24-hour sampling survey of
the plant's intake water, waste treatment plant influent and
C-19
-------
effluent, the four main cooling water outfalls, and Goff Branch on
February 23 and 24, 1972. Two-hour grab samples were composited for
each outfall and were split with the company and West Virginia's
Division of Water Resources. The analytical results, converted to
pounds per day net loadings, are listed in Table C-6.
Analytical Results
Based on the company's data, the treatment plant's BOD(5) removal
efficiency was only 55 percent during the survey, but an upset
condition existed in the facility at the time of sampling.
About half the BOD(5) discharged into the river entered it from
the wastewater treatment plant outfall (001). The remainder was
present in cooling water discharges, mainly those from outfalls 002
and 003. The company's COD and TOG values were correlatable with
those for BOD(5) during the survey. Over one million pounds per day
of dissolved solids (related to chlorides) were discharged,
particularly from the treatment plant.
Over 100 pounds per day of phenols entered the river from the
wastewater treatment plant and 40 pounds were present in cooling
water discharges. The high load from the treatment facility reflects
the upset condition prevailing in its biological system. Under
favorable biological growth conditions, the activated sludge system
is capable of removing over 99 percent of phenols. Oil and grease
concentrations from the treatment plant were measured at 38 mg/1 by
EPA and at 19 mg/1 by the company.
Metals analyses by the State indicated that cadmium, aluminum,
magnesium, calcium, and sodium were contained in the effluent from
the wastewater treatment plant. Cadmium was measured at 330 pounds
per day (over 6 mg/1).
Toxicity of Effluents
Static bioassay tests, using fathead minnows, were made in March
1972 on the effluent from outfalls 001, 003, and 005. The effluent
had a dissolved oxygen range of 4.0 to 5.8 mg/1, a pH of 6.6 to 6.9,
and a temperature of 23 to 27 degree C. Toxicity was shown only in
the effluent from the waste treatment plant outfall (001). The
median tolerance limit (TL50) wastewater percentage at 24 hours was
24 percent, at 48 hours 9 percent, and at 96 hours 9 percent. All of
the fish that died did so within 48 hours. (The TL50 is the
percentage of wastewater by volume which will kill 50 percent of the
test organisms in the specified time.) The toxic agent was suspected
to be cadmium.
C-20
-------
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C-21
-------
Summary and Conclusions
1. The plant was in compliance with the State's pollution
control program.
2. In-plant, wastewater treatment, unit, and effluent monitor-
ing programs were extensive.
3. Toxicity was a definite problem in the wastewater treatment
system.
4. The diversion of contaminated streams from cooling water
systems which served the plant was critical to the effectiveness of
future abatement programs.
5. Additional removal of contaminants from cooling waters was
required so that the company could meet any reasonably imposed dis-
charge criteria in the future.
6. Landfill leachate containing toxic elements could cause
problems in the wastewater treatment system.
Recommendations
It is recommended that:
1. The toxicity of the effluent be reduced so that no discharge
exceed 1/20 of the 96-hour TL50. \
2. An effluent pH range of 6.0 to 8.5 be maintained.
3. Waste streams which add BOD, COD, TOG, phenols, oil and
grease, and suspended solids to cooling waters be separated and ^
treated. ^
4
4. Total phenol discharges be reduced to the State-imposed
limit of four pounds per day.
5. The total BOD(5) and TO discharges to the river be lowered
to on or more than 2,800 and 1,300 pounds per day, respectively, in
order for the Kanawha to meet the DO criterion of 4.0 mg/1 at the
proposed flow of 1,930 cfs.
6. By using process control and recycling, reduce to an ,
absolute minimum the load of dissolved solids discharged into the
river.
7. The spill potential of organic chemicals into cooling waters
be decreased by complete separation and containment wherever possible
C-22
-------
so that the wastes can be diverted to the process sewer system or the
recovery system.
8. The cadmium source be isolated and that wastewaters be
treated at the source to reduce the pollutional effects on the
treatment plant and the river.
C-23
-------
FMC CORPORATION
INDUSTRIAL CHEMICAL DIVISION
SOUTH CHARLESTON PLANT
SOUTH CHARLESTON, WEST VIRGINIA
General Plant Description
The plant is located on the left bank of the Kanawha River
(facing downstream) and occupies 3,150 feet of the river shoreline in
three separate sections (Figure D-l) between Mile Points 54 and 55.
At the time of the survey, it was called the Inorganic Chemicals
Division. The plant areas along shore were: (1) the original plant
site that housed the chlorine and related production units; (2) the
process development and quality control laboratory; (3) the
downstream site where chlorinated dry bleach production units were
located. A fourth area was inland and housed administrative offices,
hydrogen peroxide production units, and a fly ash lagoon.
The plant had changed a great deal since it became operational in
1915. Three production units had been shut down for economic
reasons, the hydrogen peroxide and dry bleach production units had
been added, and most other units had been altered to increase their
efficiency and capabilities. Employment had been stable at about
1,000 persons. The plant was being operated 24 hours per day, 365
days a year.
The plant manufactured the following products: hydrogen peroxide,
liquid anhydrous ammonia, caustic sodas, chlorine gas, chlorine
liquid, and chlorinated dry bleach. The amount of production was not
ascertained. Raw materials used included salt brine, coal, urea,
sulfur, and methane (natural gas). The brine was brought in by barge
from a concentrated supply at Ben's Run, West Virginia.
Water Usage
Plant officials had reported in their Refuse Act permit
application that it used 3.15 million gallons a day (mgd) of city
water and 180.9 mgd of river water. The total amount was used as
follows: 176.4 mgd for cooling purposes, 1.54 mgd for boiler feed,
6.05 mgd for process water, and 0.06 mgd for the plant's sanitary
system. The usage contained in the application is not compatible
with the Company's reported total discharge, 91 mgd. The amount used
as cooling water probably represented the potential available rather
than that actually used. The company stated that its water use had
been stable, both seasonally and historically.
D-l
-------
D-2
-------
Wastewater Discharges and Waste Sources
Sanitary wastes were sent to the South Charleston municipal
wastewater treatment system. Approximately 0.75 mgd was lost to
evaporation and 0.01 mgd was consumed in chemical processes. The
remainder (91.1 mgd) was discharged to surface waters.
In its permit application, the company listed 29 outfalls, 28 of
which discharged directly into the Kanawha and one into Davis Creek,
a tributary of the Kanawha (Figure D-2) . The outfalls are listed in
Table D-l by the numbers shown on the permit application.
Except for the fly ash pond (outfall 029) , there was no formal
treatment facility at the plant. Outfalls 003 through 015 lay within
a stretch of 200 feet. Outfall 003 (from the turbine condensers,
rectifiers, steam processing, brine treatment, and boiler water
treatment) had a discharge of 26.2 mgd. Outfall 018 (from the
chlorine and caustic diaphragm cells and sulfur recovery system) had
a 38.9 mgd discharge. These two outfalls accounted for over 71.5
percent of the average daily effluent flow.
Wastewater Treatment Program
Historical Development
According to the company, several waste control projects were
under way before the State began its phased pollution control program
in 1958. These projects had been designed to reduce production
losses.
To meet the State's Phase I requirements by 1963, the company:
1. Purchased land for a fly ash lagoon, and a 29-acre settling
basin was constructed to hold boiler fly ash.
2. Built a collection system in Area 3 and a mile-long waste
transfer pipeline.
3. Segregated and pumped all sanitary wastes to the South
Charleston municipal treatment plant.
4. Established a spill alert system.
To meet the Phase II requirements by 1969, the company:
1. Submerged the largest outfall to eliminate foaming.
2. Eliminated high magnesium and chloride wastes by obtaining a
new brine source at Ben's Run.
D-3
-------
_J!l illl
-=s-,E-
D-4
-------
Outfall
No.
001
002
003*
OOl*
005
006
007
008
009
010
on
012
013
OlU
015
016*
017*
018*
019*
020
021
022*
023*
02U
025
026
027*
028*
029*
TABLE D-l
WASTEWATER DISCHARGES SOURCES ADD VOLUME
HMC Inorganic Chemicals Division
Source Area
Raw water intake
Steam condensate drain
Turbine condensers, rectifiers,
steam processing, trine treatment,
boiler water treatment
Barometric condenser
Inactive
Barometric condenser
Vacuum seal for vacuum filters
Inactive
Barometric condenser
Caustic and chlorine coolers
Chlorine and caustic diaphragm
cells, sulfur recovery
Carbon tetrachloride unit
Inactive
Inactive
Ammonia production unit
Carbon bisulfide unit
Ammonia production unit-vent scrubber
Air conditioning units
Laboratories
Chlorinated cyanurate unit
it it ii
Fly ash lagoon, hydrogen peroxide unit
Total average effluent flow
Discharge
Volume (mgd)
0.091
0.22
26.2
1.01
1.6k
0.50
0.0
3-85
2.09
0.61
O.U3
0.0
0.0
l.Ht
U.I
38.9
3.3
0.0
0.0
0.5
3-6
0.11
0.01
0.50
0.60
0.9
91.181
* Effluents sampled by EPA March 1-2, 1972
D-5
-------
3. Installed a sulfate purge system to reduce chloride wastes.
4. Made process changes to recover waste salt and caustic soda.
5. Installed an oil and solvent recovery system.
To meet the Phase III requirements by 1972, the company had to:
1. Eliminate all visual pollution, including foams and scum.
2. Reduce the BOD(5) load to a maximum of 1,000 pounds per day.
3. Decrease the oxidizable nitrogen load by 65 percent.
4. Neutralize all wastes to comply with water quality criteria
for the Kanawha River.
5. Reduce all taste-and odor-producing materials to meet water
quality criteria for the Kanawha.
Waste Disposal Facilities
The company operated a landfill and used a 29-acre pond as waste
disposal facilities. Bottom ash, waste asbestos, and other plant
solid wastes were placed in the landfill. Boiler fly ash, insoluble
wastes from water and brine treatment, oil separator effluent, and
the effluent from the hydrogen peroxide plant were sent to the pond.
Although not confirmed by EPA or State analyses, the company claimed
this procedure was effective in removing organics. On an average,
the effluent discharged into Davis Creek from this facility amounted
to 0.9 mgd; this represented less than one percent of the plant's
total discharge.
Cooling Water
The cooling water discharges totaled over 90 mgd from the 28 out-
falls on the Kanawha. The exact portion contributed by leaks and
miscellaneous process wastewaters was not ascertained.
The non-contact cooling water volume was estimated at 70 mgd, and
an additional 20 mgd were contaminated by spills, leaks, contact
cooling, and process wastes.
Monitoring
The monitoring program consisted of compositing 2-hour grab
samples over a 24-hour period once a month at each outfall. Special
samples were also collected periodically at major outfalls.
D-6
-------
Efficiency of Waste Treatment
The one wastewater stream that was treated before being
discharged from one of the 29 outfalls was the one that entered
Beaver Pond. The influent to the pond contained an average of 25,000
mg/1 of suspended solids and the effluent contained an average of 5
mg/1. The removal efficiency for other constitutents was not known.
Future Plans
The most significant waterborne waste problem of the FMC
Inorganic Chemicals plant was ammonia-bearing wastes. In the
manufacture of dry bleach, much off gas was produced in the calcining
of urea. This was the source of two-thirds of the water-borne
ammonia waste, and presently a pilot operation was under way to burn
the gas and, destroy the ammonia. (If successful, this method will
satisfy the 65 percent reduction requirement of the Phase III
program.)
Spill Potential
The spill potential of the three areas of the South Charleston
Plant was great. If a spill occurred at any of the three plant
production areas, there was no provision to capture and retain any
liquid lost. According to plant personnel, the plant had had six
spills to the river, but the character and amount were unspecified.
They claimed, however, that the spills had been given immediate
attention and treated as emergencies. The effects on the Kanawha
were not ascertained. A formal spill alert system was established in
1963.
NFIC-Cincinnati Field Survey
Sampling
To ascertain the magnitude of waste constitutent discharge
loadings, the EPA conducted a 24-hour sampling survey of selected
effluents (Table D-l) on March 1-2, 1972. Two-hour grab samples
were composited and split with the company.
Analytical Results
The analytical results, converted to pounds per day, are listed
in Table D-2. The analytical results indicate that the samples from
outfalls 027 and 028 could have been interchanged. The discharge
volumes for these outfalls were 0.54 mgd and 0.67 mgd, respectively.
Since these volumes are nearly equal and less than 1.0 mgd, the total
difference in net loadings should be considered negligible when
compared to the total plant discharge of over 90 mgd.
D-7
-------
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-------
Total plant loadings are in line with data submitted to the State
in 1971 (Table D-3).
Major Sources and Loads
The plant discharged large quantities of dissolved solids, COD,
total organic carbon, ammonia, Kjeldahl nitrogen, and chlorides. The
largest sources of solids and COD were the caustic and chlorine units
(outfalls 017 and 018), the dry bleach units (027 and 028), and
"Beaver Pond " (029).
The largest source of COD and chloride was the chlorine and
caustic plant (No. 018). Chloride was also high from the chlorinated
dry bleach (No. 027) plant and "Beaver Pond". Large quantities of
total organic carbon and nitrogen originated in the dry bleach unit
(027 and 028).
Oil and grease discharges appeared to be well under control at
the plant.
Plant data reported to the State in 1971 indicated that an
average of 1,900 pounds of BOD(5) was discharged into the river per
day. The Refuse Act permit application indicated that 1,400 pounds
were discharged from the chlorine caustic plant via outfall No. 018,
which is reflected by the high COD.
Metals analyses of the effluent from the pond showed that it
contained 16 pounds per day of chromium and 0.5 pounds per day of
arsenic which were assumed to be associated with the fly ash.
Toxicity of Effluents
The only static bioassay tests conducted were made on the
effluent from outfall No. 018 from the chlorine and caustic plant.
The tests which used fathead minnows, were made of effluent which had
a dissolved oxygen range of 5.1 to 5.9 mg/1, a pH 2.9 to 6.4, and a
temperature between 23 and 27 degrees C. The median tolerance limit,
TL50 of the wastewater at 24 hours was 78 percent, at 48 hours, 60
percent, and at 96 hours, 56 percent. (The TL50 is the percentage of
wastewater by volume which will kill 50 percent of the test organisms
in the specified time.)
Conclusions
Six discharges contained high levels of dissolved solids (003,
017, 018, 027, 028, 029). The discharge from 028 contained the major
portion of the nitrogen load. The plant appeared to be meeting the
State's Phase III requirements. The spill prevention program did not
seem to be adequate to retain or to recover any liquids lost.
D-9
-------
TABLE D-3
PLANT EFFLUENT - NET LOADS (POUNDS/DAY)
FMC CORPORATION - INORGANIC CHEMICALS DIVISION
South Charleston, West Virginia
Parameter
Total Solids
Susp . Solids
Chlorides
COD
TOC
TKN
NH(3)
Oil & Grease
Chlorine
Sulfide
Mercury
Chromium
BOD (5)
NFIC-C
449,830
12,660
176,250
18,670
12,775
16,560
7,260
460
NA
76.
•
16.
March 1972
FMC
458,100
10,100
163,400
12,770
13,565
19,440
8,590
ND
0
017
5
State
478,800
1,000
209,000
NA
NA
21,840
5,420
NA
7,940
FMC
Report to State
1971 (9 Months)
366,100
8,514
163,270
5,575
21.4
1,877
NOTE: NA « not analyzed
ND » not detected.
D-10
-------
Recommendations
It is recommended that:
1. The plant take immediate steps to separate and dispose of
suspended solids, COD, and TOC wastes from the wastewater streams,
particularly those discharged via outfalls 003, 018, 023, and 027.
2. Nitrogenous loads be reduced to 3,600 pounds per day and the
BOD(5) discharge loads not to exceed 150 pounds per day in order to
meet the DO criterion of 4 mg/1 at the existing 7-day, once-in-ten-
year low flow.
3. The toxicity of effluents be reduced at least to the point
that no discharge exceeds 1/20 of the 96-hour TL50.
4. The company use less cooling water and reduce the
contaminants introduced into it.
5. The spill program be up-dated so that all hazardous and
toxic materials which have spill potential can be contained or
recovered.
6. Monitoring be increased at the major outfalls which contain
the largest sources of pollutants. Flow measurements must be more
precise and continuously recorded for outfalls 003, 018, 019, 022,
023, 027, 028 and 029.
7. The dissolved solids load discharged into the river be
decreased by in-plant recovery of salt, caustic sludge reduction, and
acid reuse.
8. Wastes from raw water treatment be removed from the
discharge of outfall 003, chromate be removed from outfalls 022, 023,
028, and 029, and lead be reduced in the discharge from outfall 018.
D-ll
-------
FMC CORPORATION
AMERICAN VISCOSE DIVISION PLANT
NITRO, WEST VIRGINIA
General Plant Description
This plant was located on the Kanawha River at Nitro, 12 miles
downstream from Charleston at Mile Point 42.7. The plant was on the
right side of the river (facing downstream) and occupied 120 acres
which included about 2,200 feet of shoreline (Figure E-l). Adjacent
installations were the Allied Chemical Company (upstream) and FMC's
Industrial Chemical Division.
The plant, which became operational in 1938, had been modified
and expanded over the years, but there had been no change in the
basic manufacturing process of the principal product, rayon staple.
Employment had fluctuated between 850 and 1,150 and totaled 1,100
in March 1972. The plant operated 24 hours a day, 365 days per year
at an average of about 80 percent of its rated capacity of rayon
staple. A significant by-product was sodium sulfate.
Basic raw materials used included highly refined cellulose sheet
pulp, caustic soda, carbon bisulfide, sulfuric acid and zinc sulfate.
Sulfuric acid was supplied through a pipeline by the Allied Chemical
Company.
Water Usage
The plant purchased an average of 20,000 gallons per day of water
from the City of Nitro for domestic and process purposes. The plant
pumped an average of 35 million gallons of water a day (mgd) from the
Kanawha. Approximately 25 to 30 percent of this water was treated by
standard precipitation, settling, filtration, and chlorination for
use as process water. Ten to 15 percent was softened for process and
boiler feed purposes.
The Company's Refuse Act permit application indicated that the
plant used 26 mgd as cooling water, 1 mgd for boiler feed, 6.5 mgd as
process water, 0.06 mgd in its sanitary system, and 1.46 mgd for
other purposes. The application also indicated that 0.4 mgd was lost
to evaporation and the rest was discharged into the river.
Wastewater Discharges and Waste Sources
The plant discharged all of its wastewaters, both industrial and
sanitary, into the Kanawha through one sewer. The sewer led to a
sump on the river bank which had two outfalls, one above water called
E-l
-------
STATE ROUTE 25
PENN CENTRAL
RAILROAD
-M.
WINFIELD LOCK A
& DAM j
+ VM|LE POINT 31.1
•NITRO PLANT
^CHARLESTON-
=<
RIVER
VICINITY MAP
0 5 10
MILES
STORAGE FACILITIES
FMC CORPORATION
AMERICAN VISCOSE
PARKING
AREA
PRODUCTION
FACILITIES
\-WASTE
WATER
TREATMENT
FACILITIES
UNIMPROVED
AREA
I
48" OUTFALL
36" OUTFALL
(MILE POINT
42.7)
FIGURE E-l
FMC CORPORATION
AMERICAN VISCOSE DIVISION
GENERAL PLAN - PLANT FACILITIES
JULY 1972
E-2
-------
the "secondary outfall" and a submerged 36-inch pipe extending 100
feet into the river called the "primary outfall". Under normal
operating conditions, all wastewaters were discharged via the
submerged outfall; a surface roil usually existed over its outlet.
At the time of the investigation, none of the discharge (26 mgd of
cooling water and 9 mgd of process water) was treated.
Information regarding specific unit sources of wastes was not
provided by the company.
Wastewater Treatment Program
Historical Development
Company officials said that a program had existed for several
years whereby process and cooling water wastes were separated. An
aeration lagoon was constructed in which about one mgd of selected
process and sanitary wastes were provided partial secondary
treatment. The lagoon had been abandoned prior to NFIC-C's field
survey and all waterborne production and sanitary wastes were being
discharged untreated.
The history of waste treatment at the plant had been one of non-
compliance with requirements of the State's phased program^
Under the principal requirements of Phase I and Phase II, the
plant was to reduce the BOD(5) loading to the Kanawha from 9,300
pounds per day to 2,800 pounds per day by June 30, 1966. This date
was later extended by the State for all Kanawha industries to June
30, 1967. The American Viscose plant did not meet the loading
limitations. West Virginia Pollution Control Permit No. 4384 was
issued to the plant on February 7, 1972, and included Phase III
requirements. The BOD(5) limitation was set at 2,000 pounds per day
and acidity was not to exceed 80,000 pounds per day by December 31,
1972.
The company agreed in a letter to the State in July 1971 to meet
the Phase III requirements by December 1972 by constructing a
secondary biological treatment facility. (In 1973 the company had
completed and was operating a wastewater treatment facility that
incorporated the following components:
1. Two primary clarifiers (each at two-thirds of total design
requirement) for zinc removal.
2. Two rotary vacuum filters for dewatering zinc hydroxide
sludge, which is disposed of in the landfill.
E-3
-------
3. Pumping equipment to direct blowdown from acid reclaim
cooling tower to waste treatment from No. 2 lift station.
4. A thickener installed ahead of the aerobic digestion
chamber.
5. Three lift stations.
6. A final clarifier.)
The company's projected removal efficiencies are listed in Table
TABLE E-l
E-l.
PROJECTED QUALITY OF TREATED EFFLUENT
(based on design flow of 9.3 mgd)
Constituent
BOD (5)
COD
Suspended Solids
Dissolved Solids
Zinc
PH
mg/1
30
243
30
10,000
5
6.0 - 8.5
Ib/day
2,340
18,954
2,340
780,000
390
units
Removal Efficiency
Percent
80
60
84
0
95
—
Solid Waste Disposal
The company reported that a portion of its property was used for
solid waste disposal. The area had a small pond, which presumably
received leachate from the disposed material and overflowed into an
outfall of the Fike Chemical Company. The pH of the effluent was 13.
Spill Potential
The FMC American Viscose Division stated that spills had been
insignificant due to good housekeeping and the nature of the process
and chemicals used. Any rejected batches of alkali cellulose crumbs
or viscose solution were placed on the company landfill. Tanks
E-4
-------
holding caustic and sulfuric acid were not diked, but were a long
distance from the river. Materials such as carbon disulfide (CS2)
and the amine-phenol mixture were handled in well-designed equipment
with good safeguards to minimize spill dangers.
NFIC-C Cincinnati Field Survey
Sampling
In order to ascertain and/or confirm the magnitude of waste
constitutent discharge loadings, the EPA conducted a 24-hour sampling
survey of the single discharge and the plant's raw water intake on
March 21 - 22, 1972. Two-hour grab samples were composited and split
with the company and the State Division of Water Resources.
It was anticipated that, as in all other plants visited, the
facilities could be toured to become familiar with the plant layout.
Due to a problem in the production area, this request was not allowed
at the time of this visit. It was agreed, however, that sampling
could be performed on a day to be mutually selected and this would
encompass the discharge and the raw water intake.
Analytical Results
The analytical results, converted to pounds per day net loadings,
are listed in Table E-2. For comparison average loadings of
constituents reported to the State for the first 10 months of 1971
are included.
Major Waste Sources and Loads
Since the loadings shown in Table E-2 were untreated, they
represented raw discharges into the river. The company was
discharging loads of BOD, dissolved solids, zinc, COD, total organic
carbon that were in excess of Phase I, II and III limit requirements
for BOD and acidity.
Toxicity of Effluent
Static bioassay tests, using fathead minnows, were made on the
plant's effluent in March 1972. The tests were made in a dissolved
oxygen range of 5.3 to 6.2 mg/1, pH 2.6 to 5.8, and a temperature
between 23 and 27 degrees C. The median tolerance limit (TL50) of
the wastewater at 24, 48, and 96 hours was 7.6 percent for each time
period. All of the fish that died did so within the first 24 hours.
The TL50 is the percentage of wastewater by volume which will kill 50
percent of the test organisms in the specified time. In the case of
this effluent, the toxic influence could have been the low pH of the
initial sample.
E-5
-------
TABLE E-2
TOTAL WATERBORNE WASTES
AMERICAN VISCOSE PLANT
Nitro, West Virginia
Net Loads - Pounds/Day
Parameter
BOD
BOD20
Total Solids
Susp . Solids
Chloride
Zinc
COD
TOC
TKN
NH3
Acidity
Phosphate
Oil & Grease
Phenol
Cyanide
pH
EPA
7,570
18,915
35^, 100
NA
NA
8,710
31,200
9,610
360
0
121,000
30
270
3.0
0
2.2
NFIC Survey
March 1972
STATE VISCOSE
7,920 13,
16,920 25,
501, 000 U29,
13,500 3,
36,300 26,
9,890 8,
NA 31,
NA 11,
609
lf05
NA 1Q3>
63
-
3.U
NA
2.2
1+50
900
100
950
800
120
300
000
550
NA
210
51
282
0
0
2.5
Viscose
Report to State
1971 (10 Months)
11, 287
NA
1+19,500
1^,300
13,^50
7,9^0
NA « Not analyzed.
E-6
-------
Conclusions
1. The history of wastewater treatment at the plant had been
one of non-compliance with the requirements of the State's phased
program.
2. The wastewater discharged into the Kanawha was toxic.
3. The pH of the wastewater discharge was 2.2, and it contained
over 400,000 pounds per day of dissolved solids and more than 8,000
pounds of zinc.
4. The spill prevention program was adequate in the carbon
disulfide facilities but not in the caustic and acid areas.
5. Contaminates were not kept completely segregated from
cooling waters.
Recommendat ions
1. All waste stream that contain BOD, COD, organic carbon, oil
and grease, nitrogenous materials, and suspended solids should be
segregated from cooling waters and routed to a treatment system.
2. The toxicity of the effluent should be reduced at least to
the point that no discharge exceeds 1/20 of the 96-hour TL50.
3. The acid load to the river should be neutralized or
otherwise treated so that the pH of the discharge is maintained
within the range of 6.0 to 8.5.
4. The oxygen demand should be reduced to not more than 300
pounds of BOD(5) per day and 100 pounds of TKN per day. The zinc
concentration in process wastewater should be limited to 1.0 mg/1.
5. The spill prevention program should be expanded to include
the caustic and acid areas.
6. Monitoring should be carried out more frequently and the
number of pollutants analyzed should be increased. Consideration
should be given to performing bioassays and BOD(20), TKN, COD, and
TOG analyses.
E-7
-------
FMC CORPORATION
ORGANIC CHEMICALS DIVISION
NITRO, WEST VIRGINIA
General Plant Description
The plant is located on the right bank facing downstream of the
Kanawha River in the Nitro, West Virginia area (Figure F-l).
Detailed information on the plant area, buildings, etc., was not made
available by the company for this survey. Since 1960, employment had
ranged from approximately 475 to 150; at the time of the survey, it
was about 170. The plant was operated 24 hours a day, 365 days a
year.
Production quantities and sales are confidential. In 1970, the
major products were plasticizers and phosphorus chemicals, and the
principal raw materials were phosphorus, chlorine, caustic, phenol,
cresylic acids, glycol ethers, organic alcohols, and propylene.
Production had varied and many product has been added and deleted.
Tributyl phosphate and tributoxyethyl phosphate were added in 1960,
phosphorus tri and oxychlorides in 1962, methyldiphenyl phosphate in
1964, and isopropylphenol phosphates in 1969. Aluminum chloride and
allyic esters production have been eliminated.
The eight main production areas and sources of wastewater as
shown in the company's Refuse Act Permit Application were: (1)
Isopropyl phenol; (2) Kronitex reaction - distillation; (3)
Kronitex refining; (4) Tributoxyethyl phosphate - tributyl
phosphate; (5) Methyl diphenyl phosphate; (6) Butyl cellosolve
adipate; (7) Phosphorus trichloride; (8) Phosphorus Oxychloride.
Raw materials, intermediates, and products manufactured are shown
in Figure F-2.
Water Usage
The following water use data (in millions of gallons a day, mgd)
are taken from the company's Refuse Act Permit Discharge Application:
1. Source: Municipal system, 0.33; Kanawha River, 3.98.
2. Use: Cooling water, 4.01; boiler feed water, 0.09; process
water, 0.21; sanitary system, 0.003.
The sanitary system discharged to the municipal treatment plant, and
all other wastewaters were discharged into the Kanawha.
F-l
-------
STATE ROUTE 25
-H*-
INDUSTRIAL
DRIVEWAY .
-Hf-
PENN CENTRAL RAILROAD
-Ht-
^T1!
NFIELD LOCK&DAM
(Mile Point 31.1)
\
KANAWHA
RIVERx/N|TRQ pLANT
CHARLESTON
Flow
VICINITY MAP
I i i i i I i i i i I
5
MILES
10
J
\
MONSANTO
84" OUTFALL,
MILE POINT
42.6
AMERICAN VISCOSE DIVISION
WASTE WATER
TREATMENT
FACILITIES
kl
.Flow
KANAWHA RIVER
FIGURE F-1 FMC CORPORATION
ORGANIC CHEMICALS DIVISION NITRO, WEST VIRGINIA
GENERAL PLAN-PLANT FACILITIES
F-2
-------
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F-3
-------
The discharge flows on which this EPA study was based were:
mgd
Waste treatment plant 0.060
Cooling water 3.615
Total 3.675
(Flows were estimated from water intake values.)
Waste Treatment Program
Historical Development
West Virginia's phased program requirements for the Nitro Plant
are shown in Table F-l. The base load to the Kanawha was established
at 7,000 pounds BOD(5) per day in 1958.
TABLE F-l
WEST VIRGINIA'S PHASED PROGRAM FOR
FMC'S ORGANIC PLANT AT NITRO
% Reduction
from Base
Phase I 40
Phase II 70
Phase III 86
BOD (5) Phenol Acidity
Limit Limit Limit (1) Compliance
Ib/day Ib/day Ib/day Date
4,200 900 35,000 6/30/63
2,100 16 10,300 6/30/66
1,700 16 (2) 12/31/72
(1) As CaC03
(2) Neutralized sufficiently to comply with applicable water
quality criteria for the Kanawha.
Under Phase I, the following projects were completed:
1. Sanitary wastes were segregated from plant wastes and piped
to the municipal treatment plant.
2. An alcohol recovery-distillation recovery unit was installed
to remove organics from the "drown" water.
F-4
-------
Under Phase II, the following equipment was installed:
1. A collection, neutralization, extended-aeration, and
clarifier system;
2. Another alcohol recovery-distillation system;
3. A hydrochloric acid adsorption and purification system;
4. Condensers to remove organics from reactor vent streams.
Plans for Phase III compliance are discussed later.
Waste Disposal Facilities
The company, in response to an NFIC-Cincinnati inquiry, reported
that some waste materials were incinerated off-site. Incineration
was the original method planned for meeting Phase II requirements but
the system was not satisfactory. No information was provided on any
landfill disposal activity.
Wastewater Treatment
The wastewater treatment plant consisted of a neutralization
tank, an aeration lagoon, and a settling basin. The aeration basin,
which was installed in 1968, had a capacity of about 500,000 gallons.
During 1969 and the first half of 1970, mechanical and other
operational problems were experienced with the new lagoon. At that
time the characterization and segregation of all waste streams were
incomplete. (This was completed by mid-1972).
Company officials stated that their abatement efforts had
resulted in a large reduction in the plant waste load in spite of
rising production rates. The monthly averages of BOD(5) and phenol
loads, as reported to the State by FMC are shown in Figures F-3 and
F-4. The upset periods and overall decrease in loads imposed on the
river are evident. The phenol problem had not been abated as Figure
F-4 shows.
As to reducing inorganic loadings, officials reported that
chlorides had been lowered by 30 percent and acidity by approximately
40 percent.
They said that the following work was undertaken to meet the
Phase III requirements:
1. An experimental, high-rate trickling filter was being tested
in the plant to provide greater BOD and phenolic reductions.
F-5
-------
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F-6
-------
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F-7
-------
2. Installation of in-plant improvements to concentrate
phenolic and BOD-bearing wastes for treatment.
3. Installation of a floating boom at the outfall to retain
scum or oils which might accidentally enter the sewer system.
4. Investigation of chemical and biological treatment of
wastewater streams in combination with sludge-handling studies
necessary to meet future requirements.
(Final design on planned improvements was not completed in mid-1972
and it was evident that the construction schedule for Phase III would
extend to 1973.) Costs of the new treatment works were estimated at
$250,000 for 1972 and $150,000 for 1973.
Cooling Water
Cooling water was pumped from the Kanawha at a flow rate which
had ranged from approximately 3.1 to 4.9 during a 10-year period
ending in 1972. Recent measurements had indicated a temperature
increase of about 6°C. General plant cooling water contained no
inhibitors other than chlorine. Cooling water was screened and
intermittently treated with chlorine to prevent slime growths; this
method had not changed in recent years. There were two small cooling
towers which operated as closed systems with very little loss or
blowdown.
A significant portion of the total BOD(5) load discharged into
the river was carried by the cooling water stream during the survey.
Available records did not indicate what portion of the total load was
typically carried by the cooling water.
Monitoring
The company reported that 24-hour composites of the lagoon and
main sewer streams were analyzed and that any corrective action
needed was taken accordingly. Details on the analytical parameters
monitored were not provided.
Efficiency
Data on removal efficiencies were not available, but company
officials stated that they ranged from 50 percent to 90 percent.
Efficiency dropped sharply in cold weather.
Future Plans
As they did with regard to sales and production information,
company officials treated any plans for expansion or reduction in
F-8
-------
operations as confidential. Judging from the general knowledge that
production had been increasing, the production future of the plant
appeared to be good.
Spill Potential
Spills of materials were treated as a plant emergency, and formal
notification procedure had been established with the State. There
had been no recent spills in which it was necessary to notify the
State under the notification procedure. No spills into the river of
oil, refractory organics, ammonia, or high dissolved solids materials
had been recorded.
From observations during the limited study period, NFIC-
Cincinnati personnel judged that the potential for spills was
moderate and that pollution from spills generally would be evident in
the cooling water stream. The results of the plant survey indicated
that the bulk of the BOD(5) load to the river was in the untreated
cooling water stream; high total load values might, therefore,
reflect a spill or leakage in plant equipment during the sampling
period.
NFIC-Cincinnati Field Survey
Sampling
A composite was made of samples collected every two hours during
a 24-hour period on February 16 and 17, 1972. NFIC-Cincinnati also
took samples for the State, but corporation personnel took their own
samples on the same schedule. Sample points were:
1. Wastewater treatment plant inlet;
2. Wastewater treatment plant outlet;
3. Outfall (combined flow from treatment plant and cooling
water).
4. Raw river water.
The outfall was the only active discharge point into the river. The
plant's sanitary waste was not sampled because it was discharged into
the municipal sewer system. Sampling for bioassay tests was limited
to the discharge at the outfall.
Analytical Results
The analytical results in concentrations are shown in Table F-2
which gives the values determined by EPA, State, and company
F-9
-------
Table F-2
FMC ORGANIC - HITRO, WEST VIRGINIA, PLANT
Analytical Results - 2/16/72 - 2lt-hr. Composite Sauries
SamDle Point
Flow M3D
BODj ng/1
BOD20
COD "
IOC "
pH
Tot. Solids mg/1
Sus. Solids "
1KB
NH3-N
Nitrite & Nitrate "
Tot. Phosphorus "
Chloride "
Sulfate "
Oil & Grease "
Phenols "
Cyanide "
Arsenic ^ ug/1
Lead'3' mg/1
ZincW
Aluminum(3) "
Cadmium (3) "
Chromium (3) "
Copper <3)
Iron (3)
Magnesium'3) "
Manganese' 3) "
Nickel ^3)
Bioassay TLj, 2l*-hr
l*8-hr
96-hr.
EPA
2790
5U80
llltO
-
10600
113
88
2.1
0.6
7"*
-
-
980
660
0.01
-
-
-
-
-
0.18
0.13
^
-
-
-
-
1
WTP Inlet
W.Va.
1890
6072
2000
6.9
10988
287
6.7
1.1
6000
758
5309
< 0.26
< 0.02
OJ.O
0.31
1.8
1.1*
0.2
0.12
0.15
2.9
0.16
0.1
Co.
698
1575
7000
6.8
10757
210
0.1*6
5319
386
780
0.0066
< 0.02
0.31*
i*.o
< 0.005
0.153
0.032
0.25
2.U6
0.18
0.055
2
WTP Discharge
EPA
2930
5360
1290
-
9670
22i*
62
100
0.7
63
-
-
560
630
< 0.01
-
-
-
-
-
0.19
0.13
-
-
-
-
-
W.Va.
1650
5565
7.7
920U
673
99
79
5600
1323
5563
< 0.26
0.03
0.18
0.39
5.1
2.1*
0.1
0.12
1.6
3.6
0.33
0.1
Co.
0.06
975
1325
1.6140
1775
6.8
9126
680
0.17
1*219
1*10
750
< 0.001
0.02
0.39
6.88
< O.O05
0.190
0.063
1.81*
3-03
0.35
O.lOl*
3
Total Waste Outfall
SPA
161*
221*
277
29
-
761*
66
-
<0.5
0.1*
2.6
31*0
-
21
11*
< .01
-
-
-
-
-
0.06
-
-
-
-
-
13
13
13
W.Va.
113
275
2.1*
1*57
31*
1.8
1.2
1*00
1*5
98-9
< 0.26
< 0.02
0.010
0.20
1.8
1*.2
< 0.1
< 0.1
1.1
l*.9
0.12
< O.I
Co.
3.6
93
123
301*
1*5
2.2
1*18
68
0.36
1.25
2.0
11.
< 0.001
< 0.02
0.21
1.1*0
0.007
0.061*
0.013
2.07
l*.68
0.11
0.025
5
Raw River Water
fct>A
16.5
13
8
-
1*08
32
-
< 0.5
0.3
< 0.1
315
-
< 1
0.05
< 0.01
-
-
-
-
-
-
-
-
-
-
-
-
w.va.
3-1
< 1*
7.2
156
36
0.33
< 0.06
19
3.2
612
: 0.26
C 0.02
0.025
0.15
0.1*
l.i*
: 0.1
0.1
0.9
1*.3
0.10
: o.i
CO.
1.
16
9
7.1
-
30
0.1*6
30
19.2
0.008
0.006
< 0.02
O.lU
1.28
< 0.005
0.009
0.01
1-91
1+.68
0.10
0.012
Sample point Ho. 1*, Nitro City Water, was cancelled because it was sampled under the Monsanto investigation in Sitro.
Arsenic analysis not run by NFIC-Cinti.
NFIC metals analyses results are below detectable or normal reporting limits except as shown.
F-10
-------
laboratories. The data for selected parameters are converted to net
pollutant loads in pounds per day in Table F-3.
The results of the survey did not generally confirm the data the
company had reported to the State by FMC-Organic, as a comparison of
the values presented in Table F-3 and Figure F-3 for BOD(5) will
show. The reason for the significantly higher BOD(5) during the
survey has not been determined. The 419-pound-per-day value for
phenol is higher than that usually reported monthly; the company
reported 420 pounds per day average for February 1973.
Toxicity of Effluents
Fish bioassays on the plant's combined wastewater were performed
at pH range of 2.6 - 5.8, the DO was 4.5 - 9.3 mg/1, and the
temperature was 23 °- 2rc, The results indicated a TL50 of 13
percent at 24, 48, and 96 hours. The flow of 0.060 from the
treatment plant was mixed with 3.6 of cooling water, a 60 to 1
dilution. The 13 percent TL50 was measured in the combined effluent
stream and indicates that the plant's liquid wastes were a strongly
toxic source.
Summary and Conclusions
1. High phenol discharges continued to be a problem at this
plant. The State's Phase II and III requirements were a maximum of
16 pounds per day, but recent levels had averaged more than 10 times
that amount.
2. The pH of the discharged wastewater was too low, reflecting
inadequate acid recovery efforts by the company. The pH ranged from
2.0 to 2.4 in 1972, which was not a significant improvement over the
few previous years.
3. Performance of waste treatment could not be appraised on the
basis of the 24-hour sample because of the extended time wastewater
was retained in the lagoon.
4. Pollution abatement efforts over the previous five years had
significantly reduced overall BOD(5) loads to the river. Other than
the required reduction of phenols and the low pH of the discharge,
the company appeared to be meeting State requirements on an average
basis.
5. Phase II use criteria for the Kanawha River would require
reductions in pollutants.
6. The high toxicity of the outfall was of considerable
concern. The impact of this toxicity on the receiving water and the
F-ll
-------
TABLE F-3
NET
POLLUTANT LOADINGS
FMC Organic Chemicals Division
LOAD IN POUNDS PER DAY
Outfall/ Flow
Location MOD
WWTP Inlet 0.06
WWTP Disch. 0.06
Total Waste
Outfall 3.6
WWTP Inlet
WWTP Disch.
Total Waste
Outfall
WWTP Inlet
WWTP Disch.
Total Waste
Outfall
WWTP Inlet
WWTP Disch.
Total Waste
Outfall
WWTP Inlet
WWTP Disch.
Total Waste
Outfall
EPA
1389
11+59
to
2737
2677
7931
5103
1*538
1069!+
1+1+
31
-
330
315
1+18
WVA
BOD-
9^5
825
3301
COD
301+0
2786
8261
TS
51+2^
^5 30
901+2
TKN
3.2
U9
1+1+
PHENOL
2352
21+79
CO
3^9
1+88
2761).
3^79
2315
8652
5182
^570
12557
-
-
-
EPA WVA
BOD2Q
-
-
6729
TOC
567 977
6U2
631
SS
1+1 126
96 319
1021 60
NEL-N
1.1 0.55
50 1+0
36
CO
789
663
3695
-
881+
1081
90
325
111+2
-
-
-
OIL & GREASE
391
376
1+20
1+91 378
280 661
631 1256
181+
196
F-12
-------
possible effect on waste treatment performance were definitely
problems that needed to be solved.
Recommendations
It is recommended that:
1. A BOD(5) discharge limit of 240 pounds per day be achieved
by December 31, 1975. This is based on the approved future use
criteria requiring a dissolved oxygen level for the Kanawha River of
4.0 mg/1 DO at 25°C and a seven-day once-in-10-year low flow of 1930
cfs.
2. The toxicity of the effluent be reduced at least to the
point that it does not exceed 1/20 of the 96-hour TL50 for standard
test organisms.
3. Extended and higher priority efforts be made to meet the 16
pound-per-day State limit for phenol; additional reductions will be
required in the future.
4. Facilities and processes be provided to adequately
neutralize the acid wastewaters and the pH of the discharge should be
in the 6.0 to 8.5 range to meet anticipated effluent criteria.
5. FMC should determine what portion of its loads to the river
is from untreated wastewaters, and report the findings to regulatory
authorities. Further efforts to segregate wastes and route them to
the treatment plant are desirable.
6. Monitoring frequency should be increased at the outfall and
wastewater treatment plant. Flow measurement must be more precise
and be continuously recorded for all wastewater discharged into the
main sewer system.
F-13
-------
MONSANTO COMPANY
ORGANIC CHEMICALS DIVISION
NITRO, WEST VIRGINIA
General Plant Description
The plant is located on the right side (facing downstream) of the
Kanawha River at Mile Point 42.3 about a mile downstream from Nitro
and about 15 miles northwest of Charleston. The property fronts on
the river for about a mile, of which approximately 1,700 feet are
occupied by the plant. The total plant area is 224 acres. Some 70
acres were used for production facilities, 35 for the waste treatment
plant, and another 35 for a landfill (Figure G-l). The remaining
land may be used for expansion.
Operation of the plant was initiated by its first owner, Rubber
Services Laboratories, in 1922. Monsanto purchased the plant in 1929
and employed 240 persons during the first year of operations. About
650 persons were employed in February 1972.
The plant produced approximately 318 million pounds of organic
chemicals in 1971, the highest in its history. The proprietary names
of the chemicals produced are listed in Table G-l. Represented are
rubber chemicals (accelerators, antitoxidants, intermediates, and
vulcanizing agents), agricultural chemicals, oil additives,
plasticizers, and paper chemicals. These organic chemicals were
manufactured in 25 production units, many of which manufactured more
than one product. With one exception, the process units were of the
batch type. Twenty of the units were likely to be operating at any
given time.
Production operations included distillation, drying, mixing,
extracting, absorption, crystallization, adsorption, sizing,
filtration, evaporation, and many others. The plant operated
continuously and operations were not significantly affected by
seasonal changes. There were, however, variations in product demand
and raw material supply. The more than 100 raw materials used at the
plant are listed in Table G-2.
Water Usage
Data on water usage in 1971 are presented in Table G-3. The
company indicated there had not been any definite trend for the
previous 10 years.
G-l
-------
ROCK BRANCH
GOLF CLUB
z
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ORGANIC |
IEMKALJ>iy.
FMC CORP. AMERICAN VISCOSE DIV.
<
t—
LEGEND
I PRODUCTION FACILITIES.
I UNIMPROVED PROPERTY.
WASTEWATER TREATMENT
FACILITIES.
ICITY OF NITRO'S WASTE-
WATER TREATMENT
FACILITIES.
! LANDFILL.
FIGURE G-l
MONSANTO - NITRO PLANT
GENERAL PLAN - FACILITIES AND OUTFALLS
JULY, 1972
G-2
-------
TABLE G-l
PRODUCTS OF THE MONSANTO NITRO, WEST VIRGINIA, PLANT
A- 32
A-100
Avadex BW Tech
Avadex BW-UK
Avadex BW-US & Fargo
Avadex Tech
Avadex UK
Avadex US
Calcium MHA
DTO HV
DTO SHV
EL- Sixty
EM- Tall 906
EM- Tall 926
Flectol H
M-530
MET
Mersize 70 TFL
Mersize 77T
Mersize 77 TFL
Mersize 80 TFL
Mersize 100
MHA Acid
NS-PVI
PA-1260
TFL
PC-13UU
Rosin
RD-18-500
Mersize 603
Mersize-603-A
RT-28-A
RT-52-A
RT-53-A
FT-6U-A
RT-252
Santocure 26
Santocure MOR
Santocure MOR-90
Santocure NS-Pellets
Santocure US-Powder
Santocure Pellets
Santocure Powder
Santoflex 503A
Santoflex A-85
Santoflex AW
Santoflex DD
Santoflex DDS
Santogard
Santolene
Santolene C
Santolene CM
Santolene CP
Santolene CX
Santolube 70
Santolube 70-A
Santonox R
Santopoid 22 RI
Santopoid 22 RIA
Santopoid RI
Santopoid 23 RIA
Santopoid 33
Santopoid 35
Santopoid 39 MI
Santopoid S
Santopoid SJ
Santopoid SL
Santoquin
Santosize 70
Santosize 70T
Santovar A
Santovar AX
Santowhite Crystals
Santowhite Powder
Santowhite MK
SFA
Sodium MET-22$
Sodium MBT-50fc
Stabilized Vegadex Tech
Sulfasan R
Tetra
Thimore
Thiofide
Thitax AP
TORA
UFA Bleached
Vegadex
Vegadex Tech
G-3
-------
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TABLE G-3
WATER USAGE BY MONSANTO IN 1971
Source and Use
Amount
mgd
Kanawha River Water
Tall oil barometric condenser water
Cooling water
Total river water
Nitro City Water
Boiler feed
Cooling (make up)
Sanitary
Process
Total purchased water
6.55
2.9
9.45
0.690
0.147
0.060
1.250
2.147
Wastewater Discharges and Waste Sources
The Company had two active outfalls on the Kanawha. One was from
the treatment plant and the other was the combined tall oil process
wastewater and cooling water. All other wastewater from the plant,
including storm sewer water, flowed to a lift station and was pumped
to the wastewater treatment plant which was located approximately 0.5
mile downstream from the plant. A tabulation of discharges and waste
sources is shown in Table G-4.
G-5
-------
TABLE G-4
MONSANTO WASTEWATER DISCHARGES - 1971
Number
001
002
Description of Outfall
Treatment plant
Tall oil process and cooling
water
Milepoint
41.8
42.5
Flow
2.15
9.45
Wastewater Treatment Program
Historical Development
According to Monsanto, the plant began extensive pollution abate-
ment work in 1958 when Phase I of the State's Department of Natural
Resources started its phased program for cleaning up the Kanawha.
The pollution control requirements for Monsanto, starting with a base
load of 16,420 pounds of BOD(5) per day to the river, are shown in
Table G-5.
TABLE G-5
WEST VIRGINIA PHASED PROGRAM FOR MONTSANTO PLANT AT NITHO
% Reduction
from Base BOD (5) Discharge Limit
Phase I
Phase II
Phase III
40
70
86
9,850 pounds per day
5,000 pounds per day
2,500 pounds per day
Compliance Date
6/30/62
6/30/66
12/31/72
The Phase II limits applied for the period of this study.
Pollution control improvement was evident from a check of Monsanto's
self-reporting data to the State and calculations from monthly
averages. There had been difficulty, however, in meeting the BOD(5)
limit:
G-6
-------
1968: 5,900 pounds per day average
Averages exceeded 5,000 pounds per day limit for 8 months
1969: 5,600 pounds per day average
Averages exceeded 5,000 pounds per day limit for 6 months
1970: 5,900 pounds per day average
Averages exceeded 5,000 pounds per day limit for 7 months
1971: 3,600 pounds per day average
Averages exceeded 5,000 pounds per day limit for 2 months
1972: 4,088 pounds per day average
Averages exceeded 5,000 pounds per day limit for 1 month
(5 months)
Development of the wastewater treatment system started in the
early 1960's, when flow meters and samplers were installed on all
outfalls. Large-scale pilot plants were constructed to check out
standard biological treatment processes and certain variations of
them. Activated sludge did not perform well because of settling
problems. The aerated lagoon system showed promise, was checked
further, and selected for the full-scale plant. An outline of the
construction schedule follows:
Primary lagoon and interceptor completed June 1963
Neutralization pit and first aerated
lagoon completed October 1963
Second aerated lagoon completed May 1966
Aeration capacity doubled April 1970
Process wasteloads were also reduced by in-plant methods. The
BOD(5), BOD(20), and total Kjeldahl nitrogen (TKN) loads per day for
recent years are shown in Figures G-2, G-3, and G-4. The decline in
BOD loadings was broken for a period of several months starting in
October of 1971. According to the Company, an upset in the
wastewater treatment plant was caused by a minor change made to
improve efficiency in a manufacturing process. This change had an
unexpected side reaction which produced a member of the sulfa drug
family in trace quantities, but sufficient for the antibiotic to
cause a major upset in the biological treatment system. The problem
had been corrected and low loadings were being achieved even during
times of marked increases in production. This contrast in production
levels and effluent loads and the declining effluent loading per unit
of production are shown in Figures G-5 and G-6, provided by the
company.
G-7
-------
G-8
-------
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100-r
90- -
80--
70- -
-S 60+
§ 30 +
O
40- -
30- -
20- -
10--
1958
PRODUCTION
EFFLUENT LOAD - 5 DAY BOD
I I I I I I I—K-hH—h-r
60
62
66
68
70
64
FIGURE G-5
EFFLUENT LOAD REDUCTION AND PRODUCTION INCREASE
MONSANTO NITRO, WEST VIRGINIA PLANT
G-ll
-------
POUNDS OF BOD5 PER 100 POUNDS
OF CHEMICAL PRODUCTION
1 1 1 1 1
1958
66
68
70
FIGURE G-6
DISCHARGED BOD5 AS A FUNCTION OF PRODUCTION RATES
MONSANTO NITRO, WEST VIRGINIA PLANT
G-12
-------
Waste Disposal Facilities
Monsanto reported that in 1971 it had disposed of 8,782 pounds
per day of TOG by landfill and 18,940 pounds per day by incineration.
On the basis of all waste loads reported as TOG, landfill and
incineration represented approximately 57 percent of the total.
Table G-6 contains data reported by the company except that its
numbers for by-product sale, waste load reductions through
monitoring, etc., and material recycled to process have been deleted
as inappropriate in a reckoning of the actual total plant waste load.
TABLE G-6
DISPOSITION OF THE TOTAL WASTE LOAD
MONSANTO PLANT - 1971
Total Organic Carbon
Disposal Method (lb/day)
Material landfilled 8,782
Material burned 18,940
Material to disposal pond 9,372
Material to treatment plant (value low because
sampling missed solids and oils) 8,102
Tall oil barometric condenser uncontrolled
load (1962 level) 3,207
48.403
Wastewater Disposal
For the tall oil process barometric condenser wastewater, which
was discharged along with a cooling water stream, all wastes entered
sewers and were processed through the treatment plant (Figure G-7).
Primary treatment was provided in three large lagoons. The first
served as a pump sump after the gravity interceptor from the
production area. The second and third (four- to five- and two-day
retention times, respectively) removed settleable solids and floating
material and provided equalization and storage capacity. A spill or
upset could be segregated in the largest lagoon and slowly blended
into the main flow. pH adjustment was provided by passing the flow
G-13
-------
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G-14
-------
through a 5,000-ton crushed limestone bed. This provided, the
company said, reliable control without the problems of instrumenta-
tion and metering pumps.
Secondary treatment was provided by two aerated lagoons, each
having a capacity of 1.2 million gallons. Aeration was provided by
one fixed Infilco 50-hoursepower turbine aerator (rated capacity
5,000 pounds per day oxygen transfer) and three Lightnin floating
aerators (rated capacity of each was 3,900 pounds per day oxygen
transfer). The aerated lagoons were originally designed to be
operated in parallel, but had been operated experimentally in series-
parallel (all flow from one lagoon discharging into the second, both
lagoons receiving equal amounts of primary effluent) to obtain
increased efficiency.
The capacity of the treatment plant was:
1. Primary treatment-visual pollution removal: above 5.8 mgd.
2. Primary treatment-solids and oil removal plus full
equalization: 4.5 mgd.
3. Limestone bed and biological treatment: 2.6 mgd maximum.
Cooling Water
All plant cooling water was discharged through outfall No. 002.
This stream also contained the tall oil process barometric condenser
wastewater. The discharge from outfall No. 002 represented a
significant portion of the total BOD(5) load discharged into the
river. The stream was untreated at the time of the survey. (A new
skimming pond to remove fatty acids was completed in August 1972.)
Appraisal of thermal loadings was not a part of this study and
cooling water temperatures were not measured.
Monitoring
In-plant monitoring was provided by means of continuous sampling
at the manufacturing plant, the wastewater lift stations, and the
tall oil intake and discharge points. TOG analyses, supplemented by
gas chromatographic analyses, were performed daily. In addition,
continuous hot-wire instrument coupled with an alarm and recorder was
used to detect volatile solvents in the sewer line to the lift
station.
At the treatment plant, flow was measured and recorded by
magnetic flow meters. Effluent TOC and pH were analyzed daily, and
other parameters weekly — BOD(5), BOD(20), total solids, suspended
solids, Kjeldahl nitrogen, acidity, and chloride.
G-15
-------
Removal Efficiency
Company officials reported that only a limited amount of data had
been collected on overall treatment plant efficiency. Their emphasis
had been on monitoring soluble organics, because they believed that
suspended solids and oils were almost completely removed in the
primary lagoons. They had, however, recently established the BOD(5)
and TOO ratio on current wastewaters and applied it to estimated raw
BOD loads for 1971 (Table G-7).
The samples taken and analyses made do not provide good data for
evaluating removal efficiencies. It was necessary, because of a
concurrent sampling load at nearby plants on the Kanawha, to do all
the Monsanto sampling (as at the other plants) during one 24-hour
period.
Future Plans
(Monsanto recently expanded the wastewater treatment plant, as
indicated in Figure G-8, to comply with the State's Phase III
requirements. Construction started in July and was completed in
December 1972. The salient features are a five-fold increase in
retention time, additional aeration capacity, and improved
flexibility in operation. Construction of a new skimmer pond for
removal of fatty acids by flotation from the tall oil stream was
completed in August 1972. These improvements will provide capacity
for increased loads.
New facilities for removal of ammonia nitrogen from the major
source began operation in January 1973. The ammonia is stripped
under alkaline conditions and is incinerated.
Research work toward a major improvement in the largest single
process source (25 to 30 percent of the treatment plant load)
recently passed a critical point and is reported as highly encour-
aging. It is anticipated by the company that this reduction will be
achieved by late 1974.
A continuing program is being carried out by Monsanto to review
the contribution from each individual process and institute new
control methods.)
Spill Potential
Monsanto had an exemplary system for minimizing the effects of
process spills on the river. All wastes, except tall oil and cooling
water, flowed to the treatment plant. The primary lagoons provided
equalization to reduce the shock of any spill on the biological
G-16
-------
TABLE G-7
MONSANTO NITRO, WEST VIRGINIA, PLANT, 1971 TREATMENT
Plant Efficiency
Five-Day BOD Load
January
February
March
April
May
June
July
August
September
October
November
December
Est . Input
Pounds Per day
12,592
16,301
15,613
14,933
22,858
12,477
9,689
9,923
12,221
11,705
12,131
11,947
Discharge
Pounds per Day
3,363
4,324
4,257
2,189
2,543
2,458
2,076
1,832
2,117
1,544
3,377
4,094
% Removal
73.5
76.1
79.6
83.2
86.1
81.7
76.1
81.4
82.8
83.6
71.0
65.7
Average 13,533
2,765
78.45
G-17
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G-18
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treatment system. The potential pollution of the river from in-plant
spills was, therefore, considered to be minimal.
NFIC-Cincinnati Field Survey
Sampling
The two outfalls were sampled for a 24-hour period on February 16
and March 12, 1972. Water purchased from the city and raw river
water were also sampled. Samples were taken at two-hour intervals
for 24-hour composites. NFIC-Cincinnati collected split samples for
the State and Monsanto collected its own.
The second date for sampling was scheduled because the tall oil
process was unexpectedly not operating on February 16. The March 21
effort was expanded at the company's request to include the waste
treatment plant. The request was made because officials did not
consider that the treatment plant had not completely recovered from
the reported sulfa drug upset at the time of the February 16
sampling.
Analytical Results
Analytical results are presented in Tables G-8 and G-9. A
portion of the March 21 data, converted to loads in pounds per day,
is shown in Table G-10.
For the purposes of this survey, reasonable agreement of the data
from EPA, State, and Monsanto sources was obtained, but certain
significant exceptions have been noted.
The Company has stated that the BOD(5) loads for the tall oil
discharge on March 21 are too high.
f
The NFIC-Cincinnati tall oil discharge analytical results for
phenol and oil and grease have also been questioned by the company.
The EPA analysis for oil and grease was 36 mg/1, the company's was
zero. The skimmer pond was not yet in operation, therefore, the zero
value is certainly questionable. The NFIC-Cincinnati phenol analysis
of the March 21 tall oil wastewater sample is much higher than those
of the State and company. It should be noted, however, that the
State's analysis would indicate a phenol load of 28 pounds per day as
compared with its limit of 4 pounds per day under minimum flow
conditions, and that the company's phenol analyses shows the same
value of 0.30 mg/1 for city water, river water, and the tall oil
discharge.
G-19
-------
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rH
0 0
VO H
CM O
O 0
V
CO
VO OJ
CO O
rH
O
•pi? 6
W O
rS-5" ^
O
o
o o
883
» S S
rH iH H
iHHrHHHrHHrHiH.
fi
0)
I
ITN OJ
888
m m o
lid
lids
•d w
rH rrj
O 0)
-------
TABLE G-9
MONSANTO NIVRO W. VA. PLANT - ANALYTICAL RESULTS FOR 3/21/72 SAMPLING
Sample Point
Flow MOD
BODj mg/1
BOD20
COD
TOC "
pH
Tot. Solids mg/1
Sus . Solids "
Vol. Solids "
TKN "
NHj-N "
Nitrite & Nitrate "
Tot .Phosphorus "
Chloride "
Sulfate "
Oil & Grease "
Phenols "
Cyanide "
Mercury Mg/1
Arsenic Mg/1
Lead mg/1
Zinc "
Aluminum "
Cadmium "
Chromium "
Copper "
Iron "
Manganese "
Magnesium "
Nickel
Bioassay TI^ 2l*-hr.
l*8-hr.
96-hr.
1
WWTP Inlet
EPA
330
1670
1*80
2.5
1*700
1*8
818
37
36
0.8
5-5
350
1.3
<0.01
W.Va.
801
1021
2.8
1*853
174
157
i*.o
3600
1000
0.01*5
Co.
2.005
1*11
837
1550
595
2.85
l*5l*0
262
230
7-
251*0
1075
3U.2
1-3
2
WWTP Discharge
EPA
230
5l+l*
1300
290
6.6
8660
ll*2
1100
220
190
0.1*
18
2620
22
0.33
•C0.01
10
7.6
7.6
W.Va.
217
!*93
6.6
8771*
21*0
215
17
0.07!*
CO. (
1.712
271
1*26
109!*
1176
335
6.1*
861*8
80
9
267
215
16
3180
2510
l*
0.6
3
Tall Oil Discharge
EPA
39
133
29
5-7
210
20
26
1.0
1.0
0.8
0.1
1*0
68
36
2.6
<0.01
39
39
39
W.Va.
52
75
5-8
230
1.3
0.1+9
0.5
100
80
0.51*
Co.
7-92
28
35-7
11+.8
1*0
6.2
202
202
1*0
28
20
0
35
111
0
0.30
1*
River Water
EPA
3-2
13
6
6.1
251*
21
100
0.8
0.5
0.9
1.0
1*0
87
1
0.1
<0.01
W.Va.
3-5
l*.l*
6.2
236
1.2
0.1*9
0.27
!*9
80
0.110
Co.
11.5
13.5
15
25
6.2
236
16
3.9
1.2
0
35
102
0
0.30
5
City Water
EPA
< 5
5
7-3
1*8
6
30
0.2
<0.5
1.1
<0.01
W.Va,
Co.
2.76
l*.7l*
57-1*
35
7.1*
150
2.60
0.87
0
35.
78.
0
0.30
G-21
-------
TABLE G-10
WWTP Inlet
WWTP Disch.
001
Tall Oil
002
WWTP Inlet
WWTP Disch.
001
Tall Oil
002
WWTP Inlet
WWTP Disch.
001
Tall Oil
002
WWTP Inlet
WWTP Disch.
001
Toll Oil
002
RESULTS OF 3/21/72 SAMPLING AND ANALYSES
MONSANTO NITRO, WEST VIRGINIA, PLANT
LOAD IN POUNDS PER DAY
Outfall/
RAPP No.
WWTP Inlet
WWTP Disch.
001
Tall Oil
002
Flow
MGD
2.005
1.712
7-92
EPA WVA CO
BOD
5500 13000 6800
3300 3100 3800
2 toO 3200 1100
COD
EPA WVA
BOD20
17000
7800 7000
14700
TOC
CO
itooo
6100
1500
27900
18600
7930
77800
16000
TS
73000
12300 125000 121000
TKN
600 2900 14.300
3100 3UOO 3800
13. 6.6 1600
17.
PHENOL
0.7 17.
k.7 1.0 IK 3
79^0
lj-070
1520
700
SS
9360
1+280
990
160
28 20.
NH -N
600 2600 3800
2700 3100 3coo
33 - 12^0
OIL & GREASE
5900 - 570
3A - 57
2 too o
G-22
-------
Toxicity of Effluents
Static bioassays were conducted with fathead minnows using waste-
water taken from the two outfalls. At least a portion of the
toxicity measured may have been from a neighboring plant, FMC Organics.
The toxicity measured at the treatment plant was significantly higher
than the discharge from FMC Organic and test animals died immediately
in a 56 percent test solution.
Bioassay test conditions for the treatment plant discharge were:
DO range of 4.7 - 7.2 mg/1; pH range of 6.3 - 6.5; and temperature
range of 23 - 27°C. The TL50 (median tolerance limit) was 10 percent
at 24 hours and 7.6 percent at 48 and 96 hours. (TL50 is the
concentration of effluent that would be lethal to 50 percent of the
fish held in it for a specified time period, i.e., 24, 48, or 96
hours. Thus, the lower the TL50, the higher the toxicity of the
effluent.)
For the tall oil discharge, the bioassay test conditions were: DO
range of 4.7 - 6.7; pH range of 5.7 - 6.5; and temperature range of
23 -27 °C. The TL50 at the FMC Organic plant discharge, about 200
yards upstream from the Monsanto intake, was 13 percent at 24, 48, 96
hours.
The high discharge BOD(5) load on February 16 was caused by an
upset from which the treatment plant had not recovered, as mentioned
earlier. The low input BOD(5) load to the treatment plant on March
21 is attributed to the fact that a production unit which ordinarily
is a large source of the load was down on that date.
Summary and Conclusions
1. Pollution abatement programs carried out since the
establishment of the 1958 baseload had reduced the load to the river
despite large increases in production.
2. As shown by the records, BOD(5) loads discharged into the
river had fluctuated widely.
3. Additional monitoring should be conducted at the treatment
plant.
4. There is a need to establish the precision and accuracy of
the company's analytical techniques, particularly in instances where
its determinations vary widely from those of the State and NFIC-C.
5. Achievement of water quality improvement goals for the
Kanawha will require significant additional abatement efforts over
those existing at the time of the survey. (Although the recent
G-23
-------
expansion of the treatment plant is expected to meet the State's
Phase III requirements, its ability to meet future use criteria has
not been appraised.)
6. Specific corrective action must be taken with regard to the
toxic discharge problem.
7. The combined cooling water and tall oil barometeric
condenser discharge contained significant amounts of process wastes
measured as BOD(5), COD, oil and grease, and phenol.
8. The spill prevention and control system at the plant was
very good.
Recommendations
It is recommended that:
1. The company reduce its BOD(5) load to the river to a total
of no more than 320 pounds per day and its total nitrogen load to
1,400 pounds per day. These numbers are based on the maintenance of
4 mg/1 DO at the Kanawha River's sag point at a seven-day once-in-10
year low flow of 1,930 cfs at Charleston.
2. The toxicity of the effluent be reduced at least to the
point that no discharge exceeds 1/20 of the 96-hour TL50.
3. The company maintain the pH of all discharges in the 6.0 -
8.5 range.
4. The company meets the State's phenol discharge limit of 4
pounds per day.
5. The company establish a monitoring system at the treatment
plant which will include determination of inlet values for BOD(5),
TOG, and TKN. This will provide for a way to improve the pollution
abatement effort.
6. Improved monitoring, including continuous pH and temperature
measurements, be effected for better characterization of the cooling
water and tall oil process water streams.
7. Consideration be given to using the primary lagoon
facilities as an anaerobic lagoon to meet future wastewater treatment
requirements. This has been successfully demonstrated elsewhere in
the treatment of organic chemical wastewaters. Neutralization of
wastewaters before the primary lagoon would be required.
G-24
-------
8. The Monsanto Company make every possible effort to further
separate process wastes from cooling water and tall oil process
water.
G-25
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