PA-670/2-74-009
:ebruary 1974
                        Environmental  Protection Technology Series
Analysis of Pollution  Control Costs

                                   Office of Research and

                                   U.S. Environmental Protectio

                                   Washington, D.C. 20460

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             RESEARCH REPORTING SERIES
Research reports of the  Office  of   Research  and
Monitoring,   Environmental Protection Agency, have
been grouped  into five series.  These  five  broad
categories  were established to facilitate further
development   and  application   of    environmental
technology.    Elimination  of traditional  grouping
was  consciously  planned  to  foster   technology
transfer   and  a  maximum  interface  in   related
fields.  The  five series are:

   1.  Environmental Health Effects  Research
   2.  Environmental Protection Technology
   3.  Ecological Research
   1.  Environmental Monitoring
   5.  Socioeconomic Environmental Studies

This report has  been assigned to the ENVIRONMENTAL
PROTECTION    TECHNOLOGY   series.     This    series
describes   research   performed  to  develop  and
demonstrate    instrumentation,    equipment    and
methodology   to   repair  or  prevent environmental
degradation from point and  non-point  sources  of
pollution.  This work provides the new or  improved
technology  required for the control and treatment
of pollution  sources to meet environmental quality
standards.

                   EPA REVIEW NOTICE
This report has been reviewed by the Office of Research and
Development, EPA,  and approved for publication.  Approval does
not signify that the contents necessarily reflect the views
and policies of the Environmental Protection Agency, nor does
mention of trade names or commercial products constitute
endorsement or recommendation for use.

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                                                   EPA-670/2-7^-009
                                                   February
         ANALYSIS OP  POLLUTION CONTROL COSTS
                      By
                Frank • J.  Doyle
        Harasiddhiprasad G.  Bhatt and
                 John R.  Rapp
        ARC Contract No.  72-87/RPC-713
               Project  lUOlO HQ.C
            Program Element IBBO^O

              Project Coordinator

             Dr. David  R.  Maneval
        Appalachian Regional Commission
            1666 Connecticut Avenue
            Washington, D.C.  20235
                 Prepared for
        APPALACHIAN REGIONAL COMMISSION
            WASHINGTON,  D.C.  20235
                       and
       OFFICE OF RESEARCH AND DEVELOPMENT
      U.S. EjmROIMENTAL PROTECTION AGENCY
            WASHINGTON,  D.C.  2C&60
For sale by the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402 • Price $3.20

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                               ABSTRACT

This report fulfills requirements for an effective, workable handbook on
pollution control costs and factors effecting these costs for the Monon-
gahela River Basin.  The information in the report is based on the latest
technological developments and cost analyses of recent reclamation projects.
Although the report was developed for the Mbnongahela River Basin study,
the cost estimates and supporting data should prove useful for all of
Appalachia and other areas with similar topography, mine drainage pollution
problems and mining history.

Specific areas covered by the report are surface mines, refuse piles, mine
sealing, mine drainage treatment, air pollution control, solid waste hand-
ling and disposal, abandoned automobiles, and erosion and sedimentation
control.

This report was submitted in partial fulfillment of Project number lUoiO HQC
under Appalachian Regional Commission Contract Number 72-87/RPC-713 by
Michael Baker, Jr., Inc., Beaver, Pennsylvania  15009, under the cooperative
sponsorship of the Appalachian Regional Commission and the U.S. Environmental
Protection Agency.  Work was completed as of February 1973-
                                  ii

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CONTENTS

Abstract
Executive Summary
Introduction
Part A - Abatement of Coal Mine Drainage Pollution and Mining
Related Problems
I Strip Mine and Refuse Bank Backfilling and Grading
II Revegetation of Lands Disturbed by Coal Mining
III Mine Sealing
IV Stream Diverson
V Treatment of Mine Drainage
VI Other Mine Drainage Abatement Procedures
VII Refuse Bank and Mine Fires
VIII Mine Subsidence Control
Part B - Abatement of Pollution from Sources Other Than
Coal Mining
I Cost Estimate for Air Pollution Control Equipment
II Solid Waste Handling and Disposal Costs
III Abandoned Automobile Removal Costs
IV Erosion and Sedimentation Control Costs
V Industrial Wastes "Orphan" and Other Environmental
Problems in the Public Sector
Addendum
Acknowledgment s
Page
ii
V
1

13
43
57
109
115
319
329
345

359
385
401
409
419
427
437
  iii

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                         EXECUTIVE SUMMARY

       At the Monongahela Enforcement Conference convened in Pittsburgh,
Pennsylvania in August,  1971, the Appalachian Regional Commission was
charged with the task of developing a comprehensive environmental improve-
ment program for the  Monongahela River Basin.  As part of this  responsibil-
ity,  the Commission must determine as accurately as possible the costs of
various remedial programs which it recommends. An effective,  workable
handbook on pollution control costs and factors effecting these costs based on
the latest technological developments and cost analyses of recent reclamation
projects  is needed to perform this function.

       This  study performed by Michael Baker,  Jr. ,  Inc. under  ARC Con-
tract No. 72-87/RPC-713 titled  "Analysis of Pollution Control Costs" provides
the data which will enable the Appalachian Regional Commission to estimate
costs of pollution abatement in the Monongahela River Basin.  Although this
publication was  developed for the Monongahela River Basin study, the cost
estimates and supporting data should prove useful for all of Appalachia and
other areas with similar topography, mine drainage pollution problems and
mining history.   The unit price cost estimates are based on the best available
information and are suitable for budget estimates and preliminary planning,
but they do not replace the  detailed cost estimate  required in producing con-
tract plans and specifications.

       The subject matter is separated into two parts.  Part A, Abatement
of Coal Mine Drainage Pollution and Mining Related Problems, contains:
1.  Strip Mine and Refuse Bank Backfilling and Grading,  2.   Revegetation of
Lands Disturbed by  Coal Mining, 3.  Mine Sealing, 4.  Stream Diversion,
5.  Treatment of Mine Drainage, 6.  Other Mine Drainage Abatement  Proced-
ures, 7.  Refuse Bank and Mine Fires and 8.  Mine Subsidence Control.  Part
B, Abatement of Pollution  from Sources Other Than Coal Mining, contains:
1.  Cost  Estimates for Air Pollution Control Equipment,  2.   Solid Waste Hand-
ling and Disposal Costs,  3. Abandoned Automobile Removal Costs,  4. Erosion
and Sedimentation Control  Costs and 5.  Industrial Wastes "Orphan" and Other
Environmental Problems in the Public Sector. An "Addendum" reports on recent
publications noted after completion of the main body of the report.  The report
contains  about 275 references  to important publications on pollution abatement
and nearly 200 tables and text figures.

                 Unit Costs for Mine Drainage Abatement

       Significant unit costs for mine drainage abatement recommended for
use in  remedial program planning for the Monongahela River Basin are:

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Surface Mine and Refuse Bank Reclamation

1.  Strip Mine Backfilling and Grading
2.  Refuse  Bank Contouring and Grading
3.  Soil Cover for Graded Refuse Bank
4.  Refuse  Bank Removal and Burial
5.  Soil Cover at Burial Site
6.  Clearing and Grubbing
7.  Re vegetation

Mine Sealing
                                                   $l,250/Acre
                                                   $l,000/Acre
                                                   $2,500/Acre
                                                   $ 1.00/C. Y.
                                                   $ 0.50/Yd.2
                                                   $  300/Acre
                                            $350 to $  400/Acre
3.
4.
5.
6.
7.
Hydraulic Seals for Accessible Mines
a)  Halliburton Type Seals (Chemical grout
      and aggregates  including remedial grout-
      ing, but no grout curtain)
b)  Reinforced Concrete Seal including
      100 L.F.  of grout  curtain         $15,000
Hydraulic Seals for Inaccessible Mines
a)  Grouted Double Bulkhead Seal
      including  100 L.F. of grout curtain
b)  Grouted Single Bulkhead Seal including
      100 L. F.  of grout  curtain
Limestone Barrier Mine Seal (Permeable  Plug)
Air Seal (Masonry)
Dry Seal (Clay)
Dry Seal (Masonry)
Grout Curtain                               $40
  $10,000/Each

to $20, 000/Each


  $21, 000/Each

  $  5, 000/Each
  $  7, 500/Each
  $  5, 000/Each
  $  1, 500/Each
  $  3, 500/Each
to $     80/L. F.
Stream Diversion
Treatment of Mine Drainage
                                                  $
        20/L.F.
       The design of mine drainage treatment plants is in its infancy.  The
capital and operating costs of existing treatment plants may not be an indica-
tion of future treatment costs because most of the actual cost data developed
to date is based on lime neutralization.  A great deal of effort has been ex-
pended in the last few years  by government agencies and industry in develop-
ing processes for treatment  of mine drainage other than lime neutralization
which has several disadvantages  including the production of large volumes of
sludge and the addition of hardness to the effluent.   The mine drainage treat-
ment processes which show promise are:  1) limestone neutralization, 2) com-
bination  lime-limestone neutralization,  3) ion exchange,  4) biochemical oxi-
dation followed by limestone neutralization, and 5) reverse osmosis. Several
treatment plants  are now  in operation using the first four processes. A re-
duction in capital and operating costs  should occur as progress is made in
design and methods  of operation.
                                  VI

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       It is difficult to recommend capital and operating cost formulas for use
in developing overall cost estimates for mine drainage treatment in the Mon-
ongahela River Basin.  It is necessary to not only predict inflationary trends,
but also  the effect a technological development or breakthrough would have on
costs. Based on the  mine drainage treatment data in this report,  Gibbs & Hill,
Inc. proposed using the following capital cost formula and operating cost in
their study for the Appalachian Regional Commission:

          Installed Capital Cost           $  = 350, 000 Q°- 72
                   Where Q is flow expressed in MGD

          Operating  Cost            20£/1,000 gallons  treated

       The  capital cost is developed from U. S.  Bureau of Mines cost curves
for limestone treatment plants, whereas, operating cost is based on using hy-
drated lime as a neutralizing agent.

                 Unit Costs  for Mining Related Problems^

Extinguishment of Coal Refuse Bank Fires

       The  following formula based  on project costs  tabulated in this report,
where refuse was sluiced into a lagoon using  a water  cannon, is being used by
Gibbs & Hill, Inc. in their study for the Appalachian Regional Commission:

       $ = 1.1 V              Where  V is volume in  million cu. yds.

Mine Subsidence Control

       Fly Ash Injection Methods                        $75, 000/Acre
       Grouted Aggregate Pier Method                  $85, 000/Acre

       The  report contains the results of an extensive study  of pollution con-
trol project cost data.  A thorough search was made  of the literature, and it
is believed most of the significant recent publications were reviewed. Signifi-
cant pollution control cost figures in older publications were updated using the
Engineering  News-Record Cost Index.  Comparisons were made of the estimated
costs of  construction with actual "as built" project costs and factors  causing
errors have  been identified.  Meetings were held with many individuals in gov-
ernment  and industry and their cooperation in supplying unpublished information
used in this study is gratefully acknowledged.
                                   VII

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                           INTRODUCTION




                        TABLE OF CONTENTS




                                                              Page No.




Purpose and Scope of Report                                       3




Format of Report                                                 5




Monongahela River Basin Pollution Studies                          5




References                                                       8
                                 -1-

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                             INTRODUCTION

Purpose and Scope of Report

       In 1971, the Environmental Protection Agency reconvened in Pittsburgh,
Pennsylvania an interstate water pollution control conference on the Monongahela
River Basin( 1 > 2).  The purpose of the conference was to adopt new standards at
both the  state and federal levels to curb mine drainage pollution, to recommend
a mine drainage abatement program and to discuss the results of studies on mine
drainage pollution within the  basin completed since the first conference  was held
in 1963(3>4'5).

       The conferees, consisting of representatives from the states of West
Virginia, Pennsylvania and Maryland, the Ohio River Valley Water Sanitation
Commission (ORSANCO) and the  Federal Government,  recognizing that  aband-
oned mine drainage pollution in the Monongahela River Basin is primarily a
regional problem,  requested the  Appalachian Regional  Commission to direct
and coordinate with the Environmental Protection Agency and other appropriate
agencies the abatement program  recommended  by the state and  interstate  con-
       The Appalachian Regional Commission is charged with the task of devel-
oping a comprehensive environmental improvement program for  the Monongahela
River Basin.  As part of this responsibility, the Commission must determine as
accurately as possible the costs of various  remedial programs which it recom-
mends.  An effective, workable handbook on pollution control costs and factors
effecting these costs is needed  to perform this function.  The Appalachian Reg-
ional Commission engaged Michael Baker,  Jr. , Inc. to perform  the pollution
control cost study under ARC Contract No.  72-87/RPC -713 titled "Analysis of
Pollution Control Costs. "

       This report provides data which will enable  the Appalachian Regional
Commission to estimate costs of abating mine drainage and other environmental
problems in the Monongahela River Basin.  In order to produce an effective,
workable handbook,  it is  necessary to accumulate and analyze available project
cost data on pollution control on a region-wide basis and translate it into a form
from which projections for costs of future work can be estimated.  For this
assignment,  Michael Baker, Jr.,  Inc. was  required to perform the following
tasks:

1.   Collect, become familiar with, analyze and evaluate currently available
     literature on costs of mine drainage pollution abatement. Existing publi-
     cations^, 8) on  mine drainage pollution control costs were developed using
     data prior to 1966, but more effective work has been accomplished in this
     field since 1966 than in all the previous  years.
                                   -3-

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2.  At meetings with State, Federal and private individuals  or through other
    analysis gather  relevant data and then analyze  recent (since 1966) mining
    area restoration projects in Appalachia to determine the costs  of recla-
    mation.

3.  Compare the estimated costs of construction with actual "as built" project
    costs to furnish initial insight into the problem of accurately projecting
    construction costs.

4.  Identify factors  causing errors  in cost estimates.

5.  Using appropriate factors,  update pollution  control cost figures in the lit-
    erature prior to 1970 where updating would  be  reliable and of current use-
    f ulne s s .

6.  Prepare a handbook setting forth unit costs  for abatement of coal mine
    drainage pollution and mining related problems.   The  handbook should in-
    clude figures for the latest technological developments or processes  in-
    cluding those utilized immediately prior to the reporting.

7.  Prepare analyses  of presently available abatement techniques  and determine
    average unit costs for abatement of pollution from sources other than coal
    mining. This  part of the project merely asked for the best estimates of
    costs from the  best data presently available for the following environmental
    deterrent categories:  a)  air pollution, b) solid wastes,  c) abandoned auto-
    mobiles,  d) erosion and sedimentation,  and e)  industrial wastes "orphan"
    and  other environmental problems in the public sector.

       Although this publication is concerned mainly with an analysis of pollution
control costs applicable for use in developing a comprehensive environmental im-
provement program  for the  Monongahela River Basin, the  cost estimates and sup-
porting data should  prove useful for all of Appalachia and other areas with similar
topography, mine drainage pollution problems and  mining history.   Emphasis was
placed on reclamation project cost data from areas within or adjacent to the  Mon-
ongahela River  Basin.  But  since Pennsylvania,  followed by  Vest Virginia, are
the leaders in mine drainage pollution abatement,  the  project cost  data from these
states would include most of the significant data on mine drainage abatement in
the United States.  Maryland, Ohio,  Kentucky and Tennessee have  recently passed
stringent mining regulations and have active mine drainage abatement programs,
but there is only a limited amount of information available from these states at
present.

       The unit price cost estimates in this publication are  based on the best
available information and are suitable for budget estimates and preliminary plan-
ning,  but are not intended to replace the  need for a detailed  cost estimate  re-
quired in producing contract plans and  specifications.
                                   -4-

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Format of Report

       The report has been divided into two main categories, "Abatement of
Coal Mine Drainage Pollution and Mining Related Problems" and "Abatement
of Pollution From Sources Other Than Coal Mining. "  Each category contains
sections dealing with  individual environmental problems within that category.
For convenience and easy reference,  there is a general "Table  of Contents"
at the beginning  of the report and each section has a detailed "Table of Con-
tents"  which lists tables  and figures found in the  section.  An "Addendum"
was necessary to report  on recent  publications noted after completion of the
appropriate section.

Monongahela River Basin Pollution Studies

       The Monongahela River Basin  overlies one of the most valuable and  ex-
tensively developed deposits of bituminous  coal in the world.  Coal  mining,
coking and iron and steel manufacturing have made  this district world famous(°).
The basin lies entirely in the Appalachian Plateau Province and is characterized
by  rugged topography with narrow stream valleys.  The drainage basin comprises
a total of 7, 340 square miles of which 57 percent is in West Virginia, 38 percent
in Pennsylvania  and 5 percent in Maryland.  Stream flow in the  basin is regulated
to some  extent by a network of multiple purpose dams and  reservoirs  in the head-
waters.   The  lower Monongahela River passes through one of the most densely
developed industrial areas in the nation.

       The mine drainage inventory completed by the Environmental Protection
Agency(l»2) documented  the  belief  that the  Monongahela River Basin is more
intensely polluted by mine drainage than any other major drainage basin in the
United States.   The total net acid load from all coal mining sites was over one
million pounds per day and the iron load more than  300, 000 pounds  per day.
This data did  not reflect  the  additional pollution of other chemicals  or sediment
which are found  in mine drainage as a result of industrial and urban develop-
ment,  timbering, farming and other activities within  the basin.   Less than 18
percent depletion of the original bituminous coal  resources has  resulted in this
vast mine drainage pollution problem.

       If we assume that drainage  from combination underground-surface mines
originates primarily from underground sites,  the inactive  underground mines
would be  responsible for about 55 percent of the net acid load and 54 percent of
the iron.  Active mining  sites (8 percent of the total inventoried) contributed 35
percent of the total net acid load and 40 percent  of the iron.  Approximately ZO
percent of the total sources inventoried contribute 85 percent of the net acid
load.

       The Environmental Protection  Agency' •"•» *•> estimated the total cost for
"at source" abatement of mine drainage and water treatment range from $218
million to $656 million for a ZO year period.  Garvey(lO) believes the  high fig-
ure is  much too low and should be in the neighborhood of two billion dollars.
                                   -5-

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       The damaging environmental effects of mine drainage pollution in the
Monongahela River Basin has been a topic  of discussion for over 60 years'  »
Since at least the  1920's, mining activity along the Monongahela River has  been
causing increasing problems for public water works located  on the river(13).
The first  comprehensive approach to mine drainage control in the drainage basin
was initiated in the 1930's by Federal and State governments through relief ad-
ministration programs  such as  Works  Progress Administration, Federal Emer-
gency Relief Administration and Civil Works Administration^).  Much of this
work consisted of the construction of air seals at abandoned mines.  In 1938,
Hodge(14) concluded from his studies that air sealing of abandoned mines,  di-
version of water from mines, and the construction of large flood control dams
were the best methods for assuring the maintenance of satisfactory stream con-
ditions for public  water  supplies, industrial uses and recreational activities.
The U. S.  Public  Health Service^' came  to a similar conclusion in 1942.   Their
study indicated there was a significant reduction  in acid mine drainage as  a re-
sult of the air sealing program, but  chemical neutralization of mine drainage
was not economically feasible.  Madison^   ' in a paper presented before the
American Chemical Society in 1950, stressed the significant amounts of organic
pollution carried by the  Monongahela River and indicated that as effective  mine
drainage controls  are developed, the need  for sewage treatment plants will in-
crease.

       In the 1960's as a result of pollution studies  by the U. S. Public Health
Service^) and others, the Federal Government became  increasingly aware that
a serious  interstate pollution problem was occurring in  the Monongahela River
Basin.  The Secretary of Health, Education and Welfare called an Interstate
Water Pollution Control Conference  which was held in Pittsburgh,  Pennsylvania
in December, 1963.  The conferees  established a Technical Committee to  ex-
plore the  means of abating  pollution  caused by coal mine drainage.  The Com-
mittee established a project called the Monongahela River Mine Drainage Re-
medial Project and set up headquarters in Wheeling, West Virginia in  1964.
The Project was charged with making a study to determine sources,  types  and
amounts of pollution from coal  mines,  and the means and costs for abating such
pollution.   The actual work of locating, sampling and describing the sources of
mine drainage began in  1965 and continued through 1968. Interim  reports  were
published  by the Federal Water Pollution Control Administration' 1') and
Pash(18' 19) between 1968 and 1970.  During this  period, Ward and Wilmoth(20)
of the U.  S. Geological Survey  made a study of the effects of mine drainage on
the groundwater hydrology  of the Monongahela River Basin.  The final report
of the Monongahela River Mine  Drainage Remedial Project was made public
by the Environmental Protection Agency(l< 2)  at the  second conference  held in
Pittsburgh, Pennsylvania in August, 1971.  The Advisory Work Group of the
Project was responsible for the first handbook on mine drainage pollution con-
trol costs(7).
                                  -6-

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        The activities  of the Ohio River Valley Water Sanitation Commission'^)
since its beginning in  1948 in reducing pollution, especially mine drainage, in
the Monongahela River Basin should not be overlooked.   This organization was
responsible for early  interstate cooperation and studies  on the fundamental
principles of acid mine drainage formation and methods  of control'^  '.  Based
on ORSANCO  studies, Clark(^2) in 1964,  analyzed the water quality trends  in
the Monongahela River Basin during the past 50 years.

        The extent of pollution in the Monongahela River  Basin is discussed in
several studies on mine drainage pollution in Appalachia.  Biesecker and Georg
of the U. S. Geological Survey made the first major regional stream quality
reconnaissance of Appalachian in 1965 and reported that  the  severity of mine
drainage pollution was substantially greater in the more  heavily mined northern
third of the Appalachian region which includes  the Monongahela River Basin.
The  Federal Water Pollution Control Administration(24,  27) ^n their 1967 report,
revised 1969,  came to a similar conclusion.  The Appalachian Regional Com-
mission under the Appalachian Regional Development Act published a series of
reports in 1969 on acid mine drainage  in Appalachia(8> 25-30)_

        The Mine Drainage Abstracts prepared by Bituminous Coal Research,
Inc. (31) an(j their Coal Mine Drainage  Library has facilitated the study of mine
drainage pollution and methods of control in the Monongahela River Basin.  The
library, established in 1961, is sponsored by the Coal Industry Advisory Com-
mittee to ORSANCO.  The preparation of the mine drainage abstracts is sup-
ported by the  Pennsylvania Department of Environmental Resources.  References
in the text of the report include the code designation used by Bituminous Coal
Research,  Inc.  in their bibliography, ex.  (BCR 71-39).
                                  -7-

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                             REFERENCES

 1.   U. S. Environmental Protection Agency,  1971,  Mine Drainage Report to
     Conferees:  Enforcement Conf. , Pittsburgh, 22 p.  (BCR 71-39)

 2.   U. S. Environmental Protection Agency,  1971,  Summary Report, Monon-
     gahela River Mine Drainage Remedial Project:  Enforcement Conf. ,
     Pittsburgh,  235 p. (BCR 71-40)

 3.   Sidio, A.  D. and Mackenthun, K.  M. , 1963, Report on Pollution of the
     Interstate Waters of the  Monongahela River System:  U.S. Public Health
     Service (BCR 63-24)

 4.   Shaw, J.  R. ,  1963, Statement;  Chairman,  ORSANCO, Conf. of Pollution
     of Monongahela River and Its Tributaries, Pittsburgh,  30 p. (BCR 63-115)

 5.   Wilbar, C.  L. , 1963, Water Pollution Control in the Monongahela River
     Basin;  Pa.  Dept. Health, Div. Sanitary Eng. , Publ. No. 6, 86 p.
     (BCR 63-23)

 6.   State and  Interstate Conferees,  1971, Recommendations - Monongahela
     Enforcement Conference: Pittsburgh, 2 p.  (BCR 71-43)

 7.   Hyland, John,  Project Director, 1966,  Handbook of Pollution Control Costs
     in Mine Drainage Management:  Federal Water Pollution Control Adm. ,
     prepared  by Monongahela River Mine Drainage Remedial Project,  54 p.
     (BCR 66-118)

 8.   Cyrus Wm.  Rice and Co. ,  1969, Engineering Economic Study of Mine
     Drainage  Control Techniques, Appendix B to Acid Mine Drainage  in Appa-
     lachia:  Rept. to Appalachian Regional Comm. ,  281 p.  (BCR 69-79)

 9.   Lyon, W. A.,  1971,  Water Quality Management in the Monongahela River
     Basin:  Pa.  Dept. Environ. Resources,  Bur. Sanitary Eng. , Publ. No. 29,
     102 p.  (BCR 71-41)

10.   Garvey, J.  R. , 1971, Statement:  Enforcement  Conf.,  Monongahela  River
     and Its  Tributaries,  Pittsburgh, 2 p. (BCR 71-42)

11.   Trax, E.  C. ,  1910,  The Acid Waters of Western Pennsylvania:  Eng. Record,
     62_, 371-2 (BCR 10-1)

12.   Roberts,  T.  P., 1912,  Acids  in Rivers and Mills.  With Special Reference
     to the Monongahela:   Professional Memoirs, 4_,  501-4 (BCR 10-16)

13.   Morgan, L. S. , 1931, Acidity and Hardness Difficulties at Monongahela
     River Plants:  Eng.  News-Record, 106, 850 (BCR  30-17)

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14.  Hodge,  W. W., 1938, Effect of Coal Mine Drainage on West Virginia
     Rivers  and Water Supplies: W. Va.  Univ. Bull. No. 18, _38_ (BCR 30-43)

15.  U. S. Public Health Service,  1942,  Ohio River Pollution Survey, Final
     Report  to the Ohio River Committee, Supplement "C",  Acid Mine Drain-
     age Studies:  Office  of Stream Sanitation, 68 p. (BCR 40-11)

16.  Madison, K. M. ,  1950,  Pollution in the Allegheny,  Monongahela and Ohio
     Rivers  in Allegheny County, Pennsylvania:  Am. Chem. Soc. ,  188th Nat.
     Meet.,  Chicago (BCR 50-26)

17.  Federal Water Pollution Control Administration,  1968,  Stream Pollution
     by Coal Mine Drainage,  Upper Ohio River Basin:  Ohio Basin Region,
     Wheeling Field Station, Work Doc. No.  21 (BCR 68-64)

18.  Pash, E. A., 1969, The Coal Mine  Drainage Problem  in Northern West
     Virginia: Soil  Conserv. Soc.  Am.,  W.  Va.  Chapter, Ann. Meet.,
     Jacksons Mill,  11 p. (BCR 69-57)

19.  Pash, E. A., 1970, The Coal Mine  Drainage Problem  in Southwestern
     Pennsylvania:  Spring Geogr.  Conf.  Environ. Pollut. ,  Calif.  State Coll.,
     California,  Pa.,  13 p. (BCR 70-45)

20.  Ward,  P. E. and Wilmoth, B.  M. ,  1968, Ground-Water Hydrology of the
     Monongahela River Basin in West Virginia:  W. Va.  Geol. Econ. Surv. ,
     River Basin Bull. 1, 59 p.  (BCR 68-173)

21.  Ohio River Valley Water Sanitation Committee, 1964, Principles and
     Guide to Practices in the Control of Acid Mine-Drainage:  Coal Industry
     Advisory Committee,  30 p. (BCR 64-28)

22.  Clark,  C. S. ,  1964,  Mine  Acid Formation and Mine  Acid Pollution Con-
     trol:  Proc. 5th Ann. Sym. on  Ind. Waste Control, Frostburg State College,
     Maryland, p. 50-73 (BCR  64-50)

23.  Biesecker,  J.  E.  and George,  J. R. , 1966,  Stream Quality in Appalachia
     as Related to Coal-Mine Drainage,  1965: U.  S. Geol. Surv.  Circ.  526,
     27 p.  (BCR 66-18)

24.  Federal Water  Pollution Control Administration,  1967,  Stream Pollution
     by Coal Mine Drainage in Appalachia: 279 p. (BCR 67-182)

25.  Appalachian Regional Commission,  1969, Acid Mine Drainage in Appala-
     chia:  Rept. to  President,  126  p. (BCR 69-77)

26.  Whitman, I.  L. ,  Nehman,  G. I., and Qasim, S. R. , 1969, The Impact of
     Mine-Drainage Pollution on Industrial Water Users  in Appalachia, Appendix
     A to Acid Mine Drainage in Appalachia:  Rept. to Appalachian Regional
     Comm.  , 253 p. (BCR 69-78)


                                   -9-

-------
27.  U. S. Army Corps of Engineers,  1969, The Incidence _and Formation of
     Mine Drainage Pollution, Appendix C to Acid Mine Drainage in Appalachia:
     Rept. to Appalachian Regional Comm. , 411 p.  (BCR 69-80)

28.  The  Fantus Co., 1969, The Impacts of Mine Drainage Pollution on Location
     Decisions  of Manufacturing Industry in Appalachia, Appendix D to Acid Mine
     Drainage in Appalachia:  Rept.  to Appalachian Regional Comm. , 304 p.
     (BCR 69-81)

29.  Robert  R.  Nathan Assoc. , Inc., 1969, Mine Drainage Pollution and Recre-
     ation in Appalachia, Appendix E to Acid Mine Drainage in Appalachia:
     Rept. to Appalachian Regional Comm. , 114 p.  (BCR 69-82)

30.  Katz, Max,  1969, The  Biological and Ecological Effects of Acid Mine
     Drainage with Particular Emphasis to the Waters  of the Appalachian
     Region,  Appendix F to  Acid Mine Drainage in Appalachia: Rept. to
     Appalachian Regional Comm. ,  65 p. (BCR 69-83)

31.  Bituminous Coal Research, Inc., 1965, Mine Drainage Abstracts,  A Bib-
     liography:  Annual Supplements, Sponsored by Coal Industry Advisory
     Committee and Pennsylvania  Department of Environmental Resources
                                  -10-

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                     PART A

ABATEMENT OF COAL MINE DRAINAGE POLLUTION
        AND MINING RELATED PROBLEMS
                      -11-

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                    STRIP MINE AND REFUSE BANK
                      BACKFILLING AND GRADING

                         TABLE OF CONTENTS

                                                                 Page No.

Introduction                                                         15

Cost Analysis                                                        16
       Access Roads                                                 22
       Clearing  and Grubbing                                        22
       Strip Mine Backfilling and Grading                            28
       Refuse Bank Contouring and  Grading                          32
       Strip Mine and Refuse Bank Sealants                          34
       Summary                                                    34

References                                                          39

                            LIST OF TABLES

1.  Strip Mine Reclamation Projects - Variables Affecting
    Backfilling and Grading Costs                                    23

2.  Coal Refuse Bank Reclamation Projects - Variables
    Affecting Grading and Removal Costs                             25

3.  Clearing and Grubbing Cost Analysis                              27

4.  Strip Mine Backfilling and Grading Cost Analysis                  30

5.  Refuse Pile Contouring and Grading Cost Analysis                 33

6.  Strip Mine and Refuse Bank Sealant Cost Analysis                 35

7.  Summary of Cost Estimates  - Strip Mine and Refuse
    Bank Reclamation                                                36

                            LIST OF FIGURES

1.  Contour Backfill                                                  17

2.  Pasture Backfill                                                  18

3.  Reverse  Terrace Backfill                                        19

4.  Swallow-Tail Backfill                                            20

5.  Refuse Pile - Grading and Contouring                             21

6.  Strip Mine Backfilling and Grading Cost Analysis                  29

                                  -13-

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                    STRIP MINE AND REFUSE BANK
                      BACKFILLING AND GRADING
Introduction
       Since the primary purpose of this  section is a cost analysis of strip
mine and refuse bank backfilling and grading, a discussion of the extent of
coal mining and its impact  on the Monongahela River Basin is  omitted.  The
extent of acid mine drainage  pollution in the  Monongahela River  Basin caused
by strip  mining and refuse  banks  is discussed in recent publications by  the
Environmental Protection Agency' »',  U. S. Army Corps of Engineers^  ' r
and Lyon'  ).

       According to  the U. S. Army Corps of Engineers Report' '"",  1969,
the objectives of basic  strip mine  and refuse bank reclamation are  1) water
quality through  proper  drainage,  2) the  covering of  toxic materials, and 3)
the revegetation of affected areas.  This definition does not imply restora-
tion to approximate original contour and is primarily concerned with the con-
trol of acid mine drainage and siltation  of receiving streams.  Udall(^), U.S.
Department of Interior^ ' and Sullivan!?) suggest the inclusion of restoration
of reclaimed lands and water courses to productive uses compatible with ad-
jacent areas and restoration  of pre-mining aesthetic values as additional
objectives for sound  reclamation  programs.

       Prevention of acid mine drainage by burial of acid  producing materials
and backfilling is based on  the principle that in the absence of oxygen,  the oxi-
dation of pyritic material is significantly  reduced or prevented (Singer  and
Stumm(8), NUS  Corporation^9), Smith and Shumate^1*), Truax-Traer Coal
Company(H), Wilson,  et al.(12)). Grube, et al.(13) and Caruccio  and  Pari-
zek(^) conclude that reduced acid mine drainage formation can  be  obtained
by segregating acid producing materials from spoil overburden and burying
these materials with clay or  other impervious materials at the base of  a back-
fill.   Proper backfilling and grading of  spoil material not only decreases the
volume of water flow through acid producing areas,  but also reduces contact
time as implied by Hill(^).

       The two  major types of strip mine backfilling procedures in current
use in the Monongahela River Basin and surrounding areas are  contour  and
terrace methods. Several  modifications of these two methods are employed
to meet the requirements of particular  geographic and  topographic  conditions
and type  of mining operation.  A description of other backfilling methods is
presented in Krause(l6).
*This report was prepared by the U. S. Army Corps of Engineers for the
 Appalachian Regional Commission.  The majority of the report consists
 of material previously published by FWPCA and the U.  S. Bureau of Mines
 in 1967-68.  The FWPCA publication was revised for this report.
                                  -15-

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        Contour backfilling consists of moving spoil material back into the
 pits and grading to approximately the original contour with an absence of
 possible water collection depressions (Figure 1).  This type of backfill is
 generally restricted to slopes of 10° to 15° or less because of problems
 resulting in increased erosion and subsequent siltation of receiving waters
 as  pointed out by Cyrus Wm.  Rice and Company^?).   Contour backfilling
 has been recommended on the majority of Pennsylvania reclamation projects
 but is of limited use on most reclamation projects in West Virginia because
 of  slope limitations in the West Virginia  part of the Monongahela River Basin.

        Terrace  backfills involve the grading of spoil to form a "modified
 bench" gently sloping either toward or from the highwall area.  Sufficient
 grading is required to insure  adequate burial of acid producing substances
 and usually includes outslope  and highwall slope limitations.  Highly frac-
 tured highwalls should be "topped" to avoid possible safety and drainage
 interference problems (Hill'*")).  Particular attention should be given to
 proper backfilling techniques  on the "outslope" areas to reduce  the  possi-
 bility of landslides.

        There are several variations of terrace backfills of which pasture
 backfill (Figure  2), reverse terrace backfill (Figure  3) and swallow-tail
 backfill (Figure  4) are the most common.  These variations  are primarily
 designed to divert or reduce the  volume of surface and ground water flow
 through potential acid producing  areas in the backfilled spoil (Bullard(19))t

        The backfilling and grading of deep mine refuse piles usually re-
 quires some type of physical sealing to reduce the volume of acid mine
 drainage.   The most  commonly used sealants  are  soil and clay, but bitum-
 inous products and possibly plastics could be used if economically feasible.
 Adequate precautions should be taken to avoid possible degradation  of bor-
 row areas.

        Grading of refuse is performed in such a manner as to limit erosion
 and the formation of water collection depressions  (Figure 5). Compaction
 of  refuse may be necessary to reduce percolation  of water through the acid
 producing  materials.  In some areas, slope characteristics will necessitate
 removal of refuse as the only feasible method of reclamation.  Removal of
 refuse banks is probably most feasible when performed in conjunction with
 adjacent strip mine reclamation projects.  The refuse can be placed in the
 bottom of strip pits prior to backfilling.

 Cost Analysis

        The  cost data presentation is limited  to an  analysis of the costs
for  recent abandoned strip mine  and refuse bank reclamation projects
in the Monongahela River Basin and surrounding areas.  Although this
limitation significantly reduces the amount of available  data that  can be
used,  it does minimize  the errors that  can be introduced  by  variables
in geographic location,   the differences   in topography, on site physical

                                  -16-

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 and chemical characteristics,  methods  of  mining,  and  the inequalities
 in  bond forfeiture  reclamation projects  from one area  to another.  To
 better  facilitate cost estimation,  cost analyses  have been divided into sev-
 eral major categories.  Since  some projects,  depending on physical and chemi-
 cal conditions present,  will not require all aspects of the reclamation program,
 it will  be possible to delete those parts not applicable.  Administrative, engi-
 neering and post-reclamation evaluation costs as  well as  cost of mine seals,
 water diversion,  spoil neutralization and revegetation have been omitted from
 this section.  It will,  therefore, be necessary to  review other  sections of the
 report to arrive at the total strip mine or refuse  pile reclamation cost esti-
 mate.

        It is recommended that a uniform method  of reporting data be developed
 and adopted by state and federal agencies involved in reclamation programs.
 This not only would make future reclamation cost estimates more meaningful,
 but would also  increase the efficiency of data retrieval and enhance  the possi-
 bility of computerization of data.  The variables  that should be considered in
 reporting strip mine and refuse  bank reclamation project data are presented
 in  Tables 1  and 2.  These  variables should also be considered in the planning
 stage in order  to obtain a more meaningful estimate of reclamation costs.

        Access Roads - Very little information exists on access road construc-
 tion costs for strip mine and refuse bank reclamation.  In most instances, this
 cost has been included in the backfilling and grading costs. From the limited
 information available, it appears the construction costs for access  roads  in-
 cluding clearing and grubbing, ranges from $2.50 to $3, 00 a lineal  foot.  An
 increase in the cost of construction can be expected if culverts or other drain-
 age structures are needed.

        Clearing and Grubbing  -  The costs of clearing and grubbing  range from
 $33.54 to $700.. 00 per acre with a mean of $218.77 per acre.   Forty three re-
 cent reclamation projects  were reviewed and only seven included  sufficient
 data to permit  an estimation of clearing and grubbing costs. A summary  of
 this data is  presented in Table 3.  The costs reported  by  McNay(20) for clear-
 ing and grubbing at Moraine State Park, Pennsylvania are based on work time
 and the average operating  cost of a D-7 Dozer and do not  represent  actual
 recorded values.

        The  higher  costs per acre for  clearing and grubbing can be attributed
 to  density of growth and a  requirement on some projects  to cut pulpwood for
 the landowner (Scott,  et al.'   '); slope of terrain and weather  conditions
(McNay(20)); the amount of partially buried timber encountered (Griffith,  et
al. (22)); and the amount of scrap and solid waste present (Jones(  ').  The
overall reclamation cost may be  reduced if brush and trees are chipped and
used as mulch instead of burying and burning.
                                  -22-

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                                 TABLE 1

                  STRIP MINE RECLAMATION PROJECTS
      VARIABLES AFFECTING BACKFILLING AND GRADING COSTS

  1.   Geographic  location

  2.   Topographic setting (Original, pre-reclamation and final ground slopes)

  3.   Type of strip mine

      a) Area   b) Contour   c) Area-contour   d) Other

  4.   Coal seams  mined and thickness

  5.   Inclination of coal seams in back of highwall

      a) Dip   b) Rise   C) Horizontal

  6.   Condition  of coal seams  in back of highwall

      a) Not mined   b) Auger mined    c) Drift mined (Entries opened or caved)
      d) Mine workings exposed by stripping operation

  7.   The probable hydraulic head that could develop if  coal in back of highwall
      was mined

  8,   Strip mine area information

      A.   Length,  width and area (acres) covered by spoil before reclamation
      B.   Highwall height (maximum and average height)
      C.   Highwall length
      D.   Number  of  cuts
      E.   Total area affected during reclamation in acres (including area above
          highwall and outside  outs lopes)
      F.   Volume  of spoil to be moved (cubic  yards)
      G.   Average haul distance for backfilling and grading
      H.   Texture  of  spoil
      I.   Amount  of large rock and material requiring special handling (mining
          timbers, machinery  and debris, junked cars,  and other solid waste)
      J.   Amount  and reactivity of pyritic material (mineralogy and mode of
          occurrence, e.g., finely dispersed; single  crystals  or crysta] aggre-
          gates;  coatings on joint surfaces; in  form of lenses,  layers or nodules;
          "sulfur balls"; pyritic shales;  etc.)
      K.   Clearing and grubbing requirements

 9.   Type of backfill
      a) Contour   b) Pasture-reverse slope    c) Swallowtail
      d) Head of  hollow   e) Submergence  f)  Other

10.   Physical sealants for covering toxic material
      a) None    b) Clay   c) Bituminous  material   c) Plastic material
      e) Other

11.   Compaction desired
      a) None   b)  Only toxic materials   c) All spoil material with exception
      of upper layer (1 to 3 feet)
                         -23-

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                         TABLE 1 (continued)

12.  Accessibility factors

     A.  Right-of-way problems
     B.  Ingress and egress construction (include clearing and grubbing for
         access and post-construction revegetation)
     C.  Other factors affecting access

13.  Surface and subsurface ownership of strip mined area.  Also ownership
     of properties for ingress and egress.
     a) Public   b) Private   c) In process of being acquired or lien placed on
     property   d) Abandoned   e) Temporary easement   f) Other

14.  Time of year reclamation performed

15.  Weather conditions during reclamation period(s)

16.  General contractor and subcontractors

17.  Types of construction equipment used and equipment records if available

18.  Source of project funding

19.  Productive use to be made of reclaimed land

20.  General observations  and  recommendations

     A.  Difficulties  in writing an effective bid proposal
     B.  Contractual problems  during  construction
     C.  Unanticipated problems requiring change orders
     D.  Recommendations and possible solutions that could in future projects
         avoid the difficulties encountered in A, B and C

21.  Evaluation of the overall success or failure  of the project (one, two and
     five years later)

     A.  Percent  of pollution reduction (acid mine drainage and siltation)
     B.  Cost per pound of acid reduction
     C.  Effectiveness of soil treatment if any
     D.  Growth and  survival of vegetation
     E.  Aesthetic evaluation
                          -24-

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                                 TABLE 2

             COAL REFUSE BANK RECLAMATION PROJECTS
        VARIABLES AFFECTING GRADING AND REMOVAL COSTS

 1.  Geographic location

 2.  Topographic setting (Original, pre-reclamation and final ground slopes)

 3.  Coal refuse bank area information

     A.   Length,  width and area (acres) before reclamation
     B.   Height of refuse bank (maximum and average height)
     C.   Total area to  be affected during reclamation in acres (including
          areas outside perimeter of refuse  bank and burial sites)
     D.   Volume of refuse to be graded or removed (cubic yards)
     E.   Average haul  distance for  grading
     F.   Average haul  distance to burial site(s)
     G.   Texture  of refuse
     H.   Amount of large rock and material requiring special handling (mining
          timbers,  machinery and debris,  junked cars,  and other solid waste)
         See Item 8.C
     I.  Amount and reactivity of pyritic material (mineralogy and mode  of
          occurrence,  e.g.,  finely dispersed;  single  crystals of  crystal aggre-
          gates;  coatings on joint  surfaces; in form of lenses, layers or nodules;
          "sulfur balls"; pyritic shales;  etc.)
     J.   Clearing and grubbing requirements

 4.  Method of refuse bank construction

     a) Tippler form   b) Layer piling  c) Layer piling with clay   d) Other

 5.  Coal seam that was deep mined and its characteristics

 6.  Type of roof and bottom rock in the deep mine

 7.  History of refuse  bank

     A.  Years during  which refuse bank was  being constructed  and last year
         of placement of refuse on bank (Mining methods have changed over
         the years and  the composition of banks are  variable depending on
         mining method, coal seam mined,  type of roof and bottom rock,  and
         age of bank)
     B.  Has refuse bank ever been on fire or is part of refuse bank burning
         now?
     C.  Has refuse bank been cleaned for waste coal?

 8.  If refuse bank is burning

     A.  Volume of burning refuse (cubic yards)
     B.  Special procedures or  methods of handling burning refuse
     C.  Number and size of large lumps of fused ash requiring  special
         handling

 9.  Reclaimable  resources that  can offset cost of reclamation

     a) Coal  b) Red dog   c) Other

10.  Type of reclamation

     a) Grading    b) Grading and sealing   c)  Other
                         -25-

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                          TABLE 2  (continued)

11.  Physical sealants for covering toxic material

     a) None   b) Clay   c) Bituminous material   d) Plastic material   e) Other

12,  If clay is used as a sealant

     A. Size of  borrow area and volume of material needed for sealing (cubic yards)
     B. Location,  accessibility,  and distance from borrow area to refuse bank
     C. Clearing and grubbing requirements at borrow area
     D. Revegetation requirements at borrow area

13,  Compaction desired

     a)  None   b) All of refuse material with exception of upper layer (1 to 3 feet)
     c) All of the refuse material and all but  upper layer of clay covering (1 to 3
     feet  d) Other

14,  Accessibility factors

     A. Right-of-way problems
     B. Ingress and  egress construction (include clearing and grubbing  for
         access  and post-construction revegetation)
     C. Other factors affecting access

IS.  Ownership of refuse  bank and surface area.  Also ownership of properties
     for ingress, egress and borrow areas.

     a) Public    b)  Private    c) In process of being acquired or lien placed on
     property    d) Abandoned   e) Temporary easement   f) Other

16,  Time of year reclamation performed

17.  Weather conditions during reclamation period(s)

18,  General contractor and subcontractors

19.  Types of construction equipment used and equipment records if available

20.  Source  of project funding

21,  Productive  use to be made of reclaimed  land

22,  General observations and recommendations

     A. Difficulties in writing an effective bid proposal
     B. Contractual  problems during construction
     C. Unanticipated problems requiring change orders
     D. Recommendations and possible solutions that could in future projects
         avoid the difficulties  encountered  in  A, B and C.

23.  Evaluation of the overall success or failure of the project (one, two and
     five years later)

     A. Percent of pollution reduction (acid  mine drainage and sillation)
     B. Cost per pound of acid reduction
     C. Effectiveness of  soil treatment if  any
     D. Growth  and survival  of vegetation
     E. Aesthetic evaluation
                         -26-

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                                     -27-

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       Strip Mine Backfilling and Grading - The strip mine backfilling and
grading costs used in preparing the cost analysis are presented in Table 4.
For all methods of backfilling and grading, the costs per acre range from
$211. 57 to $2, 007. 00 and the mean  cost is $859. 78 per acre.

       The cost of contour-type backfilling and grading ranged from $472.00
to $1,520.00 per acre and the mean is $922.66.  Table 4 indicates that ter-
race-type reclamation methods,  which include the pasture reverse slope and
swallowtail methods, are about 43 percent lower in cost per acre compared
to the contour-type.  The average cost for terrace-type backfilling and grad-
ing is $525. 98 per acre and  costs range from $211.57 to $918.00 per acre.
Combination contour-terrace reclamation methods ranged from $472. 00 to
$2, 007. 00 per acre and the mean is $1, 263. 84.

       A  review  of the projects show there is no relationship between the
number of acres  reclaimed and the  backfilling and grading costs per acre
for any of the reclamation methods. A definite relationship does exist for
the contour-type  reclamation method between the volume of spoil per unit
area and the cost per unit volume of backfilling and grading (Figure 6).

       The mathematical expression for this  relationship is

                                    -1.82760
                        y = 760.2 x
                            or
                    log y =  -1.82760 log x +2.88094

where  y is the cost per unit  volume (cents/cubic yard) and x is the total vol-
ume of spoil to be  moved per unit area (cubic yards/acre).

       Because of the lack of data on volume  for the  majority of terrace-
type reclamation projects that were reviewed, the relationship between cost
per unit volume  and total volume of spoil per unit area to be  moved can only
be inferred.  If it is assumed that differences in cost per cubic yard are pro-
portioned to differences in cost per acre when comparing costs of contour and
terrace-type  reclamation methods,  it would be possible to use the same re-
lationship developed for the  contour reclamation method by reducing total cost
by an appropriate cost differential factor.  Using the cost per unit area data
presented in Table 4,  it appears the cost of the terrace-type  reclamation
method is  about 57 percent of the contour-type.  This value compares favor-
ably with  figures presented by Cyrus Wm. Rice and Company'-*- ' / in their  1969
report to  the  Appalachian Regional  Commission in which cost estimates for
terrace reclamation methods were  53 percent of the  contour-type.

        Using the  57 percent differential as a reducing factor,  the following
inferred mathematical expression for terrace-type backfilling and grading costs
is possible.
                                  -28-

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-------
                                    -1.82760
                        y = 433.3 x
                             or
                     log y = -1.82760 log x +2.63679

        Again, y is the cost per unit volume (cents/cubic yard) and x is the
 total volume of spoil to be  moved per unit area (cubic yards/acre).  Because
 of the limited data used in  formulating this expression,  it should only be used
 for a rough approximation  of terrace-type backfilling and grading costs.

        The amount of spoil that has to be moved during reclamation is  the
 principal factor in the differences in backfilling and grading costs per unit
 area.  In the  cost analysis  made by Cyrus Wm. Rice and Co.(   ', it was es-
 timated that the contour reclamation method required movement of 75 per-
 cent  of the total spoil present while the terrace-type method required move-
 ment of only 25 to  40 percent of the total spoil. Other factors responsible
 for greater costs for the contour method are the increased amount of buried
 timbers encountered (Griffith, et al.'   ') and a longer average haul distance
 (Oldham(25)).

        Increased overall backfilling and grading costs as compared to pre-
 reclamation estimates can be attributed to several factors.  McNay^^/ reports
 that costs were greater because of frozen ground conditions, the number of
 sandstone slabs larger than one cubic yard,  and the spoil texture. Scott,
 et al.'2!) lists  separation of toxic materials, adverse weather conditions,  and
 highwall "topping" as the factors which increased backfilling and grading costs.

        A possible  cost offset which may be employed during certain strip mine
 reclamation operations, where the highwall area has been mined, is recovery
 of coal.  Proponents of this method of cost offset usually concur that it is gen-
 erally restricted to areas of shallow mine cover where  there has been limited
 underground mining  because of the expense of  separating coal from collapsed
 mine workings.  However,  it is the contention of some individuals that even
 though this  procedure may be inefficient from  the standpoint of coal recovered
 vs.  cost of recovery, it may be economical when considering  savings on mine
 seals and mine drainage treatment costs.  An  individual site would have to be
 studied  before a conclusion could be made as to whether this method would re-
 sult in an overall cost reduction.

        Refuse Bank Contouring and Grading -  The majority of refuse bank rec-
lamation projects have been performed  in conjuction with strip mine  and sub-
sidence area backfilling operations. Because of the ambiguity and incomplete-
ness of records for many of the refuse bank reclamation projects, only those
projects permitting a somewhat reliable cost analysis of contouring and grading
costs are summarized in Table 5.   It must be emphasized that these  costs only
reflect the cost of contouring and grading of refuse and do not include the cost
of access road construction,  clearing and grubbing, sealants,  water diversion
and revegetation.
                                   -32-

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-------
       Based on Table 5,  the cost of contouring and grading ranged from.
$100. 00 to $3, 000. 00 per acre and the mean is $1, 008. 54.  The cubic yard
cost ranges from $0.333 to $1.00 and the average cost is $0.758 cubic yard.
Only one of the projects reviewed, SL  109-1C in Indiana County, Pennsylvania,
involved the removal and deposition of refuse.  During one phase of the pro-
ject,  47, 500 cubic yards were removed at any average cost of $0.944 cubic
yard.  This cost per cubic yard is approximately three times the average cost
reported by Daniels on and White(2?) for refuse disposal at two active coal
mines in Kentucky and Alabama.  The  difference  in cost probably can be  attrib-
uted to haul distances,  use of on-site  equipment and the advantage of removal
at an active site.

       Future reclamation projects involving removal of refuse could be com-
bined with refuse utilization where economically feasible.  Refuse material  has
been crushed  for secondary  coal recovery, for base materials for roadways and
parking areas, and for production of anti-skid material and cement  (Greenlee
and Spicer(28)).  Production of brick (Environmental Science  and Technology^)),
carbonate bonding of refuse  for roadway use and as a sealant,  and sulfur re-
covery (Black, Sivalls and Bryson, Inc. (30, 31)) have been demonstrated  and
may possibly  be  economical uses  for coal mine refuse.

       Strip Mine and Refuse Bank Sealants - The cost of borrow and spreading
of sealants over toxic material during strip mine and  refuse bank reclamation
ranged from $0.26 to  $2.00 per cubic  yard and the mean was $0.406 based on
the data  presented in Table  6.  All but one of the projects reviewed employed
soil as a  sealant. The soil  material was used to cover the toxic material to re-
duce  infiltration of water and to promote  revegetation.  The soil was approved
run of the bank material and can be loosely classified as "topsoil. " The high
cost of $2.00 per cubic  yard on Project SL 111-1 can  be attributed to  an  unbal-
anced bid and it should be noted only a total of 5, 000 cubic yards was  needed for
the project.  The only project that employed a sealant classified as  clay  had a
cost of $1.75 per cubic  yard.  There  does not appear  to be a  relationship be-
tween cost of sealant and borrow  area distance for the projects reviewed, but
haul distances were less than one mile.

       Little data exists for sealants other than "clay" and soil.  The MSA  Re-
search Corp. (32) in 197! conducted studies  on several possible sealants  for
sealing toxic  material in strip mines  and refuse banks.  The  sealants included
polyethylene sheeting,  urethane foam, linseed oil,  polyvinyl chloride  cacooning
and fly ash.  Only polyethylene sheeting and urethane  foam were effective in
reducing water percolation.  The cost of polyethylene sheeting was  estimated
at $4, 356. 00  per acre and urethane foam at $10, 018. 00 per acre.  The life  ex-
pectancy of the sheeting is three to five years according to Kamal'-^ ).  The
costs do not include contouring and grading.  It is highly improbable that these
sealants can be economically applied in reclamation projects at the present time.

       Summary - The  cost estimates were made using data from recent aban-
doned strip mine and refuse bank reclamation projects in the Monongahela River
Basin and surrounding area. Table 7  is a summary of the cost estimates.

                                  -34-

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-------
        Based on analysis of strip mine backfilling and grading costs  for pro-
jects in both Pennsylvania and West Virginia,  it appears updated (1972) costs
would be about:

                         Contour type       $l,000/acre
                         Terrace type          600/acre

        An analysis using  only Pennsylvania projects, which included contour
and combination contour-terrace methods, indicates the average cost per acre
is a little over $1,200.  The strip mine backfilling and grading costs were
much lower for West Virginia projects,  but no information was available for
any of the West Virginia projects on volume  of material moved per acre and
cost/cubic yard.

        Since Federal and State reclamation requirements are becoming more
stringent,  and since West Virginia reclamation requirements  prior to passage
of new surface mining reclamation regulations in 1971 were not as strict as
Pennsylvania's,  a cost of $l,250/acre is estimated for  strip mine backfilling
and grading in the Monongahela River Basin.

        This cost estimate of $l,250/acre is for backfilling and grading old
abandoned operations in which the spoil material is mixed.  Although it is
difficult to separate actual stripping costs from  reclamation costs for active
operations meeting State and proposed Federal reclamation regulations,  it is
the opinion of individuals  in  the coal mining industry that complete reclama-
tion including revegetation cost can be accomplished for $200  to $300/acre
above actual stripping cost,  if the work is performed at the time of stripping.
Accomplishing this work at such  a  low cost requires pre-planning and proper
development of the strip mine  operation.  The acidic materials must be sep-
arated and buried during stripping, the backfilling performed  as  stripping
progresses and the top soil stockpiled for later covering of the completed op-
eration, all this  work being  performed with on-site equipment used in the
stripping  operation.

        This estimated cost for active operations conducted in accordance with
the above methods and procedures does not imply that bond forfeiture require-
ments are adequate or inadequate.  A poorly planned stripping operation  in
which the operator goes bankrupt or forfeits his  bond can conceivably cost as
much to reclaim as an old abandoned strip mine.

        There is  very little reliable information available on the cost of refuse
bank contouring and grading.  Therefore, based on limited information and dis-
cussions with individuals familiar with this work, a cost of $1, 000/acre is
estimated.  This cost estimate would not include a soil  cover.  Covering  the
graded  refuse with soil should cost about $2, 500/acre ($0. 50/cubic yard).
                                   -37-

-------
       Refuse  bank removal and burial is another item on which there is  very
little reliable information,  probably because much of this work to date has
been performed in conjunction with strip mine  reclamation and costs  are  not
separated.  Major factors effecting a cost estimate for this work are haul dis-
tance,  volume  of material to be moved, volume of large rock and material
requiring special  handling, and compaction requirements at burial site (see
Table 2 for other  factors).

       For general planning purposes in the Monongahela River Basin, a cost
estimate of $1.00/cubic yard should be used for refuse bank removal and burial.
Where specific site information is available, cost estimates should be based on
recognized construction estimating practices,  taking into consideration haul
distances,  hourly wage and equipment rates, site accessibility and other  known
factors that would affect removal and burial costs.  Soil covering at the burial
site should be estimated at $0. 50/cubic yard, i.e., $0. 50/square yard of cover.

       An average cost of $300/acre for clearing and grubbing is satisfactory
for estimates in the Monongahela River Basin, but all sites will not require this
item.  Most of the refuse banks,  culm ponds and some highly acidic strip mines
should be more or less barren.
                                   -38-

-------
                              REFERENCES

 1.  Environmental Protection Agency, 1971, Summary Report, Monongahela
     River Mine Drainage Remedial Project:  Enforcement Conf. ,  Pittsburgh,
     235 p. (BCR 71-40)

 2.  Environmental Protection Agency, 1971, Mine Drainage Report to Con-
     ferees:  Enforcement Conf.,  Monongahela River & Its Tributaries,  Pitts-
     burgh, 22 p. (BCR 71-39)

 3.  U. S. Army Corps of Engineers,  1969, The Incidence and Formation of
     Mine Drainage Pollution, Appendix C to Acid Mine Drainage in Appalachia:
     Rept. to Appalachian Regional Comm. , 411 p.  (BCR  69-80)

 4.  Lyon,  Walter A.,  1971, Water Quality Management in the Monongahela
     River Basin:  Pa. Dept. Environmental Resources, Bur. Sanitary Eng.
     Publ. No.  29,  102 p. (BCR 71-41)

 5.  Udall,  S. L. , 1966, Study of Strip and Surface Mining in Appalachia, An
     Interim Report to the Appalachian Regional Commission:  U.S.  Dept. of
     Interior, 78 p. (BCR 66-59)

 6.  U.S. Dept.  of Interior,  1967, Surface Mining  and  Our Environment,  Special
     Report to the Nation:  124 p.  (BCR 67-82)

 7.  Sullivan, G. D. ,  1967, Current Research Trends  in Mined-Land Conser-
     vation and  Utilization:  Am.  Inst. Mining Eng.  Preprint No.  67F65,  18 p.
     (BCR 67-11)

 8.  Singer, P.  C.  and Stumm, W. , 1969, Oxygenation of Ferrous Iron,  The
     Rate Determining Step  in the Formation of Acidic  Mine Drainage:  Fed.
     Water  Quality Adm., Res. Ser. DAST 28,  216 p.  (BCR 69-64)

 9.  NUS Corporation,  1971, The Effects of Various Gas Atmospheres on the
     Oxidation of Coal Mine Pyrites: Environmental Protection Agency, Water
     Quality Office, Res. Ser.  14010 ECC 08/71,  140 p. (BCR  71-

10.  Smith, E. E. and Shumate, K.  S. , 1970, A Study  of the Sulfide  to Sulfate
     Reaction Mechanism as it Relates  to the Formation of Acid Mine Waters:
     Fed. Water Quality Adm. , Res. Ser. 14010 FPS 02/70, 115 p.  (BCR 70-3)

11.  Truax-Traer Coal Company, 1971, Control of Mine Drainage from Coal
     Mine Mineral Waste:  Environmental Protection Agency, Water Quality
     Office, Res. Ser.  14010 DDH 08/71,  148 p. (BCR  71-69)

12.  Wilson, L.  W. ,  Matthews, N.  J.  and Stump, J. L. ,  1970, Underground
     Coal Mining Methods to Abate Water Pollution: Environmental Protection
     Agency,  Water Quality Office, Res.  Ser. 14010 FKK  12/70,  50  p. (BCR
     70-120)
                                  -39-

-------
13.   Grube,  W. E. , Jr., et al. , 1971, Mine Spoil Potentials for Water Quality
     and Controlled Erosion:  Environmental Protection Agency, Water Quality
     Office,  Res. Ser. 14010 EJE 12/71 (BCR 71-72)

14.   Caruccio, F.  T.  and Parizek,  R. R., 1967, An Evaluation of Factors In-
     fluencing Acid Mine Drainage Production from Various Strata of the Alle-
     gheny Group and  the Ground Water Interactions  in Selected Areas of Western
     Pennsylvania:  Pa. State Univ.  Spec. Res. Rept. SR-65,  213 p.  (BCR 67-87)

15.   Hill, Ronald D.,  1969,  Reclamation and Revegetation of 640 Acres of Sur-
     face Mines, Elkins, West Virginia;  Intern. Sym. Ecology Revegetation of
     Drastically Disturbed Areas, University Park,  Pa.,  by Pa. State Univ.,
     47 p. (BCR  69-53)

16.   Krause, R. R.,  1972, Mining and Reclamation Techniques to Control Mine
     Drainage;  Fourth Sym.  Coal Mine Drainage Res. Preprints,  Pittsburgh,
     p. 425-30 (BCR 72-

17.   Cyrus Wm. Rice and Co.,  1969, Engineering Economic Study of Mine
     Drainage Control Techniques. Appendix B to Acid Mine Drainage in
     Appalachia;  Rept.  to Appalachian Regional Comm.,  28 p. (BCR 69-79)

18.   Hill, Ronald D.,  1971,  Restoration of a Terrestrial Environment - The
     Surface Mine:  Bull. Assoc. Southeastern Biologists,  JJ3(3)p.  107-16
     (See BCR  71-11)

19.   Bullard, W. E.,  1965,  Acid Mine Drainage Pollution Control Demonstra-
     tion Program Uses of Experimental Watersheds;  Intern. Assoc.  Scientific
     Hydrology Sym. , Budapest, p.   190-200 (BCR 65-68)

20.   McNay, L.  M. ,  1970, Surface  Mine Reclamation, Moraine State Park,
     Pennsylvania:  U.S. Bur. Mines, Inf. Circ. 8456, 28 p.  (BCR 70-52)

21.   Scott, R.  B., Hill, R. D. ,  and Wilmoth, R. C. ,  1970, Cost of Reclama-
     tion and Mine Drainage Abatement - Elkins Demonstration Project: Am.
     Inst. Mining Eng. , SME Fall Meet. ,  St. Louis, Preprint No. 70AG349,
     22 p. (BCR 70-70)

22.   Griffith, F. E. ,  Magnuson, M. O. and Kimball, R. L.,  1966,  Demonstra-
     tion and Evaluation of Five Methods  of Secondary Backfilling of Strip-
     Mine Areas:  U.  S.  Bur. Mines Rept. Invest. 6772,  17 p. (BCR 66-159)

23.   Jones,  Robert, 1972, Personal Communication: Jones and Brague Mining
     Company,  Blossburg, Pa.

24.   Grim,  Elmore, C. , 1972,  Personal Communication:  Unpublished informa-
     tion compiled by Mr. Grim,  Surface  Mining Specialist, Environmental
     Protection Agency,  National Environmental Research Center,  Cincinnati
                                  -40-

-------
25.  Oldham, F. S. , 1972, Personal Communication: Director, Bureau of
     Planning and Developmental Research,  Pennsylvania Department of
     Environmental Resources

26.  Molinski, A. E. ,  1972, Personal Communication;  Unpublished infor-
     mation compiled by Mr.  Molinski, District Engineer, Office of Engineer-
     ing and Construction, Pennsylvania Department of Environmental Resources,
     Ebensburg Office

27.  Danielson, V. A.  and White, D. H.,  1969,  Waste Disposal Costs at Two
     Coal Mines in Kentucky and Alabama:  U. S. Bur. Mines Inf.  Circ.  8406,
     27 p.  (No BCR No.)

28.  Greenlee, J. K. and Spicer,  T. S.,  1971,  Crushing Anthracite Refuse:
     Pa. State Univ. Spec. Res. Kept. SR-87, 67 p.  (No BCR No.)

29.  Environmental Science and Technology,  1972, Tekology Process Turns
     Garbage into Building Materials; _6_ (6),  p. 502-03

30.  Black, Sivalls and Bryson, Inc., 1971,  Carbonate Bonding of Coal Refuse;
     Environmental Protection Agency, Water Quality Office, Res. Ser.  14010
     FOA 02/71, 44 p.  (BCR 71-

31.  Black, Sivalls and Bryson, Inc., 1971,  Study of Sulfur Recovery from
     Coal Refuse:  Environmental Protection Agency,  Water Quality Office,
     Res. Ser. 14010 FYY 09/71, 67 p.  (BCR 71-

32.  MSA Research Corp., 1971,  Mine Refuse Pile Coverings  to Reduce  Water
     Percolation;  Sum. Rept.  to Pa. Dept. of Environ.  Resources, 32 p.
     (BCR  71-8)

33.  Kamal,  MusaR.,  ed.,  1967, Weather ability of Plastic Materials:  Inter-
     science Publishers
                                 -41-

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       REVEGETATION OF LANDS DISTURBED BY COAL MINING




                           TABLE OF CONTENTS




                                                                Page No.




Introduction                                                        45




Cost Analysis                                                      45




Use of Soil Tests and Factors Affecting Reclamation Decisions        48




Green Thumb Program                                             53





References                                                         54




                           LIST OF TABLES




1. Variables Affecting Revegetation Costs                           46




2. Cost Analysis for Revegetation                                  50




                           LIST OF FIGURES




1. Soil Test Report - Pennsylvania State University                 49
                                  -43-

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       REVEGETATION OF LANDS DISTURBED BY COAL MINING

Introduction

        To insure the success of strip mine and refuse bank reclamation pro-
jects adequate vegetation cover must be established (U.S. Department of
Agriculture' *•>).  Revegetation of areas disturbed by coal mining prior to 1940
consisted almost entirely of tree planting (U.S. Department of Interior' ').
However, it has  been demonstrated from past reclamation experience that an
easily established ground cover (grasses and legumes) is needed for erosion
control and initial surface stabilization (Struthers  and Vimmerstedt'^').  The
most logical approach to revegetation appears to be the methods outlined by
Hill''*/ in which a ground cover is  rapidly established followed by overplanting
with trees.

        Low pH is the most common factor responsible for the failure of re-
vegetation on strip mines and refuse  banks  (Czapowskyj  and McQuilkin(^);
Mellinger(6) and Smith, et al. (7)). The Truax-Traer Coal Company(S)  and
Tyner and Smith(9) found that repeated applications of lime were necessary
to enable the establishment of a ground cover.  Capp and Adams(lO) report
similar results with  the application of fly ash to increase buffering  capacity
of spoils.  However, Magnuson and Kimball( •'••'•) conclude that application of
lime on spoils having an initial pH above 4. 5 is not likely to increase sur-
vival rate.  Other factors responsible for revegetation failures are salt tox-
icities (Bergl-^); Berg and Vogel(^3); Beyer and Hutnikf^'*) ancj Coleman,
et al.'")),  nutrient deficiencies (Cummins, et al.^0); Hart  and Byrnes(17)
and Struthers( ^),  soil temperatures and moisture  content (Maguire(19) and
Marx and Bryam^/). A detailed description of adverse  factors affecting the
revegetation of strip mines and refuse banks is presented in  a publication by
Nicholas and Hutnik(21).

       Since soil characteristics can vary considerably  from one reclamation
site  to the next (Sullivan(22))( it is unlikely that uniform planting recommen-
dations can be developed.  However,  soil mapping of spoils  to obtain repre-
sentative samples as suggested by Limstrom and Merz'"', Paton,  et al. (24)
and Grube,  et al.(") can supply the information needed  to develop planting
recommendations at  specific sites.  Krause(^") recommends  greenhouse tests
of various spoils to get more specific information  on the capability  of the mat-
erials to produce and sustain vegetation.  Grube, et al.(25) concurs and rec-
ommends independent soil analysis prior to soil treatment,  fertilizing and
seeding.

Cost Analysis

        To facilitate future cost estimates for revegetation,  it is recommended
that  a standard format be developed  for reporting costs.  A listing of the vari-
ables that can affect  revegetation costs in strip mine and refuse bank reclama-
tion  is presented in Table 1.  In Table 1, soil treatment, seeding and mulching
                                  -45-

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                               TABLE 1

           VARIABLES AFFECTING REVEGETATION COSTS*
                 LANDS DISTURBED BY COAL MINING

1.  Soils Analysis (Based  on soil mapping to obtain representative samples)

    A.   pH Soil
    B.   pH Buffer**
    C.   Soil Nutrient Level  (P, K, Ca and Mg)
    D.   Moisture Content
    E.   Drainage Characteristics of Soil
    F.   Organic Content
    G,   Toxic Salts
    H.   Other Factors

2.  Greenhouse Analysis (Using proposed soil treatment,  seeding mixtures
    and mulching)

3.  Recommended Soil Treatment (Methods,  applications,  rates, year and
    months)

    A.   Lime or Ground Limestone (tons/acre)
    B.   Fertilizer (Ibs. of N-P2O5-K2O/acre)

4.  Recommended Vegetation (Planting methods,  species or varieties,  rates,
    year and months)

    A.   Ground Cover
         1.  Grasses (Ibs./acre)
         2.  Legumes (Ibs./acre)
    B.   Trees and Shrubs, seedling  or saplings  (number/acre)
    C.   Special Wildlife or Ornamental Plantings (description and number/
         acre)

5.  Recommended Mulching  (None,  one or more of the following)

    A.   Hay or  Straw (tons/acre)
    B.   Wood Cellulose Fiber (Ibs. /acre)
    C.   Hardwood Bark (cubic yards/acre)
    D.   Chipped Brush and Trees from Clearing and Grubbing (cubic yards/
         acre)
    E.   Other Mulch

6.  Vegetation Survival Analysis (1,  2, 3 years or a longer period following
    initial planting)

    A,   Percent of Ground Cover (including survival of individual varieties
         of grasses and legumes)
                                 -46-

-------
                          TABLE 1 (Continued)

     B.   Percent of Trees and/or Shrubs (including survival of individual
          species  or varieties)
     C.   Size of Surviving Trees and/or Shrubs (below average, average,
          above average for age  of each species or variety)
     D.   Reasons for Poor Survival of Specific Grasses, Legumes, Trees
          and Shrubs  (non-adaptive to soil conditions,  climatic factors,  com-
          petition  from other  species or other factors)

 7.  Volunteer Vegetation (1, 2,  3 years or a longer period following initial
     planting)

     A.   Grasses (species or varieties and percent of ground cover)
     B.   Weeds,  Wildflowers and Other Plants (species and percent of ground
          cover)
     C.   Trees and Shrubs (species, size and  percent of cover)

 8.  Subsequent Recommended Soil Treatment

     A.   Same Information as Item 3

 9.  Subsequent Recommended Vegetation

     A.   Same Information as Item 4

10.  Soils Analysis (1, 2, 3 years or a longer  period following initial planting)

     A.   Same Information as Item 1
     B.   Weathering Characteristics of Soil
  #These  variables are in addition to those factors listed in Tables 1 and 2 of
   the section titled "Strip Mine and Refuse Bank Backfilling and Grading".

 **Used to determine lime requirement and to calculate  the milli-equivalents
   of hydrogen ions per  100 gm soil (me H"*~ per 100 gm soil).  The second
   value is used in calculation of the cation exchange  capacity (CEC).
                                  -47-

-------
are treated as separate operations, but in actual practice one, two or all
three of the operations may be combined into one operation,  as  in the ex-
ample of hydroseeding.  Also even when these operations are combined or
performed separately, the total requirements for soil treatment,  seeding
and mulching may not be applied at the same time.  As an example, seed
and one half of the fertilizer requirement may be hydroseeded in one appli-
cation in the spring and the remainder of the fertilizer applied in the fall.

       In preparing this section,  only information from recent strip mine
and refuse bank reclamation projects  in the  Monongahela River  Basin and
surrounding area was used.  Table 2  presents a tabulation of revegetation
costs for  these projects.  Revegetation costs ranged from $90 to $500 per
acre and the mean cost was $278.56.  A wide variety of soil treatment and
planting methods is represented on this table and variable degrees of reveg-
etation success  is reported. Generally, figures  are presented as lump sums
or cost per acre.  Where possible, the  application rates of limestone and
fertilizer are included.  Because  of the limited sample size  and a lack of
information on initial soils  analysis,  no conclusions can be  made on cost of
planting various species or varieties  of grass, legumes,  trees and shrubs
or possible relationships  between area, spoil pH and  revegetation costs.

       A  further difficulty in evaluating revegetation  costs even when only
recent projects  are used in the analysis, is  that knowledge concerning re-
vegetation of lands  disturbed by coal mining has increased so rapidly in the
last year  or two that  it is doubtful the same  vegetation procedures would be
used on many of these projects today.

       Based on a review of selected  revegetation projects,  either planned
in the near future or  completed,  it is  estimated that revegetation costs per
acre should be between $350 and $400 depending upon soil treatment require-
ments, the type of revegetation and the  use of mulch.

Use of Soil Tests and Factors Affecting Reclamation Decisions

       Figure  1 shows an agricultural soil test report for a  strip  mine area
in Elk County,  Pennsylvania made by  Pennsylvania State University for
Michael Baker, Jr.,  Inc.'  ').   The area strip mined is  approximately 15
acres.  Three  samples were submitted for soils  analysis and each sample
was a composite of at least 15  samples  collected throughout  a portion of the
strip mine and quartered down to about a 1/2 pint size.  The test results of
the samples are comparable and Figure 1 is  representative of soil conditions,

       The area was  more  or less graded after strip mining, but  there are
no trees  and it is barren except for occasional poverty grass, ferns and an
annual sage.  Intermittent acid seepage occurs at several places and during
rainfall ponding occurs in some areas.  Only minor grading  is required in
areas gullied by erosion and to improve drainage.  The strip mine is sur-
rounded by densely wooded  land.  The objective of reclamation, in this case,
                                 -48-

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08/25/70
OATf
4533
LAI NO.
72874
SEklAlNO.
a iu u ±\.£j i
ELK
COUNTY

ACRES
7CC
FIELD

SOtl |
. SOIL TEST REPORT FOR:
      MICHAEL  BAKER JR  INC
      P 0  BOX  111
      ROCHESTER PA
       15074
                 THE PENNSYLVANIA STATE UNIVERSITY
                 SOIL & FORAGE TESTING LABORATORY
                      COLLEGE OF AGRICULTURE
                  UNIVERSITY PARK, PENNSYLVANIA 16802
• LABORATORY RESULTS;
3.9
pH
SOU.
5.4
PH
BUFFER
4
r
(Ita/A)
0.10
if
0.5
«9
(«|pr1Ng«.)
0.7
Co
17.4
CK
0.5
K
3.4
Me
% Saturation
4.3
Co
OTHER:


• SOIL NUTRIENT LEVELS:


 PHOSPHORUS  (P)

 POTASSIUM   (K)
 CALCIUM     (Ca)

 MAGNESIUM   (Mg)
LOW
               MEDIUM
                                  HIGH
                                               EXCESSIVE
• LIMESTONE AND FERTILIZER  RECOMMENDATIONS  FOR ft SIDING OF LEGUME  C'R
 LEGUME-GRASS  MIXTURE.
 CALCULATED NUTRIENT  REQUIREMENT IS  20-211-420 PER ACRE.
 ***FERT ILIZER-WORK  IN  DEEPLY  180 LBS OF  PHOSPHATE PLUS 360 LBS  CF POTASH
 PER ACRE.
 ***FERTILIZER - DRILL  20-40-40  PER ACRE.  BAND PLACE  IF POSSIBLE.

 ***LIMESTONE-APPLY  14000 POUNDS OF STANDARD GROUND LIMESTONE  CR
 EQUIVALENT PER ACRE.

 APPLY 240  LBS OF MAGNESIUM PER  ACRE.  IF  RECOMMENDED  AMOUNT WAS
 APPLIED WITHIN THE LAST 12 MONTHS* NO ADDITIONAL MAGNESIUM IS NEEDED NOW.
 SEE LEAFLET ST-2.

 FOR OTHER  CROPS, SEE LEAFLET  ST-2, FERTILIZER TABLEt  COLUMN 1
FERTILIZER APPLIED.
                                      -49-
                                                      TOTAL COST/ACRE.

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         -51-

-------
is  to improve soil conditions so that a volunteer tree cover can be established.
This can best be accomplished  by improving soil pH and establishing a ground
cover of grass and legume  (creeping red fescue and birdsfoot trefoil).

       The lime recommendation of 7 tons per acre shown on the Soil Test
Report will adjust the soil pH to 7. 0  In strip mine reclamation, a soil pH
adjustment of 6. 0 to  6. 5 should be sufficient, depending on the intended use
of the land.  Therefore, in this example,  an application of 6 tons of ground
limestone per acre was recommended. It was further  recommended that one
half of the  ground limestone requirement  be  spread and incorporated into the
soil to a minimum depth of 4 inches  in the fall preceding  spring planting so
the limestone would have time to react with the  acid soil.   One cause of seed-
ing failure is soil acidity, and failure  may occur even though sufficient ground
limestone is applied  at seeding time because the limestone does not have
enough time to react with the acid  soil before germination.

       Of significance in Figure 1 is the magnesium requirement of 240 Ibs.
per acre.  In some areas soils  are highly deficient in magnesium and this
requirement is  often overlooked when  it can be met with little or no additional
cost during revegetation.  If the local limestone source produces a high cal-
cium limestone, the  magnesium requirement can be met  by blending one ton
of imported high magnesium, limestone per acre with local limestone.  This
is  probably the  cheapest way but other magnesium materials  such as Magox,
GranuMag  and Alcan Magnesia  can be  used to satisfy this  requirement.

       The calculated nutrient  requirement shown on Figure  1 is the amount
of nitrogen,  phosphate and  potash (N-P2O5-K2O) calculated by a standard
formula needed to support the yield goal of a crop, taking into consideration
the nutrients available in the soil and the  requirements to maintain nutrient
level in the soil (Hinish,  et al. '  ').  Since this calculated nutrient require-
ment is for top  agricultural production, the fertilizer amount can be reduced
by 1/4 to 1/3 for reclamation of lands disturbed by coal mining unless the
intended use is  agricultural or  grazing.

       In most  revegetation projects to date, fertilizers  of the home garden
variety such as  10-10-10 and 5-10-10  have been used.  These N-P2O5-K2O
standard ratios* of 1-1-1 and 1-2-2  do not appear  to be indicative  of nutrient
levels  of "soil" found at many strip mine  and refuse bank areas based on soil
test reports. A 1-4-4 standard ratio appears to be more  applicable.  In Fig-
ure 1,  the  calculated nutrient requirement of 20-211-420 can be satisfied by
using a 6-24-24 custom mix, therefore,  50-200-200 Ibs.  N-P2O5-K2O was
recommended.  Although the potash requirement is twice  that of phosphate,
the latter is more significant since there  is no crop yield and removal index
*At the request of the fertilizer industry, many states have agreed to restrict
fertilizer recommendations to a minimum of ratios .   The calculated  nutrient
requirement is  adjusted to the "best fit" of one of twelve standard fertilizer
ratios .
                                  -52-

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values for potash do not have to be considered.  This is not the  only recom-
mendation that would satisfy nutrient requirements.  As  an example a 5-10-10
or a 10-10-10 fertilizer could have been used along with 20 or 46% super phos-
phate.  In addition to satisfying nutrient requirements, recommendations should
be based  on cost and availability of fertilizer mixtures.

       Bulk deliveries in tank trucks of blended fertilizer  mixtures should  be
considered because equivalent nutrient values can be obtained with a reduction
in trucking and material costs.

Green Thumb Program

       Substantial savings in revegetation and in clearing and grubbing costs
may result if advantage is taken of the Green Thumb program'   '.  Green
Thumb is an Operation Mainstream program sponsored by the National Farm-
ers Union and funded by the U. S. Department of Labor.   The program pro-
vides community improvement jobs for men 55 and older with farm or rural
backgrounds.

       Crews of Green Thumbers are assigned to projects at the request of
local nonprofit organizations, both public and private.  Local sponsors supply
materials, equipment  and supervision in return for the manpower needed for
a particular project.   There is no red tape,  no bookkeeping and  no cash con-
tributions.  The crews remain on the Green Thumb payroll and all agreements
are informal.

       The program was  started in 1966 and many crews are working  in Appa-
lachia. They have worked at developing state parks, highway beautification
and development of roadside parks.

       In the Monongahela river Basin,  the  program is presently operating in
Pennsylvania.  For information contact:

                Pennsylvania Farmers Union Green Thumb
                240 N. 3rd Street, Room 1106
                Payne-Shoemaker Building
                Harrisburg, Pennsylvania   17100

       Requests for expanding Green Thumb into states where there is now no
program should be addressed to:

                U. S.  Department of Labor
                Manpower Administration
                Division of Work Experience
                1741 Rhode Island Avenue,  N. W.
                Washington, D. C.   20210
                                 -53-

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                              REFERENCES

 1.  U. S. Dept. of Agriculture,  1968,  Restoring Surface Mined Land: Misc.
     Publ. No.  1082,  18 p. (BCR 68-162)

 2.  U. S. Dept. Of Interior,  1967, Surface Mining and Our Environment, A
     Special Report to the Nation:  124 p.  (BCR 67-82)

 3.  Struthers,  P. H. and Vimmerstedt, J. P.,  1965, Advances in Strip Mine
     Reclamation:  Ohio Rept. on Res. and Development,  jj£(l), p. 8-9
     (BCR 65-26)

 4.  Hill, Ronald D. ,  1969, Reclamation and Revegetation of 640 Acres of Sur-
     face Mines, Elkins, West Virginia: Int. Sym. Ecology Revegetation of
     Drastically Disturbed Areas, University Park,  Pa. State  Univ.,  47 p.
     (BCR 69-53)

 5.  Czapowskyj, M.  M. and McQuilkin, W. E. , 1966, Survival and Early
     Growth of Planted Forest Trees on Strip-Mine Spoils in the Anthracite
     Region:  U.S. Forest Service, Res. Paper NE-46, 29 p. (No BCR No.)

 6.  Mellinger, R. H. ,  I960,  Results  of Revegetation of Strip  Mine Spoil by
     Soil Conservation Districts in West Virginia: W. Va. Univ. Agr. Exp.
     Sta. Bull.  No.  540, 18 p. (No BCR No. )

 7.  Smith, R.  M. , Tryon, E. H. and Tyner, E. H. ,  1971, Soil Development
     on Mine Spoil:  W.  Va. Univ. Agr. Exp. Sta. Bull.  640T, 47 p. (No BCR
     No. )

 8.  Truax-Traer Coal Company, 1971,  Control of Mine Drainage from Coal
     Mine Mineral Wastes: Environmental Protection Agency, Water  Quality
     Office,  Res. Ser. 14010 DDK 08/71,  148 p.  (BCR 71-69)

 9.  Tyner,  E.  H. and Smith, R.  M. ,  1945, The Reclamation  of the Strip-
     Mined  Coal Lands of West Virginia with Forage Species:  Soil Sci. Soc.
     Am. Proc.  _10_, p.  429-36 (No BCR No.)

10.  Capp,  J. P. and Adams,  L. M. ,  1971,  Reclamation of Coal Mine Waters
     and Strip Spoil with Fly Ash:  Am. Chem.  Soc.  Div.  Fuel. Chem. Preprints
     _l_5 (2), p. 26-37 (BCR 71-31)

11.  Magnuson,  M.  O. and Kimball,  R. L.,  1968, Revegetation Studies at Three
     Strip-Mine Sites  in North-Central Pennsylvania:  U.  S. Bur. Mines Rept.
     Inv. 7075,  8 p. (No BCR No.)

12.  Berg,  W. A.,  1965, Plant-Toxic  Chemicals in Acid  Spoils: Coal Mine
     Spoil Reclamation Sym. Proc., Pa.  State Univ., p.  91-93 (No BCR No.)
                                   -54-

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13.  Berg,  W. A. and Vogel, W. G., 1971, Aluminum and Manganese Toxicities
     of Plants Grown in Acid Coal Mine Spoils:
14.  Beyer,  L. E. and Hutnik,  R. J. ,  1969,  Acid and Aluminum Toxicity as
     Related to Strip-Mine Spoil Banks In Western Pennsylvania:  Pa.  State
     Univ., Spec. Res.  Rept. SR-72, 94 p.  (BCR 69-34)

15.  Coleman, N. T. , Kamprath,  E.  J. ,  and Weed, S. B. , 1958, Liming:
     Advance. Agron. 10, p. 475-522

16.  Cummins, D. G. , Plass,  W. T. and Gentry, C. E. ,  1965, Chemical and
     Physical Properties of Spoil Banks in Eastern Kentucky Coal Fields:  U. S.
     Forest Service, Res.  Rept.  CS-17,  lip.  (No BCR No. )

17.  Hart, G.  and Byrnes, W.  R.,  I960,  Trees for Strip-Mined Lands,  A
     Report on 10-Year  Survival and Growth  of  Trees Planted on Coal-Stripped
     Lands in Pennsylvania's Bituminous Region:  U.  S.  Forest Service, 136 p.
     (No BCR No.)

18.  Struthers, P. H. ,  1964, Chemical Weathering of Strip-Mine  Spoils:  Ohio
     Jour. Sci. 64 (2), p. 125-31 (BCR 64-34)

19.  Maguire, W. P., 1955, Radiation, Surface Temperature, and Seedling
     Survival:  Forest Sci. j_, p.  277-85

20.  Marx, D. H. and Bryan, W. C. , 1971, Influence of Ectomycorrhizae on
     Survival and Growth of Aseptic Seedlings of Loblolly Pine at High Tem-
     peratures:  Forest  Sci. 17, p. 37-41

21.  Nicholes, A. K.  and Hutnik, R. J. ,  1971,  Ectomycorrhizal Establishment
     and Seedling Response  on Variously Treated Deep-Mine Coal Refuse:  Pa.
     State  Univ., Spec.  Res. Report SR-89,  121 p. (No BCR No.)

22.  Sullivan, D. C,,  1967, Current Research Trends in Mined-Land Conser-
     vation and Utilization:  Am.  Inst.  Mining Eng. Preprint No. 67F65, 18 p.
     (BCR 67-11)

23.  Limstrom, G.  A. and Marz, R. W. , 1949, Rehabilitation of  Lands  Stripped
     for Coal in Ohio: U. S. Forest Service, Central States Forest Exp. Sta.
     Tech. Paper No. 113,  41 p.  (BCR 40-56)

24.  Paton, R. R. ,  et al. ,  Tree Planting Guide for the Reclamation of Strip
     Mine  Lands in Ohio:  Ohio  Reclamation Assoc. ,  Tech. Bull.  No.  70-1,
     21 p.  (BCR 70-40)
                                  -55-

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25.  Grube,  W. E. , Jr., et al. , 1971, Mine Spoil Potentials for Water Quality
     Controlled Erosion: Environmental Protection Agency,  Water Quality
     Office,  Res. Ser. 14010 EJE 12/71, 206 p. (BCR 71-72)

26.  Krause, R. R.,  1972, Mining and Reclamation Techniques to Control
     Mine Drainage;  Fourth Sym. Coal Mine Drainage Res.  Preprints, Pitts-
     burgh,  p. 425-30 (BCR 72-

27.  Scott, R. B., Hill, R. D.  and Wilmoth,  R. C. ,  1970, Cost of Reclamation
     and Mine Drainage Abatement - Elkins Demonstration Project:  Am. Inst.
     Mining  Eng. ,  Soc.  Mining Eng.  Fall Meeting, St. Louis, Preprint No.
     70-AG-349, 22 p. (BCR 70-70)

28.  Grim,  Elmore C., 1972, Personal Communication Compiled by Mr. Grim,
     Surface Mining Specialist, Environmental Protection Agency, National
     Research Center, Cincinnati

29.  Michael Baker,  Jr.,  Inc., 1970, Acid Mine Drainage Survey - East Branch
     Clarion River Watershed,  Elk and McKean Counties: Rept. to Pa. Dept.
     Mines Mineral Ind. , Project SL-108, 379 p. (BCR 70-113)

30.  Hinish,  W. W. , Heddleson, M.  R. and Eakin,  J. H., Jr.,      ,  Soil
     Testing Handbook:  Pa. State Univ., College of Agruculture,  30 p., forms,
     written for County Agricultural  Extension Agents

31.  Appalachia, 1972, Green Thumb in Appalachia Provides Employment for
     the Elderly:  5. (5), p.  1-6.
                                  -56-

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                            MINE SEALING

                         TABLE OF CONTENTS

                                                                Page No.

Introduction                                                       61

Hydraulic Mine Seals                                              63

       Grouted Double Bulkhead Seal                               65
       Grouted Single Bulkhead Seals  and Curtain Grouting          71
       Review of Unit Bid Prices for Three Hydraulic Mine
           Sealing Projects                                       76
       Hydraulic Sealing of Accessible Mine Headings               80
           Quick Setting Double Bulkhead Seal (No.  1)              80
           Quick Setting Double Bulkhead Seal (No.  2)              82
           Quick Setting Single Bulkhead Seal                      82
           Expandable Grout Retainer Seal                        86
           Grouted Limestone Aggregate Seal                      89
       Reinforced Concrete Hydraulic Seal                         89
       Summary of Costs for Sealing Accessible Mine Openings     94
       Estimated Cost for Grouted Double Bulkhead Seal            95
       Factors Affecting Cost of Hydraulic Mine Seals              95

Limestone Barrier Mine Seals (Permeable Plug)                    96

Dry Mine Seals                                                    99

Air Mine Seals                                                   100

Summary of Costs for Dry and Air Mine Seals                      105

References                                                       106
                                 -57-

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                            LIST OF TABLES

                                                                 Page No.

 1.   Cost Tabulation - Deep Mine Seals,  Moraine State Park           68

 2.   Cost Tabulation - Deep Mine Seals,  Slippery Rock Creek          70

 3.   Cost Tabulation - Pressure Curtain Grouting,
     Thomas Mills Area                                              75

 4.   Unit Bid Prices - Deep Mine Seals,  Moraine State Park           77

 5.   Unit Bid Prices - Deep Mine Seals,  Slippery Rock Creek          78

 6.   Unit Bid Prices - Pressure Curtain Grouting and Reclamation,
     Thomas Mills Area                                              79

 7.   Cost Data - Grouted Aggregate Seals, Harrison County,
     West Virginia                                                   91

                            LIST OF FIGURES

 1.   Isometric Drawing of Grouted Double Bulkhead Seal               66

 2.   Construction Drawing  of Grouted Double Bulkhead Seal            67

 3.   Plan View  - Portion of Thomas  Mills Mine Area                  72

 4.   Design of Single Bulkhead Mine  Seal                             73

 5.   Quick Setting Double Bulkhead Seal  - Mine No. 62-008            81

 6.   Quick Setting Double Bulkhead Seal  - Mine No. RT5-2             83

 7.   Plan View  of Remedial Construction - Mine No. RT5-2            84

 8.   Quick Setting Single  Bulkhead Seal - Mine  No. 62-008             85

 9.   Expendable Grout Retainer Seal - Mine No. 14-042A              87

10.   Expendable Grout Retainer Seal Following Remedial
     Work -  Mine No. 14-042A                                       88

11.   Grouted Limestone Aggregate Seal - Mine No. 40-016             90

12.   Plan View  of Reinforced Concrete Hydraulic Seal -
     Essen Mine No. 2                                               92
                                   -58-

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                                                               Page No.

13. Section of Reinforced Concrete Hydraulic Seal -
    Essen Mine No. 2                                               93

14. Limestone Barrier Mine Seal (Permeable Plug)  -
    Mine  No.  RT5-2                                                 98

15. General Arrangement of an Air Seal                            102

16. Average Monthly Total Acidity and Flow Rate of the
    Mine  Effluent - Air Sealed Mine in Pennsylvania                 104
                                 -59-

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                                MINE SEALING

INTRODUCTION

        Mine sealing has been defined as the closure of mine entries,  drifts,
slopes, shafts,  subsidence holes,  fractures and other openings into under-
ground mines with clay, earth, rock, timber,  concrete blocks, brick, steel,
concrete, fly ash,  grout and  other suitable materials (Foreman^•*•)),
                                                  /
        Mine seals can be  classified into three  general  types based on function
and method of construction which to a certain extent is  the result of geohydro-
logical conditions.  The three types and their functions are:

1.  Dry Seal - The function of a dry seal is to prevent air and water from
    entering the mine.  This type of seal is constructed at openings which do
    not have a discharge or the discharge is so slight there  is little danger
    of a hydraulic head developing.

2.  Air Seal - An air seal is designed to  exclude air from entering a  mine but
    it permits the normal water flow from the mine to  be discharged.  The air
    seal is designed with  a water trap and the  principle is similar to  the way
    water traps  in sinks and drains function.

3.  Hydraulic Seal - A hydraulic seal is constructed at a mine with a discharge
    to prevent water flow  from the mine.  A hydraulic  head  is created which
    floods the mine and air is excluded by inundation.

        Although  acid mine drainage discharges from deep mines has been a
significant pollution problem for over a century, any mine sealing work prior
to the  1930's generally was performed as a safety precaution and not to reduce
acid discharges.  The concept of sealing coal mines as a means  of reducing
acidity was the subject of discussion in  several technical papers in the 1920's
and early 1930's.  The U.S.  Bureau of Mines performed much of the early re-
search and an experimental mine sealing  program was  started in 1932 in which
three mines were sealed with a water trap designed to  exclude air from enter-
ing the  mine but permitting the normal  flow of water at the discharge (Air Seals).
An analysis of water samples collected  from the mines over a period  of a year
indicated  a decrease in acidity of the discharges.

       A  large mine sealing  program was started in Pennsylvania and West
Virginia in 1933  as a result of these studies.  The mine sealing work was per-
formed under the Works Progress Administration and the Civil Works Admini-
stration.  The effectiveness of the programs in reducing acid discharges has
been questioned by some,  but Maize' ' indicates acid discharges were reduced
in some Pennsylvania streams to the extent that fish life appeared and the water
could be used for industrial and domestic purposes.  The U.S. Public Health
Service^) estimated a 28 percent reduction in  acid loading in the  Ohio River as
as result of the abandoned mine sealing  programs.   However, the work performed
                                  -61-

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in many areas was not adequate to exclude air from the underground workings
and some mine seals failed after several years.  In other areas, the acid
water found new discharge openings.

       Pennsylvania in 1935 passed The Bituminous Mining Law, Act No. 55,
which provided for sealing of abandoned mines by the Pennsylvania Department
of Mines.  Section 1 of the Act stated "That it shall be the duty of each and
every owner,  operator,  or lessee of any abandoned bituminous coal mine or
abandoned working, which is discharging polluted water which flows into any
of the streams or rivers of this Commonwealth,  or which is in danger of being
set afire, to shoot down,  or  cause to be shot down, or otherwise seal,  or cause
to be sealed, the entries and air shafts of such abandoned coal mine or working
for the purpose of cutting off the supply of air from the abandoned mine  or work-
ing. " Mine sealing was  continued under this Act by the Pennsylvania Department
of Mines until 1947 when a law was passed by the State Legislature establishing
a Mine Sealing Bureau within the Department of Mines.  Over 2.5 million dollars
was appropriated for mine sealing under this program between 1947 and 1949.

       The first  mine sealing performed by the  new Bureau was in the  watershed
of the Casselman River, a tributary  of the Youghiogheny River.  According to
Maize^) this stream was highly polluted with acid mine drainage, but five years
later the Casselman River was  alkaline and supported fish.  Maize also states
that water analyses of the Youghiogheny River in 1937 at a point just before it
enters the MonongahelaRiver showed the stream was carrying 870 tons  of acid
per day.  In 1950 a water sample  taken at the same place  indicated the  acid load
to be 185  tons per day. As a result of this reduction in acid,  the City of
McKeesport again began taking  its domestic water supply from the Youghiogheny
River(^)>   The mine sealing  work under the program consisted of dry and air
seals,  filling of cracks,  subsidence areas, slopes and shafts,  and also a limited
amount  of drainage diversion.

       The very  encouraging results obtained with dry and  air seals in the Cassel-
man River watershed and other areas in Pennsylvania as reported by Maize^'
contrasts sharply with the negative results reported by others, such as  the recent
Elkins,  West Virginia demonstration project' ' and the study  by BraleyV^' reported
in 1962.   Braley  indicated air sealing did not substantially reduce the oxygen con-
tent of the mine atmosphere  and implied that mine sealing  of abandoned drift  mines
above drainage is ineffective in reducing the  quantity of acid discharged. No
study has been made to determine why air sealing methods  appear to be effective
in some areas and not in others.  A study of this type may be rewarding because
air seals  are less expensive to  construct  than hydraulic seals.  It may be difficult
to interpret results of a study of this type because active mining operations con-
tinue to the present in many of the watersheds where air seals were constructed
and it appears the amount of acid discharged has increased yearly because of
this later mining.  The Casselman River watershed is an example of an area
where the effects of an active air and dry mine sealing program was negated  by
later mining operations.
                                  -62-

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        Mine sealing research continued in the 1950's and 1960's with studies
being made by Bituminous Coal Research, Inc.,  Mellon Institute,  U.S. Bureau
of Mines and several universities and State agencies.  The  Ohio River Valley
Sanitation Commission (ORSANCO) adopted Resolution No.  5-60 in I960, amen-
ded 1963, which in part stated "Upon discontinuance of operations  of any mine
all practicable mine-closing measures  consistent with safety requirements,
shall be employed to minimize the formation and discharge of acid mine-drainage"
The  coal industry in the Ohio River watershed is required to  carry out provisions
of ORSANCO Resolution 5-60. An explanation of the measures approved in the
Resolution was  published in 1964\") and it was recommended  where practical
hydraulic mine  seals should be constructed because mine sealing is not effective
in preventing acid mine drainage unless the coal seam and other acid producing
strata and materials  are submerged.

        Until recently most seals constructed  at mine portals  were air seals.
New developments in mine  sealing techniques  including methods of hydraulic
sealing are a result of  increased interest in the field of environmental control.
From 1966 through 1969, the Halliburton Company'  ' had a contract with the
Federal Water Pollution Control Administration, now Environmental Protection
Agency, to develop and field test new concepts for watertight or hydraulic  seals.
Moebs and Krickovic(^) reported in 1970 on a U.S. Bureau  of Mines air sealing
project of an above drainage coal mine.  A comparison of the chemical analyses
of the mine effluent during  the two year, seven month period  before sealing and
during the  two year,  eight month period after  sealing showed that the  acid  load
had been reduced.

       Since 1969 most of the seals  constructed at deep mine portals  in Pennsyl-
vania have been hydraulic mine seals.   Grouted double bulkhead seals were de-
veloped in Pennsylvania for the Moraine State Park and Slippery Rock Creek
projects and a grouted  single bulkhead seal was designed for  the Thomas Mills
mine  area.  This extensive hydraulic mine sealing effort is part of "Operation
Scarlift, " Pennsylvania's 500 million dollar bond issue for  a  Land and Water
Conservation and Reclamation Fund.

HYDRAULIC MINE SEALS

       The objective of hydraulic or watertight mine seals  is to exclude air
from the mine by flooding mine workings.  Watertight bulkheads in mine open-
ings  must be capable of withstanding the maximum anticipated hydrostatic head.
Installation of hydraulic mine seals includes sealing of all drifts, slopes,  shafts,
subsidence areas and adjacent strata that can  affect the integrity of the water-
tight seal.
       Properly designed and constructed hydraulic mine seals will reduce the
rate  at which oxygen is supplied  for pyrite oxidation in the mines.  Theoretically,
by flooding the mine with water,  atmospheric  oxygen will not  be available for
acid producing chemical reactions.   Oxygen, however,  can be supplied at a re-
duced rate through the following  mechanisms:
                                  -63-

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1.  Water percolating downward through the overlying strata contains dissolved
    oxygen,  usually 10 to 14 mg/1.

2.  Groundwater containing dissolved oxygen may move  through the mine en-
    vironment.

3.  Oxygen in void spaces above the water table may dissolve and diffuse down-
    ward to  react with pyrite in the mine environment.

       Any or all of these mechanisms can operate to yield acid mine waters
within sealed mines or in unsealed abandoned mines advanced down dip which
are now flooded.  However, since less oxygen is available for chemical re-
actions,  less acid should be produced in a given time. In some cases sufficient
carbonate minerals may be present in the mine environment to neutralize the
smaller amount of acid produced or alkaline  groundwater flow through the mine
environment  may result in neutralization of acid.

       Hydraulic mine sealing construction methods are divided into two general
classifications:

1.  Accessible Hydraulic Mine Sealing - The mine openings are open from the
    portal to the construction area or can be opened with minor effort.  The
    seals are constructed from within the mines.   This  type of sealing has the
    advantage of visual inspection during construction and should afford a great-
    er degree of success.

2.  Inaccessible Hydraulic Mine Sealing -  The mine openings are caved at the
    portal and cannot be  reopened for mine sealing unless there is a large  ex-
    penditure for preparation and safety.  In this case,  mine sealing must be
    accomplished from above ground by drilling holes for placement of bulkhead
    materials and for grouting techniques.  Since  there  is no opportunity for
    visual inspection other than a borehole camera, exploratory and obser-
    vation borings may be required.

       A substantial number of abandoned mines within the  Monongahela River
Basin can be classified as inaccessible.  Abandoned mines  can be expected to
have fracturing of adjacent strata due to the lack of mine support and relief
stresses.  The strata adjacent to  the mine usually has to be grouted to insure
a watertight  seal.

       Within the last few years,  several methods  of constructing hydraulic
seals have been tested and other designs  are proposed for future projects.
With the exception of the  grouted double bulkhead seal, which has been used
extensively in Pennsylvania on the Moraine State Park and Slippery Rock Creek
projects,  most hydraulic seal methods have only been tested experimentally on
demonstration projects.
                                  -64-

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        The following hydraulic mine sealing methods are discussed:

        Inaccessible Hydraulic Mine Sealing Methods

        1.  Grouted double bulkhead seal,

        2.  Grouted single bulkhead seal.

        Accessible Hydraulic  Mine Sealing Methods

        1.  Quick setting double bulkhead seal.

        2.  Quick setting single bulkhead seal.

        3.  Expendible grout retainer seal.

        4.  Grouted (horizontally) aggregate seal.

        5.  Reinforced concrete seal.

Grouted Double Bulkhead Seal

        The grouted double bulkhead method of sealing inaccessible mines was
developed for use at Moraine  State Park, Butler County,  Pennsylvania.  This
project was one of the first to be constructed under "Operation Scarlift, "
Pennsylvania's 500 million dollar bond issue for a Land and Water Conservation
and Reclamation Fund.

        A total of 69 hydraulic seals were installed in drift mines which were
advanced up dip. It is the most extensive use of this  type of seal to date.  The
design of the double bulkhead  hydraulic  seal is shown on Figures 1 and 2.

        The engineering survey of the Moraine State Park Watershed Area rec-
ommended hydraulic sealing of 60 mines at an estimated cost of $15, 000 per
seal (Gwin Engineers, Inc.v')). A contract was awarded  in 1969 for sealing
53 of these mines.  While work was in progress,  the  Pennsylvania Department
of Mines and Mineral Industries,  now Department of Environmental Resources,
recommended the sealing of an additional 20 mines.   It was later discovered,
through exploratory drilling,  that some  of the depressions were natural and not
caved mine headings,  therefore, only 69 mine seals were constructed. Curtain
grouting of adjacent strata was extended a minimum of 50 feet on both sides  of
a mine  entry.

        Table  1 is a cost tabulation showing estimated contract quantities for
various items of construction, unit bid  prices,  actual quantities required,  and
actual  cost.  The unit  cost for Item 1, Mine Sealing,  includes all the work needed
for construction of grouted double bulkhead seals, such as placing front and  rear
coarse  aggregate bulkheads,  grouting of bulkheads, pumping of water  from cavity
between bulkheads and grouting of center plug.
                                  -65-

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                                            FIGURE  2
                                                                 Bulkhead  Drill Holes 6"dia on 30'Centers
                                                                 With Alignment Across The Main Entry. Drill
                                                                 Holes To Be Extended Into Coal Ribs As Shown.
              Observation
              a/or Pump
                  Drill
               Hole 6"dia
                                  Core Drill Hotes As-
                                Directed By The Engineer
      Injection Holes For Center Plug Area,Location And
      Number of Holes Dependent on Conditions.This
      Drawing Shows The Win. Number of Holes.
      Additional Holes May Be Required.

      Grout Curtain Holes 3"dia.0n 10'Centers On
      Alignment Parallel To SApprox.Halfway Between
      Front and Rear Bukhead Drill Hotes. Minimum Of
      50'0n Both Sides Of The Mine Entry.
                    /Observation And/or
                    Pump Drill Hole
                    Location To Be
                    Determined In Field
                                                   PLAN

                                       Distance Between Front And Rear Bulkhead Alignment
                                      _Range20'to25'As Directed By The Engineer
/CoreDrill Hole And
 Injection Hole
 Alignment
                            'REAR
                            COURSE
                                                   CONCRETE
                                                CENTER  i.,   PLUG
                                      AGGREGATE
          FRONT   i
         COURSE  UlAGGREGATE
                                                     PROFILE
        CONSTRUCTION  DRAWING OF GROUTED DOUBLE BULKHEAD SEAL
After  Foreman, 1970
                          (10)
                                                -67-

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-68-

-------
        An analysis  of the cost tabulation in Table 1 shows that based on estimated
quantities and unit bid prices the average estimated cost per seal is $15,Z39.04
for 73 seals.  Using the original base bid for 53 seals, the average estimated
cost per seal is $16, 364. 15. The actual cost per seal for the 69 completed seals
was $19,588.73.  The cost per seal includes curtain grouting and air shaft seal-
ing.  Air shaft sealing was a minor item, but curtain grouting was a major factor
in increasing the cost per mine  seal and the actual quantities  shown on Table  1
greatly exceed the original estimates.

        The costs  of individual seals ranged from $8, 300 to $58, 000.   The esti-
mating of quantities of materials for inaccessible mine sealing is difficult, par-
ticularly the quantities needed for curtain grouting.  In most cases,  the existing
subsurface  conditions cannot be  determined with any degree of certainty for
quantity estimates unless  there  is an extensive  and costly subsurface investiga-
tion.   The cost of this investigation would only add to the overall cost  of recla-
mation.  A  limite.d subsurface investigation is necessary, though, to obtain
information on the probable hydrostatic head and the general character of the
rock to be grouted.  Grouting estimates should  be on the conservative side.

        Curtain grouting, Item 3 in Table 1,  represented 60.6 percent of the
total cost of the Moraine State Park Project and it is estimated the cost per
lineal  foot of grout curtain was  $80. 00.

                     Curtain Grouting Costs - Item 3

                                Estimated
                             Contract Cost       Actual Costs
       Item3                 $517,750.00         $819,745.60

       % Total Cost                  46.5                60.6

       Cost L.F. /Drilled             7.33                8.17

       Cost L.F. /Curtain           51.76               80.00 (Estimate)

       The grouted double  bulkhead mine sealing program at Moraine State Park
was successful in reducing acid  discharges.   The reduction in pounds  of acid was
estimated to  be  76 percent in December,  1969 and  continued observation accord-
ing to Foreman! H) indicates the reduction in pounds of acid is 68 percent as of
January,  1972.

       The second most extensive hydraulic  mine sealing project to date has
been sealing  of abandoned drift mines in the Argentine and Whiskerville areas
in Slippery Rock Creek drainage basin(H).   The project is currently nearing
completion and it is one of Pennsylvania's many "Operation Scar lift" projects.
The cost tabulation for this project is presented in Table 2.
                                 -69-

-------





























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-70-

-------
        The design of the double bulkhead hydraulic seals is  the same as those
constructed at Moraine State Park except that grouting of aggregate  bulkheads
before placement of the center plug was  deleted from the contract.   This change
order was the  result of a law suit brought by Layne-New York Company,  Inc. ,
for alleged damages arising out of patent infringement.   Layne-New York Com-
pany, Inc. (^2) is claiming sole ownership in United States Patent No. 3,469,405
of the concept  covering design and placement by grouting methods of double bulk-
head seals.  The Commonwealth of Pennsylvania is challenging this  claim.  Al-
though, it is believed the law suit had no affect on the bid prices for this project,
it is difficult to determine what  affect it  will have on  future bids for  this type  seal.

        The physiography and geology in  the Argentine and Whiskerville area and
in the Moraine State Park area are similar.  Bidding was based on an estimated
34 mine seals.  Only 29 mine headings were believed to require sealing,  but an
additional five were estimated in case  others were found during construction.
Actually,  only 24 seals were constructed because five of the locations were proved
by exploratory drilling to be natural depressions and not caved headings. Even
though less seals  are being constructed,   actual project cost will approach esti-
mated  total cost because curtain grouting quantities are higher than  estimated.

        Final cost figures are not available, but it is  estimated the average  cost
per seal,  including curtain grouting, will be $18, 330. 00, or 32. 8% over the con-
tract estimated cost.  The cost  per individual seal will be dependent upon the ex-
tent of required curtain grouting.  It is estimated the minimum cost per seal  will
be approximately $7, 500 and the maximum cost $40,  000.

Grouted Single Bulkhead Seals and Curtain Grouting

        Mine sealing and curtain grouting work is currently being performed in
the Thomas Mills Mine Area,  Somerset  County,  Pennsylvania (Operation Scar-
lift Project,  No. SL 151-1).  This project is under the supervision of the Penn-
sylvania Department of Environmental Resources and a plan of part  of the mine
area is shown in Figure 3.

        The work in progress involves  placement of a continuous grout curtain,
2,200 feet in length, with construction of single grouted aggregate bulkhead bar-
riers or seals  whenever mine rooms or  passage  ways are encountered.

        The design of this type seal is shown on Figure 4. The barriers are
being constructed by injecting Pennsylvania Department of Transportation
Specification 2B coarse aggregate into bore holes spaced on two foot centers.
The aggregate  is spread by mechanical methods such as tamping, vibrating a
and/or  flushing until a cone  of material is built up to the  headwall of the mine.
The barriers are  then pressure grouted,  through metal pipes extending into
the aggregate,  using a cement fly ash slurry or a cement fly ash  slurry with
bentonite  or AM 9 admixture to  form the hydraulic seal.
                                  -71-

-------
                                FIGURE 3
                              PLAN  VIEW
                PORTION OF THOMAS MILLS MINE AREA
                        Somerset County, Pennsylvonio
Source1 Pennsylvania Department of Environmental Resources^
Scale: I" = 100'
                               •72-

-------
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                                            -73-

-------
        The cost tabulation of unit prices is presented in Table 3 and it is
anticipated the contract price will be exceeded,  perhaps greatly,  because
more mine voids are being encountered than originally  expected.   The voids
will require additional grouted aggregate mine seals.  The nonavailability
of sufficiently detailed mine  maps is considered the main factor in under-
estimating material quantities.  Also of significance, is the fact that unit
prices for cement,  fly ash and bentonite admixture are substantially above
engineering estimates.  The unit price for these items  includes material
cost, transportation, storage,  and labor associated with the mixing and
grouting operations.  The unit cost of $9. 00/ton for fly ash appears reason-
able considering prices for  other similar  projects and indicates an under-
estimate by the engineer.  The unit price  for concrete at $10.00/sack and
bentonite at $1.00/lb. appears very high.

        By applying contract  unit prices to a mine void five (5) feet in height,
twelve (12) feet in width, and at a depth of 50 feet,  the approximate cost for
construction of a grouted seal would  be $2, 100 as follows:
               Item            Quantity     Unit Price      Cost
       Drill holes (8)

       Cement for grouting

       Fly ash for grouting
424 L.F.

 35 Sacks

3.9 Tons
       Bentonite for grouting    200 Ibs.
       #2B Stone
 30 Tons
$ 2.10
10.00
9.00
1. 00
9.75
Total
Call
$ 890.40
350.00
351. 00
200. 00
292.50
$2, 083. 90
$2, 100.00
       If the strata is curtain grouted for 50 feet on both sides of the seal, the
approximate cost would be $2, 000 as follows:
                Item

       Drill holes  (10)

       Curtain  grouting
       materials
 Quantity    Unit Price      Cost

530 L.F.      $  2. 10     $1, 113.00

(assume same  quantities      901. 00
as above, except 2B Stone)
                                               Total
                          $2,014.00
       Increasing the above costs by 10% to cover mobilization and demobili-
zation,  the total cost, including curtain grouting, should be about $4, 500.
                                   -74-

-------




























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-75-

-------
Review of Unit Bid Prices for Three Hydraulic Mine Sealing Projects

       Tables  4,  5 and 6 show the unit prices bid by contractors  on the
following projects:

1.   Moraine State Park, Butler County, Pennsylvania
     Operation Scar lift Project SL 105-3

2.   Slippery Rock Creek, Argentine and Whiskerville Areas,
     Butler County, Pennsylvania
     Operation Scarlift Project SL 110-1BD

3.   Thomas  Mills Area, Somerset County, Pennsylvania
     Operation Scarlift Project SL 151-1

       The range in unit bid prices, particularly grouting materials, indi-
cates this could be a major factor in cost overruns.  For example:  fly ash -
$9. 00 to $96. 00/ton;  bentonite - $0. 10 to $1. 50/lb. ;  No.  2 Stone  - $6. 00 to
$24. 00/ton; sand  - $5. 80 to $50. 00/ton and cement - $3. 00 to $10. 00/sack.
When larger  quantities of material are used than anticipated in design,  and
the unit bid price  for the item is high, large cost overruns are bound to occur.
It is suggested that in preparing bid proposals,  maximum quantities be esti-
mated.   This would,  to a certain extent, prevent contractors from capitaliz-
ing on the fact that quantities are underestimated.

       Contractors are  in business to make money,  and  a contractor in order
to survive must take  advantage of every opportunity to make a legitimate  pro-
fit,  even a very large one,  if he is to offset projects which showed a loss or
only a marginal profit.  An experienced contractor many times can  tell when
quantities are underestimated and he  will balance his unit price bids to make
the most profit and at the same time attempt to come up  with an overall low
bid for the project.  State and  federal agencies on occasion are guilty of the
practice of underestimating the cost of a project, either  because  of  false  op-
timism and the desire to get a project started, or because of an intentional
underestimate in order to get  a project approved within a limited budget,
knowing  full  well that additional funds  will be appropriated at a later date to
complete the project.
                                   -76-

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Hydraulic Sealing of Accessible Mine Headings

       The work performed in hydraulic sealing of accessible mine headings
is  limited.  The Halliburton CompanyC?) under contract to the Environmental
Protection Agency has developed several methods  and techniques for hydraulic
sealing of accessible mines.  The demonstration projects were performed at
mine openings in Harrison County, West Virginia from  1967 to 1969.  The fol-
lowing is a description of some of the hydraulic  seals constructed under this
program.

       Quick Setting Double Bulkhead Seal
       Mine No. 62-008, Opening No.  5

       As  a result of a series of laboratory and field tests on the applicability
of quick setting  slurries, this site was chosen for  construction of a quick set-
ting double bulkhead seal.   A drawing of a section  through the seal is presented
in Figure 5.

       The slurry used for construction of the bulkhead was a blend of two sep-
arate slurries which were mixed immediately before being pumped into the mine.
The blended slurry consisted of equal parts  of the  following:

             Slurry No.  1                       Slurry No. 2

       Water          870 gallons      Water             1,050 gallons
       Cement        180 sacks        Bentonite            700 pounds
                                      Sodium Silicate       350 gallons

       The void between the bulkheads was filled by pumping Halliburton
LIGHT Cement, through a grout pipe.  This grouting material is a blend of
65% portland cement,  35% fly ash and 6% bentonite with 9.9 gallons of water
per bulk cubic foot of dry material,  or 61 parts  cement, 26 parts fly ash,
5.2 parts bentonite and 82.5 parts water by  weight.

       The mine sealing is considered to be completely successful as all
flow from the mine at this heading was stopped.  The construction cost of
the seal was $9, 449. 00 based on the following breakdown of costs:

                          Item                    Cost

                Site Preparation                $   894.00

                Grouting Materials               3, 872. 00

                Equipment and Operators        4, 683. 00

                                   Total       $9,449.00
                                  -80-

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       Quick Setting Double Bulkhead Seal
       Mine RT 5-2, Seal No. 1	

       The construction details of this mine  sealing project are shown in Fig-
ures 6 and 7. A quick setting slurry was used for construction of the bulkheads
as in Mine No. 62-008.  After construction of the rear bulkhead, a center plug
was  constructed by pneumatic placement of limestone aggregate.  This aggre-
gate was grouted with a cement-fly ash-bentonite mixture (Halliburton LIGHT
Cement) after placement  of the front bulkhead.  Grouting of the mixture was con-
tinuous until a fill-up was obtained to within a few inches of the roof.  At that
time, leaks appeared around the top  corners  of the front bulkhead, so the  slurry
was  altered by adding shredded cellophane, sawdust and shredded cane fiber.
This material successfully closed the leaks.

       The total construction cost for the seal, including the  site preparation
cost of $1, 079. 00,  was $9, 463. 00 for materials and equipment.

       The purpose of the project was to develop methods  of remote  grouting
application for use in mine drifts having high water discharge rates.   The water
flow from the mine opening prior to construction of the seal was in excess of 50
gallons per minute.  The seal appears to be effective in preventing water flow
from the opening,  but when the head  of water impounded behind the seal increased,
the pressure caused  a substantial leakage from an unknown adjacent opening.
Remedial work on the second opening, Seal No. 2, was accomplished by con-
structing a bulkhead  of graded aggregate and agricultural lime; this work is dis-
cussed under "Limestone Barrier Mine  Sealing."

       Quick Setting Single Bulkhead Seal
       Mine No. 62-008, Opening No. 4

       The single bulkhead seal  was constructed using the same slurry mixture
as used in constructing the double bulkhead seal at Opening No. 5 of the same
mine.  Figure 8 is a drawing of a section through the bulkhead.  The mine seal-
ing appears to be successful  since only  a slight seepage  occurred with a hy-
draulic head of 54.4  inches.  The total construction cost was  $3,564.00 as fol-
lows:

                          Item                    Cost

                Site  Preparation               $   647.00
                Grouting Materials              1,165.00
                Equipment and Operators        1, 752. 00

                                   Total       $3,564.00
                                  -82-

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                            PLAN
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                        SECTION A-A



                   CONSTRUCTION DETAIL

                SEAL  NO. I - MINE NO. RT5-2

                       FIGURE 6
From Halliburton Co.
                    (7)
                                -83-

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       Expendable Grout Retainer Seal
       Mine No. 14-042A	

       An abandoned mine near Clarksburg, West Virginia was  selected for
application of a mine seal because of its remote location,  small but easily
accessible area and highly acid discharge.  The seal was  constructed by
placing successive layers of expandable nylon and cotton cloth grout retain-
ers and filling them with a cement grout slurry to conform to the shape of
the opening.   Figure 9  is a drawing of the seal showing the installation and
mine configuration.

       After the mine seal was installed, a reduction of 92 percent in the
discharge was observed, but cumulative leakage from small leaks in the coal
surfaces around the seal amounted to about 1.5 gallons per minute.  Grout-
ing around the grout retainers with Halliburton PWG grout fluid,  an acryla-
mide monomeric solution, reduced the leakage to  0.33 gallons per  minute.
Grouting was  discontinued because it appeared the remaining leakage was
coming from coal fractures  several feet from the  seal.

       An attempt was made to further reduce the leakage by injecting a
gelling agent into  the mine behind the seal.  The gelling material would flow
into leakage points from inside the mine.  The gelling material consisted of
bentonite,  shredded cane fiber (Fibertex) and fresh  water. At the start of
this remedial work the flow  rate from the mine was 0.40 gallons per minute.
A total of 41, 200 gallons of gelled fluid was pumped into the mine over a four
day period utilizing 30, 000 pounds of Wyoming bentonite and 295 pounds of
Fibertex.  Figure  10 is a schematic drawing of the mine to show the condition
following remedial work.

       The flow rate at completion was 0.55 gallons per minute, an increase
of 0. 15 gallons over the initial rate.  The leakage has continued to  average
0. 5 gallons per minute since treatment, therefore,  the treatment did not
accomplish desired results.

       Construction costs were not available for the grout retainer seal and
Halliburton PWG grout fluid treatment 14).  The following construction costs
were incurred for  remedial  work using the  gelling material for treatment:

                          Item                    Cost

                Access Rights                 $  300. 00
                Materials and Equipment         2,771.00
                Site Restoration                    279.00

                                   Total       $3,350.00
                                  -86-

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       Grouted Limestone Aggregate Seal
       Mine No. 40-016. 2 Openings	

       This  small abandoned mine south of Clarksburg,  West Virginia had a
moderately acid discharge and the flow from the mine ranged from 7 to 150
gallons per minute.   Two drifts were sealed by pneumatically placing lime-
stone aggregate in the openings and then grouting the aggregate with a cement
grout. A cross-section of the installation  showing construction details is pre-
sented in Figure 11.  Sealing reduced the flow by 85 percent,  but leakage
occurred through  and around the seal.

       Remedial grouting was performed using other grout slurries in an
attempt to reduce the flow further.  Essentially there was little reduction in
flow as a result of the remedial work. The grout slurries used in  the remedial
grouting  were:

1.  A grout  slurry consisting of preblended 50% Portland cement and 50% fly
    ash  by volume,  with 18% salt and 0.4% Halad-9.  Halad-9  is a Halliburton
    additive to prevent water being lost into permeable formations due to ap-
    plied pressure.  This  grout slurry was chosen because of  low  water  loss
    and  good expansive  characteristics.  The grout  slurry was mixed at  a
    weight of 14.5 pounds  per gallon using impounded mine water.

2.  Halliburton's  DOC slurry which consists of cement particles surrounded
    by a hydrocarbon base fluid incorporating a surface-active agent, or ker-
    osene,  cement and a dispersant type surfactant.  These materials are
    mixed to form a slurry  that remains inactive unless contacted by water.
    The  slurry will absorb water like a sponge to  cause  a hard dense set.

3.  The  cement-fly ash mixture used in No. 1 with the addition of  Flocele,  a
    shredded cellophane, as a plugging material.

       The cost figures for  construction of the two limestone aggregate seals
and later remedial grouting  are presented in Table 7.  The total cost was
estimated to be $17, 696. 00 for two seals or $8, 848. 00 per seal.

Reinforced Concrete Hydraulic Seal

       Figures  12 and 13 show a proposed  design for a reinforced  concrete
hydraulic seal.  The seal was designed by the Ebensburg Office of  the Penn-
sylvania  Department of Environmental Resources'*") and is to  be constructed
at the Essen No. 2 Mine, Chartiers Creek  Watershed, Allegheny County,
Pennsylvania, as  part of Operation Scarlift Project SL 102-6.  Construction
of this type of seal requires  excavation of a hitch within the mine heading to
firmly anchor the  seal.  In addition to the hitch,  mine timbering and the con-
struction of form walls are necessary.  Pressure curtain grouting  will be
extended a minimum of 50  feet on both sides  of the mine  entry.  The grout
curtain holes drilled from the surface will  be on ten (10) foot centers on
alignment with the seal.
                                  -89-

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                               TABLE 7

                              COST.DATA

                  Grouted Limestone Aggregate Seals
                    Mine No.  40-016,  Two Openings
                    Harrison County,  West Virginia
Cleaning
Aggregate
Placement
Aggregate
Grouting
Additional
Remedial Grouting
Work
Equip. Rental
Labor @ $5.00/Hr.       24 Hours
    Total

Equip. Rental           	
Material @ $3. 30/Ton   300 Tons
Labor @ $5.00/Hr.      128 Hours
    Total

Equip. Rental           	
Material                	
Labor @ $5. 00/Hr.      144 Hours
    Total

Equip. , Materials
and Labor               	
Site Preparation and
Restoration             	
    Total
Total Cost for 2 Openings

Cost per Opening
 $   267.00
     120.00
 $   387.00

 $ 3, 060.00
     990.00
     640.00
 $ 4,690. 00

 $ 1,322.00
   3,260. 00
     720. 00
 $ 5,302.00
*$ 6,007. 00

   1,310.00
 $ 7,317.00

 $17,696.00

 $ 8,848.00
*Drilling and preparation of grout holes accounted for $1, 468. 00 of this
 cost.

Source: Halliburton Co.(7) and Wenzel(15)
                                 -91-

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       The project has not gone out for bids as yet and engineers estimates
were not available.  However, the total cost, including construction of a
minimum of 100 feet of grout curtain,  should be between $15, 000 to $20, 000.

Summary of Costs for Sealing Accessible Mine Openings

       The following list summarizes  available recent information on actual
and anticipated costs for sealing accessible mine openings including remedial
grouting costs.

   Type of Hydraulic Seal              Location            Total Cost

Quick Setting Doable              Harrison County,        $ 9,449.00
Bulkhead Seal - Mine 62-008      West Virginia

Quick Setting Double              Harrison County,        $ 9,463.00
Bulkhead Seal - Mine RT5-2       West Virginia

Quick Setting Single               Harrison County,        $ 3,564.00
Bulkhead Seal - Mine 62-008      West Virginia

Expendible  Grout Retainer         Harrison County,        $18, 000. 00
Seal -  Mine  14-042A              West Virginia            (Estimated)

Grouted Aggregate Seals          Harrison County,        $ 8, 848. OO/
(Two Seals)  Mine 40-016          West Virginia            seal

Reinforced  Concrete Seal         Allegheny County,        $15, 000. 00 to
Essen No. 2 Mine                 Pennsylvania            $20,000.00

       The cost of sealing  accessible mine openings varies greatly and de-
pends on site conditions and type of seal proposed.  The work performed by
Halliburton Company was experimental and in most  cases was not effective
in completely sealing a mine. It appears successful mine sealing requires
curtain grouting because the  rock above and to either side of the mine open-
ing is usually fractured allowing flow from the sealed  mine.

       Using one of the Halliburton methods  of seal construction, drift mines
probably can be sealed at an average cost of $10,000 including remedial
grouting,  if a small flow from the mine can be tolerated.  How long these
seals will be effective is not known and it is possible substantial flows  may
occur from openings in a few years.

       A  more permanent, water tight seal such as the one proposed by the
Pennsylvania Department of Environmental Resources  for Essen Mine  No. 2
could cost as much as the average grouted double  bulkhead seal installed at
inaccessible mine entries in Moraine State Park and Slippery Rock Creek.
                                  -94-

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Estimated Cost for Grouted Doable Bulkhead Seal

       The following is a tabulation of average unit and quantity costs for con-
struction of grouted double bulkhead  seals at abandoned mines based on costs
for the 93  seals installed at Moraine State Park and Slippery Rock Creek.

                                              Unit
              Item                  Unit      Price    Quantity      Cost

1.  Mine Sealing                  Seal     $8,000.00        1   $  8,000.00
2.  Observation Drill Holes
    a) Drilling 6" Holes            L. F.         4.00       80        320.00
    b) Casing  Left in Place        L. F.         3.20       40        128.00
3.  Curtain Grouting
    a) Drilling 3" Min. Holes       L. F.         2.50    1,700      4,250.00
    b) Cement for Grouting        Sacks         5.70      900      5,130.00
    c) Fly  ash for Grouting        Tons        15.00       75      1,500.00
    d) Sand for Grouting            Tons        20.00        1         20.00
    e) Admixture for Grouting      Sacks         4.00        3         12.00
    f) Pressure Testing            Hours        20.00        8        160.00
4.  Mobilization & Demobilization  L.S.      1,000.00        1      1, OOP. 00

    Total Cost per Seal                                          $20,520.00

       Based on this tabulation, an estimated cost of $21, 000 per seal should
be used when  applied to the Monongahela River Basin to allow for  increased
construction costs.

Factors Affecting Cost of Hydraulic Mine Seals

       Important factors that can affect the  cost of hydraulic mine sealing
projects  are:

1.  Condition of portal

2.  Degree of fracturing in rock adjacent to portal

3.  Thickness of overburden above mine roof

4.  Width of barrier between outcrop and  mine workings

5.  General character of rock along  outcrop

6.  The  maximum hydraulic head that  can develop after mine sealing

7.  The  availability of accurate mine maps

8.  Accessibility of project area and  haul distances
                                  -95-

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 9.  Site preparation

10.  Type of seal to be constructed

11.  Availability and costs of materials,  equipment and labor

 LIMESTONE BARRIER MINE SEALING (PERMEABLE PLUG)

        The principle involved  in design of a permeable plug of graded lime-
 stone aggregate is  in-place treatment of acid mine drainage as it passes
 through the plug.  The aggregate must be so graded that acid mine water flow-
 ing through the plug has  sufficient retention time to be partially or completely
 neutralized.  As  acid water  reacts with the limestone,  iron hydroxide and
 possibly calcium sulfate are precipitated and eventually the aggregate void
 spaces are filled.  The final result  is a solid plug which seals ths mine.

        It is difficult to classify a permeable plug seal because of its assumed
 changing characteristics.  If the plug performs  according  to design assumptions,
 there is  an initial reduction  in volume  of discharge and an improvement in
 quality of the mine water which is discharged.   At  this stage  it cannot be com-
 pared with an air seal because air can enter the mine through aggregate void
 spaces,  and in addition,  mine  water is being treated.  As  precipitates  form,
 there should be further reductions  in mine water discharges.  Theoretically,
 the end  result is  a  hydraulic seal.

        Research and development for design of  a permeable plug was performed
 by the Halliburton Company^ ' under contract to the Environmental  Protection
 Agency.   Extensive laboratory tests and research followed by field  tests indi-
 cated this type of seal showed  promise.  Two drift mines in Harrison County,
 West  Virginia were sealed with permeable plugs as part of this study.

        Mine  No.  62-008, Opening No.  3

        This mine near Clarksburg, West Virginia  had a flow of about 3 gallons
 per minute, a pH of 3 and on acidity of 300 mg/1.   Placement of AASHO No. 8
 aggregate was performed pneumatically.  The completed seal filled the mine
 entry for a length of 36 feet at  the base and 25 feet  at roof  contact.  The drift
 measured 52 inches by 1Z feet.  A total of 67 tons of limestone aggregate  was
 emplaced. The construction cost was  $3, 048.00 as follows:

                           Item                     Cost
                 Site Preparation                $   756.00
                 Materials                          237.00
                 Equipment and Operators         2, 055. 00

                                    Total        $3,048.00
                                   -96-

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       Monitoring of the water flowing through the limestone plug showed a.
reduction in acidity  to 112 mg/1 and an increase in pH (6.3 to 6.9), but there
was no reduction in  flow from the mine.

       Mine No. RT5-2, Opening No. 2

       The second permeable plug was constructed at Opening No. 2 of Mine
RT5-2.  This opening was discovered after Opening No.  1 had  been success-
fully sealed with a quick setting double bulkhead seal.  The opening was filled
with AASHO No.  8 crushed limestone  blended with approximately 15% agricul-
tural lime. The aggregate was pneumatically placed against a roof fall and
165  tons of material was emplaced.  The pneumatic placement was hampered
by the  extreme amount of dust created when the limestone was blown into the
mine drift. In order to  combat this problem,  the ratio of lime dust was later
reduced  to 10% and a pump was used to spray a jet of water.   This helped to
some degree, but the dust problem was  still bad.

       The upper portion of the limestone plug was grouted using approximately
100  cubic feet of Halliburton LIGHT Cement slurry.  This was done  to insure
a seal  along the roof section.  Figure 14 presents a section view of the seal
and  Figure 7 is  a  plan view showing the  relationship of Openings No.  1 and No.
2.  A retaining wall was built in front of the opening with a 90 degree weir to
measure flow rate.  The graded aggregate seal was constructed at a  cost of
$8,463.00.

                          Item                    Cost

                Site Preparation                $3,447.00
                Materials                       1,696.00
                Equipment and Operators        3, 320. 00

                                   Total       $8,463.00

       The cost was higher than the previous seal of this type  because of ex-
cessive excavation required to prepare the opening, the extra materials re-
quired for  grouting the upper section and a corresponding increase in the
necessary  equipment.

       Monitoring of the completed installation showed the initial flow of  25
gallons per minute with  a head of  3. 3  feet of impounded water diminshed to
a flow of 3.6 gallons per minute with a head of 5.44 feet  in about 24 days.
Analyses made of the mine water  discharge before and after installation of
the  seal indicate a. marked improvement in water quality.
                                 -97-

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                      Before Sealing          After Sealing

          pH       2.9 to 3.2               5.6 to 6. 3
          Acidity   512 to 765 mg/1            0 to 102 mg/1
          Iron      104 to 282 mg/1           36 to  57 mg/1
          Sulfate   868 to 1, 152 mg/1        780 to 940 mg/1

       It is difficult to estimate an average unit cost for this  type of seal be-
cause only two have been constructed as part  of a demonstration project.  A
unit cost per mine seal of $7, 500. 00 is  recommended for estimating purposes
in the Monongahela River Basin.

DRY MINE SEALS

       An effective mine sealing program requires the sealing of all openings
and surface areas which permit passage of air and water into the mine.  If a
mine has an  acid discharge at one or more openings, dry seals are used in
conjunction with air,  hydraulic or permeable  plug seals to seal the  openings
which do not have a discharge.   In the case of a hydraulic seal, the hydro-
static head that is developed should not  cause  significant hydrostatic pressure
in the area of a dry seal.

       Dry sealing can be defined as the complete closure of mine drifts,
slopes,   shafts,  subsidence areas, fractures and other openings with imper-
meable  material or structures  at locations where there will be very little or
no hydrostatic pressure.  Dry  mine seals  can be  of concrete  block  or  mas-
onry construction or openings  can be filled with clay,  concrete or other suit-
able materials.  This  type of sealing is generally confined to  openings  on the
"high" side of the mine where  the body of the  mine workings lie to the  dip.

       The cost of a dry seal can vary greatly and the cost will depend on the
opening to be sealed, its extent, condition and accessibility and the material
used in  construction.  Drifts,  shafts, subsidence  areas and surface areas with
fractures that allow passage of air and percolation of water into the mine may
only require  a  fill or a covering of impervious material.  Although  the cost of
this work could be measured on a cubic yard basis,  the work  is usually per-
formed  for a lump sum fee for  the job,  i.e. ,  so many areas to be sealed.  An
example would be the dry mine sealing performed at Moraine State  Park in
conjunction with the hydraulic  sealing program.  This work involved the  seal-
ing of a total of 23 air shafts, drifts and other openings scattered throughout
the area using  available clay and other suitable materials.  The lump sum fee
was $28, 000  or an average cost per seal of $1, 217.  This cost also included
soil treatment  and seeding of sealed areas.
              reports that 450 subsidence holes were filled and 101 seals con-
structed as  part of the Elkins Demonstration Project in West Virginia.  A
total of 41 openings were sealed with clay, but cost data was  recorded for only
                                 -99-

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two areas containing a total of 16 openings.  The costs are based on the rental
of equipment.  The cost data for the  16 compacted clay seals as presented in
Scott,  et al.(17) is:

                Cu. Yds.                       Average
Work  No.  of   Compacted    Total   Cost per Cu.  Yd./    Cost/
Area   Seals    Backfill     Cost       Seal	Seal     Cu. Yd.

 1-9      10       10,490    $  9,500    $  950    1,049      $0.91

  10      _6_      11,670    $14, 160    $2,360    1,945      $1.21

          16       22,160    $23,660    $1,479    1,381      $1.07

       The  cost per cubic yard of material for Work Area 10 was higher be-
cause the haulage distance from the borrow  area was greater.

       The  cost of a masonry dry mine seal will depend on several factors,
such as:  1) accessibility of the mine, 2)  condition of the mine opening,  3)
method of construction,  4) the  volume of  materials  required  including nec-
essary timber, and  5) other items pertinent to seal construction.  Recent costs
are available for two projects where masonry dry seals were installed.

       As part of the Elkins Demonstration  Project'   ', a total of 43 masonry
dry seals were constructed.  Seal construction consisted of a single solid wall
of two courses  of fly ash blocks and the seals  were  coated  on both sides with
urethane foam.  Mine  openings were timbered to keep the weight of the roof
off the seals. The average cost per  seal was  $2,210 and costs per individual
seal ranged from $1, 358 to $6, 376.

       Seven masonry dry seals were installed at a mine site northeast of Pitts-
burgh in 1966 under  the  direction of the U.S. Bureau of Mines(°). The seals
were  erected on concrete footers and hitched  12" into ribs and  roof.  The seals
were  of double-wall, cored concrete block construction with 25  percent of the
cement replaced by  fly ash.  A 2" space between the courses was filled with
urethane foam.  Urethane foam was also used to coat the inby and outby faces
of the seals and to fill the hitch spaces.   The average cost per  seal was $5, 089.

AIR MINE SEALS
       Air mine sealing remains a controversial water pollution abatement
measure.  At some abandoned mine sites,  air sealing has  resulted in a signifi-
cant reduction in acidity of the discharge, but at other mine sites there has been
very little or  no reduction in acidity in spite of an extensive air sealing program.
It appears that the  thickness and competence of the overburden above the mine
are important factors in the success or failure of  an air sealing project.  As
pointed out by Hill(^), air  sealing was not successful at Elkins because a reduc-
tion in acidity cannot be expected in sealing a large complex mine with a  ten-
dency for subsidence.  Moebs and Krickovic^  ',  on the other hand, were
                                  -100-

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successful in reducing the acidity of a discharge from a mine that had a com-
petent rock overburden and only one subsidence depression, whereas at Elkins,
450 subsidence holes had to  be filled.

       Conventional air sealing  entails the closing of all openings to the mine
with impermeable material or structures, except that an air trap is placed in
one or more of the lower seals.  Air sealing requires a comprehensive pro-
gram of  engineering which may be difficult and expensive under adverse con-
ditions,  with no guarantee of total success^°).  It is the  opinion of Moebs and
Krickovio") that abandoned  mines above drainage which are discharging acid
water should be evaluated as individual projects  and if the geological conditions
are favorable, they should be air sealed and have water diverted  from them to
the fullest extent practicable.

       The method  of construction of air seals at Elkins, West Virginia was
essentially the same as for masonry dry seals,  except  that air seals  had two
or three  walls.  One of the walls was solid, except for  two  blocks being re-
moved from the base.  The outer wall was constructed  to a higher elevation
than the  opening in the inner  wall in  order to form a water trap that would  pre-
vent air  from entering the mine.  A  total of 1Z air seals were  installed and the
average  cost was $4,076  per seal.  Costs per individual seal ranged from
$3,128 to $5,032.

       The U.S. Bureau  of Mines project' ' sealed a small, abandoned,  highly
acid drainage drift about  40  miles northeast of Pittsburgh.   The mine is repre-
sentative of those which are  responsible for about 35 percent of the stream
pollution in the coal regions  of Appalachia.  The following topographic and
geologic  conditions  made the mine favorable for  air sealing:

1.  The  mine was overlain by competent siltstone and sandstone.

2.  The  overburden was  100 to 200 feet thick over more than 50 percent of the
    area above the  mine.

3.  Mine roof conditions  were very good.

4.  Most of the pyritic sulfur from which acid is formed occurs  in the bottom
    portion of the coal bed and in the top layer of the underclay.

       In addition to the installation of the seven masonry dry seals at this mine,
one masonry air  seal  of similar  construction was installed  along  with the two
barriers  to form the air traps.   The entry width was  22 feet and the height was
5 feet.  Figure 15 shows  the  general arrangement of an  air seal.   The cost of
the air seal was $14, 800.
                                  -101-

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       The total cost for sealing and related work and reclamation was $57,420
on this project and is itemized as follows:

       Seals and related work:
            Timber, treated (24, 390 bd ft)                     $ 5, 146
            Urethane foam, 2, 000-lb (755 sq ft)                  3,510
            Masonry blocks (2, 002)                                524
            Pipe (167 ft)                                           528
            Concrete (28 cu yd)                                    504
            Miscellaneous                                         288
                Total material                                 $10,500
            Equipment,  including operator                       8, 960
            Labor (5,000 man-hours)                            30,OOP
                Total                                         $49,460
       Sealing 2 strip pits (3 acres),  1  surface subsidence
         depression, and 1 caved entry                         $ 7, 000
       Grading access  roads and portal areas                      960
                Total                                         $57,420

       Of the $49,460 for seals, 61 percent was spent for labor,  21 percent
for materials, and 18 percent for equipment.  Equipment costs were chiefly
related to excavation and cleanup of the entries in which seals were constructed
and to grading for drainage and stability around the portals.   The significant
quantities and costs of materials used were as  follows:

                 Material               Unit    Quantity    Cost

       Urethane foam per seal        Ib.            222     $390
       Timbering per sealed entry   bd. ft.      3, 060      340
       Masonry blocks per seal      each         222       58
       Concrete footers per seal     cu. yd.       2.8       54

       As  a result of the mine sealing the acid load was reduced an average of
12 tons per year.  The  mean total  acidity  for a 2 year,  7 month period before
sealing was 514 rag/1 and for a  2 year,  8 month period after sealing it was 211
mg/1,  an improvement in quality of 303 mg/1.  The average  monthly maximum
total acidity after-sealing was 247 mg/1, which is  well below the minimum of
331 mg/1 before sealing. Figure 16 shows the  average monthly total acidity
and flow  rate  of the  mine effluent before and after  sealing.

       A somewhat lower volume of effluent after  mine sealing indicates the
quantity  of water directly entering the mine from the  surface through entries
was less.
                                  -103-

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       -104-

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       There is no doubt air sealing was effective in reducing acidity and
effluent volume, but it is interesting to conjecture what degree of abatement
would have occurred,  if  after dry sealing the mine,  a permeable plug of
limestone aggregate was installed instead of an air seal.  A demonstration
project utilizing the permeable plug principle at a small abandoned mine  with
similar topography and geology may be rewarding.

SUMMARY OF COSTS FOR DRY AND AIR SEALS

       The following tabulation summarizes available recent  cost data for
dry and air mine sealing:

                                   No.  of    Aver. Cost        Range
    Type of Seal         Project      Seals     per Seal         in Cost

Dry Seal (Clay)      Moraine S. P.   23      $ 1,217
                     Elkins          16        1,479

Dry Seal (Masonry)   Elkins          43      $ 2,210      $1, 358-$6, 376
                     Bur.  Mines     17        5, 089

Air Seal  (Masonry)   Elkins          12      $4,076      $3, 128-$5, 032
                     Bur.  Mines       1      * 14, 800

       *The  entry was 22 feet wide.

       For general estimating purposes in the Monongahela River Basin  it is
suggested that  the following average costs per  seal be used:

                    Dry Seal (Clay)           $1,500
                    Dry Seal (Masonry)       $3,500
                    Air Seal  (Masonry)        $5,000
                                 -105-

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                             REFERENCES

 1.   Foreman,  John W., 1971, Deep Mine Sealing:  Acid Mine Drainage Work-
     shop, Athens,  Ohio by Ohio Univ., 27 p. (BCR 71-47)

 2.   Maize,  Richard,  1952,  History and Progress  Made in Mine Sealing to
     Reduce  the Flow  of Acid Mine Water into the Streams of this Common-
     wealth:  Presented at Coal Mining Institute, Pittsburgh,  December, 1952,
     11 p. 12 figs. (BCR 52-31)

 3.   U.S. Public Health Service,  1942, Ohio River Pollution Survey,  Final
     Report  to the Ohio River Committee, Supplement "C", Acid Mine Drainage
     Studies: Office of Stream Sanitation,  68 p. (BCR 40-11)

 4.   Hill, Ronald D. ,  1970,  Elkins Mine Drainage  Pollution Control Demon-
     stration Project:  Third Symp.  Coal Mine Drainage Res. Preprints,
     Pittsburgh, p.  284-303 (BCR  70-24)

 5.   Braley, S. A., 1962, Special Report on an Evaluation of Mj.ne Sealing:
     Coal Industry Advisory Committee to the Ohio River Valley Sanitation
     Commission, Mellon Institute,  Res.  Proj. No. 370-8, 33 p.,  32 tables
     and figs. (BCR 62-10)

 6.   Ohio River Valley Water Sanitation Commission,  1964, Principles and
     Guide to Practices in the  Control of Acid Mine-Drainage: Coal Industry
     Advisory Committee, 30 p. (BCR 64-28)

 7.   Halliburton Company,  1970,  New Mine Sealing Techniques for Water
     Pollution Abatement: Federal Water Quality Adm. ,  Res. Ser. 14010
     DMO 03/70,  163  p. (BCR 70-82)

 8.   Moebs,  N. N.  and Krickovic, S. , 1970, Air-Sealing Coal Mines  to Reduce
     Water Pollution:  U.S.  Bur.  Mines Rept.  Inv. 7354, 33 p.  (BCR  70-1)

 9.   Gwin Engineers,  Inc.,  1968,  Moraine State Park Watershed Area, Butler
     County:  Rept.  to Pa. Dept. Mines Mineral Ind. ,  Mine Drainage  Project
     MD-8A, 109 p. (BCR 68-92)

10.   Foreman,  John W. , 1970, Evaluation of Pollution Abatement Procedures
     in Moraine State  Park:  Third Symp. Coal Mine Drainage Res. Preprints,
     Pittsburgh, p.  304-33 (BCR 70-25)

11.   Foreman,  John W. , 1972, Evaluation of Mine Sealing in Butler County,
     Pennsylvania:  Fourth Symp.  Coal Mine Drainage Res.  Preprints, Pitts-
     burgh,  p. 83-95  (BCR 72-  )

12.   Reinhold, R. H. , 1969, Mine Water Barrier:  U.S.  Pat. 3,469,405
     (Sept.  30,  1969)  to Layne-New  York Co.,  Inc.  4 p. (BCR 69-58)
                                 -106-

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13.  Pennsylvania Department of Environmental Resources, 1972, Bid Form
     and Special Requirements,  Pressure Curtain Grouting and Reclamation,
     Thomas Mills, Conemaugh Township, Somerset County, Pennsylvania:
     Issued July 11,  1972,  Contract No.  SL 151-1A

14.  Baker, A. A., 1967, Feasibility Study on the  Application of Various
     Grouting Agents, Techniques and  Methods to the Abatement of Mine
     Drainage  Pollution,  Part II - Selection and Recommendation of Twenty
     Mine Sites:  Halliburton Co., Rept. to Federal Water Quality Adm. ,
     Monongahela River Mine Drainage Remedial Project, 286 p. (BCR 67-193)

15.  Wenzel,  R. W. ,  1968,  Feasibility Study on the Application of Various
     Grouting Agents, Techniques and  Methods to the Abatement of Mine
     Drainage  Pollution,  Part IV - Additional Laboratory and Field Tests for
     Evaluating and Improving Methods for Abating Mine Drainage Pollution:
     Halliburton Co. , Rept. to Federal Water Pollution Control Adm. ,  Monon-
     gahela River Mine Drainage Remedial Project, 236 p.  (BCR  68-156)

16.  Molinski, A. E. ,  1972,  Personal Communication: Source -  Drawing No.
     102,  approved  April 21, 1971 by Mr.  Molinski, Chief Engineer,  Ebensburg
     Office, Pennsylvania Department  of Environmental Resources

17.  Scott, R.  B., Hill, R.  D.  and Wilmoth, R. C., 1970,  Cost of Reclamation
     and Mine  Drainage Abatement - Elkins Demonstration  Project:  U. S.
     Environmental Protection Agency, Water Quality Office, Res. Ser.
     14010 ---  10/70, 27 p. , revision  of Paper 70-AG-349,  Soc.  Mining Eng.
     Meeting,  St. Louis,  October 21-23,  1970.  (BCR  70-70)
                                 -107-

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                         STREAM DIVERSION





                        TABLE OF CONTENTS





                                                                Page No.





Introduction                                                        HI





Cost of Stream Diversion                                           HI




References                                                         113





                           LIST OF TABLES





1. Stream Diversion Costs for Operation Scarlift Projects           H2
                                 -109-

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                          STREAM DIVERSION

Introduction

       Water diversion is frequently utilized in active surface and deep mine
operations to ease  the physical and financial burden of pumping large quantities
of water.   In surface mining operations the most commonly used  method is to
construct a ditch on the uphill (highwall) side of the open cut.  Other methods
used in surface mining are 1) diversion of streams into  new channels to pre-
vent seepage into or flooding  of the work area, and 2) construction of trenches
or installation of pipes at the downhill side of the open cut to  remove water as
quickly as  possible.  Preventing the infiltration of  surface  waters into deep
mine workings is much more complicated, but can be accomplished to a cer-
tain extent by diversion of stream channels or the lining of stream channels
with impervious materials where they cross over deep mine workings.

       When water comes in  contact with oxidized  sulfuritic materials, acid
mine waters  are produced. A considerable quantity of acid mine drainage can
be prevented by diverting stream waters from sources of acid pollution.  This
is particularly true when the  water course upstream of the pollution source is
relatively unpolluted.

       If the stream flow cannot be diverted into a new channel because of
topographic limitations, it is usually feasible to reconstruct the channel so
that the flow  will be more  efficient, thereby reducing contact time with the
acid material.  The channel can be lined with impervious material and in
cases where  there  is seepage or flow into  a deep mine it can  be prevented by
sealing the mine opening with clay or other suitable materials.

Cost of Stream Diversion
       This section of the report is  concerned with the cost of preventing acid
mine drainage pollution  by diverting stream flow away from surface and deep
mines  which are pollution sources.  Only three stream diversion projects were
found among the many projects performed by the Commonwealth of Pennsylvania
under  the Operation Scarlift Project program.   The projects were in different
areas  of Pennsylvania, have significant lengths of channel construction and  the
volumes of excavation appear to be representative  of what can be expected in
this  type of project.  The  cost per lineal foot of channel ranged from $12.00 to
a high of $27.00 including all supplemental costs.  Table 1 presents the per-
tinent  data on these projects.

       The  cost experience in mine  related stream diversion projects is limited,
but there  is, however, a large  amount of applicable experience available in con-
struction of channel changes for streams  in connection with highway projects.
This cost information is difficult to isolate because equipment needs are not
separated in the mass contracts.  It is estimated,  however, that the costs
should approximate the following:
                                 -111-

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       Soil and shale excavation     - $0.80/C.Y.
       Premium for rock excavation - $0. 50/C. Y.
       Equipment costs             -$0. 35/C.Y.

       In addition to these costs,  the channel slopes whould be seeded with a
grass-legume mixture  at an estimated cost of $450 per acre of slope area.

       For the Monongahela River Basin a cost estimate of $20.00/L.F. will
allow for increased construction costs, channel slope grading, soil treatment
and seeding.

                              TABLE 1

  STREAM DIVERSION COSTS FOR OPERATION SCARLIFT PROJECTS

Project No.            SL 102-1-1           SL 135-1         SL 143-1

Location           Chartiers Creek     Catawissa Creek  Alder Run
                   Allegheny County    Luzerne County   Clearfield County

Length (L.F. )         4,200                1,720            4,000

Avg. Depth (Ft.)           5                   10                 5

Excavation
Quantity (C.Y.)       11,000               17,300            107,000

Unit Price (C.Y.)      $1.50                $2.60            $0.61

Total Cost             $65,100              $30,500          $108,000

Cost per L.F.         $15.50               $12.00            $27.00
                                -112-

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                            REFERENCES

1.  Pennsylvania Department of Environmental Resources,  1972,  Infor-
    mation in Files of Office of Engineering and Construction:  Harrisburg.

2.  Michael Baker, Jr., Inc., 1972, Recent Cost Estimates for Highway
    Channel Changes:  Highway Division,  Beaver, Pennsylvania.
                                -113-

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                  TREATMENT OF MINE DRAINAGE

                         TABLE OF CONTENTS

                                                                Page No.

Chemistry and Classification of Mine Drainage                      125

Neutralization                                           .
       Principle of Neutralization                                  128
       Neutralizing Agents                                         128
       Chemistry of Lime Neutralization                           131
       Chemistry of Limestone Neutralization                      131
       Neutralization of Mine Drainage with
            High Ferrous Iron Content                              136
       BCR Limestone Treatment Process                          137
       U.S. Bureau of Mines Limestone Treatment Process         157
       Combination Lime stone -Lime Treatment Process            177
       Combination Lime -Limestone Neutralization with
            Rotary Precoat Filtration for Sludge Dewatering         181
       Electrochemical Oxidation Followed by Limestone
            Neutralization                                          189
       Biochemical Oxidation Followed by Limestone
            Neutralization                                          198
       Ozone Oxidation Followed by Limestone Neutralization       206
       Neutralization of Mine Drainage with High Ferric
            Iron Content                                            222
       Mine Drainage Treatment Using Hydrated Lime              224

Flash Distillation Process                                          256

Ion Exchange Processes                                            261

Reverse Osmosis Process                                          269

Submerged Coal Refuse Combustion Process                        295

Freezing (Crystallization) Process                                  303

Electrodialysis  Process                                            307

Foam Separation (Fractionation) Process                            309

Neutradesulfating Process                                          310

References                                                         312
                                 -115-

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                            LIST OF TABLES

                                                                 Page No.

 1.   Classification of Mine Drainage                                 127

 2.   List of Neutralizing Agents Suggested for Acid Mine
     Drainage Treatment                                            129

 3.   Basis of Estimated Costs of Limestone Treatment,  Various
     Size Treatment Plants - BCR Process                          144

 4.   Estimate of Capital Cost for Limestone Treatment Plant,
     South Greensburg Coal Mine Drainage - BCR Process            145

 5.   Auxiliary Equipment Costs -  U.S.  Bureau of Mine Lime-
     stone Treatment Process                                       162

     Limestone Treatment Cost Estimates - U.S. Bureau of
     Mines Process

     6.   100, 000 GPD Plant Capacity                                163

     7.   300,000 GPD Plant Capacity                                164

     8.   500, 000 GPD Plant Capacity                                165

     9.   1, 500, 000 GPD Plant  Capacity                             166

    10.   2 Million GPD Plant Capacity                               167

    11.   6 Million GPD Plant Capacity                               168

12.   Lime stone-Lime vs. Lime at 5 GPM
     EPA - Norton, West Virginia                                  179

13.   Estimated Capital Costs for Various Size Plants Using
     Increased Efficiency Limes tone-Lime Process
     Johns-Manville Products Corporation                           184

14.   Estimated Operating Costs for Various Size Plants  Using
     Increased Efficiency Lime stone-Lime Process
     Johns-Manville Products Corporation.                           185

15.   Plant Investments, Electrochemical Oxidation Method
     Tyco Laboratories, Inc.                                        194
                                  -116-

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                                                                 Page No,

16.   Estimated Operating Expenses for Direct Electrochemical
      Oxidation Treatment Plants - Tyco Laboratories, Inc.           195

17.   Typical Operating Characteristics of Pilot Scale Biochemical
      Oxidation and Limestone Neutralization Process                201

      Ozone Oxidation Followed by Limestone Neutralization -
      Brookhaven National Laboratory

      18.  AMD Plant Cost                                           210

      19.  AMD Treatment Plant Operating Costs                     211

      20.  AMD Treatment Total Operating Costs                     212

      21.  Ozone Generated in 40 Ton/Day Plant,
          Shipped to AMD Site                                       213

      22.  Ozone Generated in 200 Ton/Day Plant,
          Shipped to AMD Site                                       214

      23.  Total Investment Costs for AMD Treatment Using
          On-Site Ozone with Recycled Oxygen Feed                  215

      24,  Comparison of AMD Total Treatment Costs                 216

      25,  Cost Breakdown for Total AMD  Treatment of
          Pennsylvania AMD Streams                                 221

26.   Cost of Brine Disposal in  Evaporation Ponds                    228

27.   Estimated  Costs of Deep Well Disposal                          228

28.   Acid Mine  Drainage Treatment Plant Capital Expenditures -
      Operation Yellowboy Projects                                   230

29.   Annual Operating Costs  -  Operation  Yellowboy Projects          231

30.   Total Annual Unit Costs -  Operation Yellowboy Projects         232

31.   Estimated  Costs of Neutralizing Highly Acid Mine Water
      Using Hydrated Lime                                          233

32.   Estimated  Costs of Neutralizing Moderately Acid Mine
      Water Using Hydrated Lime                                    233
                                  -117-

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                                                                 Page No.

33.  Estimated Costs of Neutralizing Weak Acid Mine
     Water Using Hydrated Lime                                    235

34.  Treatment Plant Operating Data, Slippery  Rock Creek
     North Branch - 1971                                            242

35.  Little Scrubgrass Creek Lime Treatment Plant
     Monthly Operating Expenses                                    250

     Multiple Stage Flash Distillation Acid Mine Drainage
     Treatment Plant - Westinghouse Electric Corporation

     36.  Cost Estimate                                             258

     37.  Summary of Operating Costs                               259

     38.  Interim Operating Costs                                    260

39.  Summary of Operating Data and  Design Water Quality -
     Ion Exchange Treatment Plant, Philipsburg,  Pa.                266

40.  Reverse Osmosis Capital Costs  - Summary of  Reference
     Conditions Used as a Basis for Tables 41,  42,  43, 45, 46,
     47,  48, 49,  50, 51                                             274

     Estimated Capital Costs for Reverse Osmosis  Process

     41.  for Cases Cited  in Table 40                                275

     42.  with  Lime Neutralization for Brine Disposal                276

     43.  with  Deep Well Brine Disposal                             277

44.  Estimated Capital Costs vs.  Capacity for Reverse
     Osmosis  Process with Deep Well Brine Disposal                278

45.  Estimated Operating  Costs for Reverse Osmosis Process
     for Cases Cited in Tables 40  and 41                             279

     Estimated Operating  Costs for Reverse Osmosis Process
     with Lime Neutralization for  Brine Disposal

     46.  in Dollars Per Thousand Gallons of AMD Treated
          Using Hydrated Lime                                      280
                                  -118-

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                                                                Page No.

    47.  in Dollars Per Thousand Gallons of Product Water
         Using Hydrated Lime                                      280

    48.  in Dollars Per Thousand Gallons of AMD Treated
         Using Limestone                                           281

    49.  in Dollars Per Thousand Gallons of Product Water
         Using Limestone                                           281

    Estimated Operating Costs for Reverse Osmosis Process
    with Deep Well Brine Disposal

    50.  in Dollars Per Thousand Gallons of AMD Treated           282

    51.  in Dollars Per Thousand Gallons of Product Water          282

52. Estimated Operating Costs vs.  Capacity for Reverse
    Osmosis  Process with Deep Well Brine Disposal                283

53. Typical Raw Water Quality Characteristics of
    Mocanaqua Discharge,  Pennsylvania                            289

54. Comparison of Water Production Capabilities -
    Reverse Osmosis Treatment, Mocanaqua, Pa.                  290

55. Relative Cost - Reverse Osmosis Treatment,
    Mocanaqua,  Pa.                                                290

56. Major Cost Items for 0.75 MGD Reverse Osmosis
    Treatment Plant - Rex Chainbelt, Inc.                          293

    Two-Stage Coal Refuse Combustion Process

    57.  Acid Mine Drainage Compositions Used in Study             299

    58.  Ultimate Analysis of Coal Refuse                           299

    59.  Capital Investment for Various Size Acid Mine
         Drainage Treatment Plants                                 300

    60.  Determination of Break-Even Price of Water  -
         5 MGD Acid  Mine Drainage Treatment Plant                301

61. Summary of Crystallization Costs Using Kittanning Run,
    Pennsylvania,  Water as Feed                                   306

62. Electrodialysis Treatment Plant Costs Using Kittanning
    Run, Pennsylvania,  Water as Feed                              308

                                -119-

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                           LIST OF FIGURES

                                                                 Page No.

 1.   Solubility of Aluminum, Iron and Manganese in Acid
     Mine Drainage at Various pH's                                 132

 2.   Solubility of Iron                                              133

 3.   Iron (II) Oxidation Rate at pH 2-1                               134

 4.   Flow Diagram of Conceptual Limestone Treatment Process      138

     Estimate  of Capital Costs vs. Plant Capacity - BCR
     Limestone Treatment with Sludge Dewatering

     5.  Total Capital Costs                                        146

     6.  Aeration  Tank and Aerators,  Reactor Tank and Mixers,
         and Holding Lagoon                                       147

     7.  Sludge Dewatering Basin, Settling Basin Sludge Pumps,
         Sludge Recirculating Pumps  and Waste Sludge Pumps       148

     8.  Settling Basin, Control Building, Sludge Pump Well,
         Chemical Feed Equipment and Control Equipment           149

     9.  Mechanical Piping and Electrical                           150

10.   Estimate  of Operating vs. Plant Capacity - BCR
     Limestone Treatment with Sludge Dewatering                   151

11.   Estimated Chemical Costs - BCR Limestone Treatment
     Process                                                       152

     Estimated Costs  (Cents/Thousand Gallons) - BCR  Limestone
     Treatment with Sludge Dewatering

     12. Total Costs                                               153

     13. Labor,  Power and Maintenance and Repairs                154

     14. Sludge Disposal and Capital Costs                          155

15.   Estimated Sludge Accumulation in One Year from BCR
     Limestone Treatment Process                                 156
                                 -120-

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                                                               Page No.

16. Flowsheet of Mine Water Treatment Process -
    U.S.  Bureau of Mines                                        157

    Estimated Capital Costs vs.  Plant Capacity for Limestone
    Treatment Plant  - U.S.  Bureau of Mines

    17. Iron as Fe++ = 50 PPM                                   169

    18. Iron as Fe++ = 100 PPM                                  170

    19. Iron as Fe++ = 500 PPM                                  171

    20. Iron as Fe++ = 1000 PPM                                 172

    Annual Operating Costs vs. Plant Capacity for
    Limestone Treatment - U.S. Bureau of Mines

    21. Iron as Fe++ = 50 PPM                                   173

    22. Iron as Fe++ = 100 PPM                                  174

    23. Iron as Fe++ = 500 PPM                                  175

    24. Iron as Fe++ = 1000 PPM                                 176

25. Lime/Limestone  Cost Ratio and Process Cost Reduction
    Norton Mine Drainage Field Site, West Virginia                180

26. Flowsheet - Lime stone-Lime Neutralization with Rotary
    Precoat Filtration of Sludge, Johns-Manville Products
    Corporation                                                  182

    Estimated Capital Costs for Various Size Plants Using
    Increased Efficiency Lime stone-Lime Process,  Rotary
    Precoat Filtration for Sludge Dewatering - Johns -
    Manville Products Corporation

    27. Total Capital Costs                                       186

    28. Individual Capital Components                             187

29. Estimated Operating Costs for  Various Size Plants Using
    Increased Efficiency Limes tone-Lime Process,  Rotary
    Precoat Filtration for Sludge Dewatering - Johns-Manville
    Products Corporation                                         188
                               -121-

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                                                                Page No.

30. Oxidation Unit for Treating 6, 000 gal. /hr. ,
    Electrochemical Oxidation Followed by Limestone
    Neutralization -  Tyco Laboratories, Inc.                       190

31. Estimated Capital Costs vs. Plant Capacity for
    Electrochemical Oxidation and Limestone Neutra-
    lization Treatment -  Tyco Laboratories,  Inc.                   196

32. Estimated Annual Operating Costs vs. Plant Capacity
    for Electrochemical Oxidation and Limestone Neutra-
    lization Treatment -  Tyco Laboratories,  Inc.                   197

33. Flow Diagram of Complete  Biochemical Oxidation
    and Limestone Neutralization Process                          199

34. Dimensioned Sketch of Experimental Pilot Scale
    Biochemical Oxidation and Limestone  Neutralization
    Plant for  Acid Mine Drainage Treatment                        200

35. Flowsheet - Biochemical Iron Oxidation Limestone
    Treatment Process,  Hollywood,  Pennsylvania                  205

36. AMD Oxidation and Neutralization Process System,
    Ozone Oxidation  Followed by Limestone Neutralization
    - Brookhaven National Laboratory                             207

37. Total AMD Treatment Costs Using Ozone Electric
    Discharge Ozonizers  - Brookhaven National Laboratory         217

38. Total AMD Treatment Cost Using Electric-Discharge
    Ozone - Brookhaven National Laboratory                       218

39. Total AMD Treatment Cost Using Chemonuclear Ozone -
    Brookhaven National  Laboratory                               219

40. Total Plant Investment Cost for AMD Treatment Using
    On-Site Electric Discharge Ozone - Brookhaven National
    Laboratory                                                   220

41. Flow Diagram, HDS Demonstration Plant at Mine 32 -
    Bethlehem Steel  Corporation                                  227

42. Capital Cost vs.  Plant Capacity - Hydrated Lime
    Treatment Plant with Sludge Disposal                          234
                                -122-

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                                                               Page No.

43.  Total Capital Cost Vs. Plant Capacity - Hydrated
     Lime Treatment Plant without Sludge Disposal                 235

44.  Total Operating Cost (Including Capital Costs ) -
     Hydrated Lime Treatment                                    236

45.  Duquesne Light Company Warwick Mine Portal No. 2
     Mine Water Treatment Plant Flow Sheet                       238

46.  Effect of the Closing of the Michigan Limestone Co.
     Plant at Boyers in December  1957 on Water Quality
     in Slippery Rock Creek                                       241

47.  Flow Diagram  - Slippery Rock Creek Mine Drainage
     Treatment Plant                                             244

48.  Mountaineer Coal Co. ,  Williams  Mine, Levi Moore
     Discharge - Flow Diagram                                    246

49.  Schematic Diagram - Little Scrubgrass Treatment Plant        249

50.  Flow Diagram of Rausch Creek Treatment Plant                252

51.  Flow Schematic - Altoona Mine Drainage Treatment Plant       254

52.  Mixmeter Model 65AE - Typical Installation  Arrangement       255

53.  Low Temperature MSF Evaporator Process for Treat-
     ment of AMD (Selective Recovery of Dissolved Minerals)        257

54. Schematic of Proposed Treatment Plant,
     Philipsburg,  Pennsylvania                                    265

55.  Flow Diagram - Flow Type Ion Exchange Units,
    Smith Township, Pennsylvania                                268

56. Operating Cost vs. Plant Capacity - Reverse Osmosis
     + Brine Disposal (Product Water)                              284

57. Operating Cost vs. Plant Capacity - Reverse Osmosis
    with and without Brine Disposal (AMD  Treated)                 285

58. Capital Cost of Reverse Osmosis  Plant with Brine
    Disposal vs.  Plant Capacity (Product Water)                    286
                               -123-

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                                                                Page No.

59, Capital Cost of Reverse Osmosis Plant with Brine
    Disposal vs. Plant Capacity (AMD  Treated)                    287

60. Flow Sheet Used for Cost Estimated, 0.75  MGD
    Reverse Osmosis Acid Mine Drainage Treatment
    Plant - Rex Chainbelt,  Inc.                                    292

61. Flow Chart-Acid Mine Water Treatment Process
    Using Two-Stage Coal Refuse Combustion Process
    - Black, Sivalls  & Bryson,  Inc.                                296

62. Effect of Plant Capacity on  Capital Investment -
    Two-Stage Coal Refuse Combustion Process                    302

63. Flow Diagram for Partial Freezing of Acid Mine
    Water  - Applied Science Laboratories                          304

64. Schematic for AMD Neutradesulfating -
    Catlytic,  Inc.                                                 311
                                -124-

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                   TREATMENT OF MINE DRAINAGE

       In the last few years, the technology of mine drainage treatment has
been reviewed in a number of publications. An excellent review  is  "Mine
Drainage Treatment, State of the Art and Research  Needs" by Ronald D.
Hill.'  '  Most of the  discussion in the first part of this section,  particularly
on mine  drainage  chemistry and the classification of mine drainage,  was
taken verbatim from Hill's publication.

CHEMISTRY  AND CLASSIFICATION OF MINE DRAINAGE

       The type of drainage produced by a particular mine is dependent upon
the product mined and the nature of the surrounding geologic formation.  In
the case of coal mining,  it is dependent upon the amount of sulfides present;
the spatial distribution of these sulfides; the crystallinity of the pyrite; the
size of the individual sulfide  particles; the presence  of bacteria associated
with acid mine drainage; and the magnitude of the fluctuation of  the water
level within the mine, if the workings are  below drainage.  In addition, the
presence or absence of  calcium in  the sulfide aggregates seems to have some
effect upon the rate  of sulfide oxidation and decomposition.

       Wide variations  exist in the chemical characteristics of  mine drain-
age and some mine waters are decidedly acid whereas others are  fairly alk-
aline.  Generally, acid  mine drainage can be said to have a low pH, net
acidity (acidity greater  than alkalinity), high iron (iron II and/or iron III),
high sulfates  and significant amounts of aluminum, manganese,  calcium and
magnesium.  Alkaline mine drainage generally can be  said to have a  pH near
or greater than neutrality, net alkalinity, high sulfate, significant calcium,
magnesium and manganese, and low aluminum.  Corbett and Growitz^  ' re-
ported that the zinc,  cadmium,  beryllium, copper, silver, nickel, cobalt,
lead,  chromium, vanadium,  barium and strontium concentrations of  coal
mine drainage were less than 1 mg/1. Analyses  of mine drainage samples
collected in West Virginia and  Pennsylvania by personnel from the Environ-
mental Protection Agency revealed concentration of similar magnitude.

       Although the exact mechanism is not fully  understood,  acid mine
drainage results from the oxidation of pyrite (FeS?) as illustrated in  Equa-
tion (1):

       2 FeS2 + 2 H2O + 7 02 	— 2 FeSO4 + 2 H2SC>4               (1)

       Subsequent oxidation of ferrous sulfate produces a ferric sulfate:

       4 FeSO4 + 2 H2SO4 + C>2	--2 Fe2(SO4)3 + 2  H2O            (2)

       The reaction  may then proceed to form a  ferric hydroxide  or  basic
ferric  sulfate:
                                 -125-

-------
       Fe2(S04)3 + 6 H2O — — 2 Fe(OH)3 J + 3 H2SO4               (3)

               )   + 2 H20 -- -2 Fe(OH)(SO4) + H2SO4                (4)
       Pyrite oxidation also occurs due to ferric iron as illustrated in equa-
tion (5):

       14 Fe+++ + FeS2 + 8 H2O — — 15 Fe + f f 2 SO4= + 16 H+        (5)

       By either mechanism,  an acid water is produced and the pH is lower-
ed. At low pH's many  metallic ions  in the mine, for example aluminum and
manganese, become more soluble and enter into the mine discharge.

       Mine drainage is a complex solution varying in quality from seam to
seam,  mine to mine, and even within the same mine.  The water  quality
from mines low in pyrite may be alkaline and closely resemble  ground water.
Often mines produce water high  in ferrous iron and acidity,  indicating that
reactions (1) and/or (5) are occurring.  The discharge may have high ferric
iron and  acidity concentration, indicating that reactions  (2) and  (3) are occur-
ring.   The discharge may also have been partially  neutralized within the
mines  thus reducing the acidity level.

       Although there is  no "typical" mine drainage, waters discharging
from mines can be  divided into four general classes as shown in Table 1.

       The wide variations in mine drainage characteristics indicate  that a
number of treatment methods  may be applicable.  The best method for any one
site will  depend on the  quality of the  mine discharge and the  ultimate use of the
water.  Treatment to meet stream water standards will be different from that
needed to meet domestic  and  industrial water use standards.

       The following mine drainage treatment methods are discussed:

1.  Neutralization

    a)   Acid mine water with high ferric iron content

    b)   Acid mine water with high ferrous  iron content

         Methods of oxidizing  ferrous ion to ferric  ion will also be discussed.

2.  Flash Distillation

3.  Ion Exchange

4.  Reverse Osmosis

5.  Submerged Coal Refuse  Combustion Process
                                -126-

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6.   Freezing

7.   Electrodialysis

8.   Foam Separation

9.   Neutradesulfating Process



NEUTRALIZATION
Principle of Neutralization - In ;he neutralization process  an alkali is mixed
with acid mine waters to neutralize the acid and to precipitate the contamin-
ating metal salts, which can then be separated by sedimentation and/or fil-
tration.   The metal salts commonly found in acid mine drainage are separated
because  they are less soluble at neutral or higher pH's than  at lower pH's.

Neutralizing Agents - The list of neutralizing agents suggested for acid mine
drainage  is presented in Table 2.  While most neutralization work to date has
utilized lime and limestone,  other agents may be used successfully in some
situations.

       The choice of an alkaline agent should be based on the following  con-
siderations:

       a)  Cost of Agent - The cheapest agent capable of fulfilling the require-
           ments should be used.

       b)  Availability of Agent - Availability is partially reflected in cost.
           The availability of certain alkaline materials, such as  a by-product
           of another industry, may not  be  available over a long term.

       c)  Basicity Factor - The amoant of alkali per unit  weight  of material
           varies  among different alkaline agents.   Basicity  factor is defined
           as the grams of calcium carbonate equivalent per  gram of alkaline
           agent.   The basicity factor is a useful tool in  comparing the cost
           of alkaline  agents.  The basicity factors  for some commonly used
           alkaline agents are given in Table  2.

       d)  Reaction Time -  The reaction rates of alkaline agents vary over a
           considerable range and are important factors  in the size of mixing
           tanks,  etc.

       e)  Sludge  Characteristic  - The  settling rate and properties of the sludge
           are important factors in the  design of settling tanks and lagoons,  and
           in the disposal of  the sludge.
                                 -128-

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                               TABLE 2

                   LIST OF NEUTRALIZING AGENTS
         SUGGESTED FOR ACID MINE DRAINAGE TREATMENT
Neutralizing Agents
Calcium Oxide (Quick Lime)
Calcium Hydroxide (Hydrated Lime)
Calcium Carbonate (Limestone)
Calcium Magnesium Carbonate (Dolomite)
Magnesium Oxide
Magnesium Hydroxide
Sodium Hydroxide (Caustic Soda)
Sodium Carbonate (Soda Ash)
Sodium Sulfide
Potassium Hydroxide
Potassium Permanganate
Ammonia
Ammonium Hydroxide
Trisodium Phosphate

CaO
Ca(OH)2
CaCO,
(Ca-Mg)CO3
MgO
Mg(OH)2
NaOH
Na2CO3
Na2S
KOH
KMnO4
NH3
NH4OH
Na3P04
Basicity Factor
1.78
1.35
1.00
1.09*
2.48
1.72
1.25
0.94
#*
0.89
##
2.94
1.43
0.92
 #Grams of Calcium Carbonate (CaCO3) equivalent per gram of agent.

##Basicity factor will vary depending on cations present in the acid mine
  drainage.
Revised from Hill,
                                 -129-

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       After treatment with calcium alkalis,  the effluent has a higher hard-
ness, may have a sulfate concentration up to 2, 000 ppm, and may contain
significant amounts of suspended solids depending on the solids separation
technique.  To the extent that acidity is removed and the soluble iron con-
centration reduced, neutralization with calcium based alkalis is successful.

       The use of sodium based alkalis, such as soda ash and caustic soda,
will effect a removal of acidity and iron.  However, these alkalis  are  sub-
stantially more expensive to use.  There  is a major technical difference
though, since sodium sulfate  is a highly soluble salt, there is no reduction
in sulfate content.  The insoluble materials are iron and aluminum hydrox-
ides and oxides and the volume of precipitates is less since sulfates are not
removed from solution.  The use of sodium based alkalis,  however, does
no!; add to effluent hardness as  in the case of calcium based alkalis.

       Many other alkaline materials could be used to  neutralize acid mine
drainage, but because of higher costs without commensurate advantages,
these materials have not been used in other than laboratory experiments  or
small scale demonstration projects.

       Coal mine drainage with a low pH,  net acidity and dissolved iron can
be neutralized with alkalis such as hydrated lime,  limestone,  caustic  soda
and soda ash.  The neutralization process removes acidity and reduces the
soluble iron concentration.  The efficiency of the neutralization process de-
pends on the alkali used, methods of application  and the characteristics  of the
mine drainage.

       The use of calcium alkalis,  such as lime, hydrated lime and limestone
will remove sulfate ions if the solubility product of calcium sulfate is  exceed-
ed.  If neutralization is accompanied by aeration or other methods of oxidation,
soluble iron salts will be removed as insoluble hydrated iron oxides.  Thus,
effluent solutions from such neutralization processes generally have no acid-
ity or slight alkalinity, contain low concentrations  of soluble iron,  and have
reduced sulfate concentrations  if the original  sulfate concentration exceeded
about 2,000 ppm as calcium sulfate.  Soluble  aluminum salts are also re-
moved from solution as precipitates of  aluminum hydroxide.

       Neutralization historically has been applied to Class I and  II mine
drainage (Table  1).  Unslaked lime, hydrated lime and more recently  lime-
stone have been  more widely used for neutralization, primarily because of
lower costs.

       Although neutralization and oxidation processes  remove acidity and
iron salts from acid mine drainage, significant technical problems exist in
separating the precipitated solids.  The sludge produced is characteristically
difficult to filter and dewater.  Sludge disposal is a serious consideration,
since it is a pollutional waste.  Disposal methods now in use include lagooning
and disposal in abandoned dry mines.  Accurate  sludge  handling and disposal
                                 -130-

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costs have not been detailed well in the literature,  although much information
is available regarding the methods of sludge disposal and the factors  involved
in the consideration of each of these methods.

Chemistry of Lime Neutralization

       Quick lime (CaO) and hydrated lime (Ca(OH)2) have been used in the
treatment of acid mine drainage.  These limes may be  either high-calcium
or high-magnesium (dolomitic).  The reactions of lime with acid mine drain-
age are illustrated in equations (6) through (10).

       CaO + H2O—— Ca(OH)2                                     (6)

       Ca(OH)2 + H2SO4	-CaS04 + 2 H2O                         (7)

       3 Ca(OH)2 + A12(SO4)3	—3 CaSO4 + 2 A1(OH)3              (8)

       Ca(OH)2 + FeSO4	Fe(OH)2 + CaSO4                       (9)

       3 Ca(OH)2 + Fe2(S04)3	—2 Fe(OH)3 + 3 CaSO4              (10)

       In addition to increasing the pH and decreasing  the acidity, lime treat-
ment will remove many  of the metallic salts. Figures  1 and 2 show the solu-
bility of aluminum,  iron and manganese at various  pH's.  Aluminum and
manganese will precipitate if the proper pH level is reached.  Calcium sulfate
will  increase the hardness of the water until its  maximum solubility is reached
(approximately 2, 000 rng/1),  then it will precipitate. Ferrous hydroxide has
a low solubility,  which decreases as the pH increases.   Ferric hydroxide is
even less soluble and its solubility decreases at higher pH's.  The oxidation
of ferrous iron results in a decrease  of the pH,  which may result in an in-
crease of the iron concentration because of the higher solubility of iron at
lower pH's.

       The addition of an alkaline agent will result in the conversion  of ferrous
sulfate to ferrous hydroxide and increase in pH.  At the higher  pH iron II will
oxidize rapidly (Figure  3) to form insoluble ferric hydroxide.  Holland, et el.'  ',
used lime in treating a mine discharge with high acidity and iron concentrations
and found that  a. pH of 10.5 was needed to assure complete iron removal.

Chemistry of Limestone Neutralization

       When iron sulfate salts are dissolved in a wa^.er medium the compounds
undergo hydrolysis reactions to liberate the hydrogen ion.  Hydrolysis is de-
fined as a reaction of an ion with water to form an associated species plus  H+
or OH  .  The general equation for a cationic hydrolysis is:
                                 -131-

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                  FIGURE I
SOLUBILITY OF ALUMINUM, IRON AND MANGANESE

    IN ACID MINE DRAINAGE AT VARIOUS pH's
                                 Sample Source:
                                 Deep Mine.Elkins.W.Va.
                                 From Hill,
                                       -220
      0
10    12   14
                   -13Z-

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                            FIGURE  2
                     SOLUBILITY OF IRON
   -4-
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   -ICH
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                 2
 I
 6


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I
8
10
I
12
  After O'Melia and Stumm, I967(82)
                               -133-

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                           FIGURE 3
1
    -2
o
o
-1  -3
    -4
    -5
                                  Stumm-Lee   Law
                 K1'
            •d log fFe (1)1
                dt
Singer- Stumm
      Modification
               2345
                                PH

               IRON (II) OXIDATION RATE AT pH 2-7
    After Singer and Stumm,  1968
    From Hill, 1968<1)
                                (83)
                              -134-

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       M+ + H20 ZHir MOH + H+                                   (11)



       In the case of iron salts the reactions would be:



For ferrous  iron



       Fe+2 + ELO ^ITZ FeOH+ + H  and                           (12)
                C*i


       FeOH+ + H20 Z^n Fe(OH)2 + H+                           (13)



The net reaction would be



       Fe+  + 2 H2O ^=±T Fe(OH)2 + 2 H+                          (14)



For ferric iron



       Fe+3 + H20 I^= Fe(OH)+2 + H+                            (15)



       Fe(OH)+2 + H2O TT~^ Fe(OH)2+ + H+                        (16)



       Fe(OH)2+ + H2O^=^Fe(OH)3 + H+                          (17)



The net reaction being



       Fe+3 + 3 H2O  .  '  Fe(OH)3 + 3 H+                          (18)



       These are equilibrium reactions and will go to completion (i.e.  com-

pletely hydrolyzed) only if the hydrogen ion is pulled out of the equilibrium.

This can be accomplished by neutralizing the hydrogen ion. with a base.



       Calcium carbonate in an acidic medium will undergo a reaction  to

form lime and carbon dioxide according to the equation:



       CaCO3 + H2O —   "- CaO + H2CO3

              _ _                                                (19)

where  H2CO3 ^~~" H2O + CO2



       The lime will react with the hydrogen ion of the  acid to neutralize it

and form  water plus the  calcium salt of the acid.



       CaO + 2 H+ - —  Ca++  + H2O                                (20)



       For the case of ferric sulfate, the reactions would be



       3 CaO + 2 H+ + SO4~ - — CaSO4 + H2O                      (21)
+++        =      +         - —    e
                                                       (22)
       2 Fe    + 3 SO4= + 6 H  + 6 OH"  - — 2 Fe(OH), I
             I         _                               ^
         +6 H+ + 3 S0"
                                -135-

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       The reaction of calcium carbonate with acidic water to form calcium
oxide, as an intermediate product,  occurs at approximately pH 7 or lower.
As the CaO reacts  with free hydrogen ions (Equation 21), a resultant increase
in .hydroxal ions occurs.* This in turn results in attachment of a sufficient
number of hydroxal ions (OH  ions) to  the ferric iron for precipitation of fer-
ric hydroxide to occur, as indicated in Equation 22.  In this reaction hydroxal
ions  are removed from solution by precipitation, and therefore,  free hydrogen
ions  are released.  These additional hydrogen  ions are then neutralized accord-
ing to Equation 21.  The reaction of ferric iron in the  above equations  to form
ferric hydroxide  is essentially complete at pH  3.5.

       In the case  of mine waters high in ferrous iron, the addition of an alkali
will precipitate all iron directly as  ferrous hydroxide,  Fe(OH)2, only if a pH
of 8.5 to 9.5 is reached.   Since C&CO% is practically insoluble in neutral solu-
tions, precipitation of ferrous iron by  addition of limestone (CaCO^) will not
occur.  If  lime instead of CaCO3  is used then the pH will rise to about 10 and
all of the ferrous iron will precipitate.

       It is obvious from the above chemistry,  that ferrous iron must be oxi-
dized to ferric iron with the formation of free acid before calcium carbonate
can react to neutralize the mine water and precipitate all iron.
       *In all aqueous  solutions any decrease in hydrogen ion concen-
       tration must result in an increase in the hydroxal ion concen-
       tration since the product of the two is a constant.

Neutralization of Mine  Drainage with High Ferrous Iron Content

       Extensive work has been accomplished in neutralization of acid mine
drainage with high  ferrous iron content.   The following methods will be ex-
plored for their feasibility and cost:

1.  BCR  limestone treatment process.

2.  U.S.  Bureau of Mines limestone treatment process.

3.  Combination lime stone-lime treatment process.

4.  Combination lime-lime stone neutralization  with rotary precoat filtration
    for sludge dewatering.

5.  Electrochemical oxidation followed by limestone neutralization.

6.  Ozone oxidation followed by limestone neutralization.

7.  Biochemical oxidation followed by limestone neutralization.
                                 -136-

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BCR Limestone Treatment Process

       As a result of extensive bench-scale tests, Bituminous Coal Research,
Inc.  ' '  ',  has developed a process whereby coal mine drainage containing
ferrous iron can be treated with limestone.   The process results in complete
neutralization of acidity and removal of iron to acceptable limits.

       The BCR limestone treatment process consists  of the  following unit
operations  in sequence:  a) Mine drainage holding or equalization, b) adding
pulverized limestone and mixing, c) aerating, d) slurry recirculation to the
mixing area, e) sludge  settling,  and f)  sludge dewatering and  disposal.

       A general concept of the limestone neutralization process is shown in
Figure 4,  The individual parts of the total system are:  a) holding tank, b)
pulverized limestone storage tank, c) limestone feeder, d) limestone reactor,
e) aerator, f) settling tank, g) optional sludge recirculation,  h) optional oxi-
dation catalyst, and i) optional coagulant aid.

       Advantages of Using Limestone

       1.  Lower costs per unit weight of chemical reagent necessary to
           neutralize the same quantity and  quality of coal mine drainage.

       2.  Fewer safety problems  in handling a less reactive reagent.

       3.  A less harmful effect on the body of water receiving the effluent
           in case  of accidental overtreatment.

       4.  A reduction  in sludge volume and an increase in sludge solids
           content.  The volume of sludge from limestone treatment can
           be as little as one-fifth  of that obtained in lime treatment,  and
           the  solids content can be almost  15 times greater.  The re-
           duction in sludge volume allows for the use of smaller settling
           basins,  and  this may be sufficient reason for selecting lime-
           stone treatment over  lime in areas where space is at a premium.

       Disadvantages of Using Limestone

       1.  The major disadvantage of the process is the slow rate of oxida-
           tion of ferrous  iron at the relatively low pH  attainable with lime-
           stone.   Long detention time and,  consequently, large tanks are
           required for mixing the mine water with limestone and for aerating
           until most of the ferrous iron has been oxidized.  This results in
           higher costs, inefficient mixing,  diffusion of oxygen,  and sparging
           of carbon dioxide.
                                -137-

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                            FIGURE 4
     Sludge
   Recirculation
    (Optional)
                                 Coal
                                 Mine
                                Water
                               Holding
                                 Tank
                              Limestone
                                Reactor
                                  D
                               Aerator

                                  E
                                Settling
                                 Tank     F
        Pulverized
        Limestone
         Storage
          Tank
Limestone
 Feeder
   C
                                                         Oxidation
                                                          Catalyst   H
                                                         (Optional)
       Coagulant Aid  j
         (Optional)

         Treated Water
             To
       Receiving Stream
                               Sludge To
                               Disposal
                       FLOW DIAGRAM  OF
    CONCEPTUAL LIMESTONE TREATMENT PROCESS
From Bituminous Coal Research, Inc. ,  1971
                                                     (5)
                                -138-

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       2.  The production of fine particles in the effluent which do not settle
           rapidly may require coagulant aids for their removal.

       3.  The availability of finely divided limestone of the desired quality.

       To be used in the treatment process, the particle size of the limestone
should be at least 74 microns (200 mesh) and preferably smaller.  In addition,
the limestone should approach pure calcium carbonate  in composition with as
low a content of magnesium as possible.  Magnesites are the least effective
neutralizing agents, followed closely by dolomitic limestones.

       Coal mine waters containing ferrous  iron in quantities as great as 5, 000
mg/1 present particular problems in treatment which have not been solved.
Treatment of such mine waters results in precipitation of calcium sulfate (gyp-
sum) during treatment with resultant scaling problems  on tanks, pipes, mixers,
aerators, and pumps.  Also, the volume  of sludge  would be greater than the
volume of treated water obtained.  These two problems are inherent in both
limestone and lime treatment.

       The laboratory studies demonstrated feasibility of the limestone treat-
ment process using laboratory-scale  pilot plant apparatus,  delineated the in-
dividual operations and sequence of operations necessary for adequate treatment,
and established basic  information pertinent to engineering design of full-scale
treatment plants.  Based on the  results of these studies, experimental results
were related to engineering design of full-scale treatment plants.  For these
engineering evaluations,  flows of 0.1, 1.0, and 7.0 million gallons per day
(mgd) were chosen and data developed for construction and operation of plants
to treat discharges having these flows.  The EPA Class I mine drainage was
chosen as the quality of mine water to be used in the evaluations, because that
type of mine drainage would present the greatest problems in treatment.

       The following three cases of the Class I mine drainage were used to
develop the flow schematics, unit designs, and material balances:

       Case A; Acidity,  mg/1 (as CaCO3)              1,000
                Ferrous iron, mg/1                      500
                Ferric iron, mg/1                         0
                Aluminum,  mg/1                           0
                Sulfate, mg/1                          1, 000

       Case B: Acidity,  mg/1 (as CaCO3)              8,000
                Ferrous iron, mg/1                    5, 000
                Ferric iron, mg/1                         0
                Aluminum,  mg/1                         500
                Sulfate, mg/1                         10, 000
                                 -139-

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       Case C: Acidity,  mg/1 (as  CaCO3)             15,000
                Ferrous  iron, mg/1                   10,000
                Ferric iron, mg/1                         0
                Aluminum,  mg/1                       2, 000
                Sulfate, mg/1                         20, 000

       In addition to the Class I mine drainage, a discharge from the South
Greensburg, Pennsylvania area was used in the laboratory studies and for
the engineering evaluation.  The estimated flow of this discharge was 4.0
mgd and the water had the following average quality:

       Case D: Acidity,  mg/1 (as  CaCO3)                190
                Ferrous  iron, mg/1                       90
                Ferric iron, mg/1                         0
                Aluminum,  mg/1                           8
                Sulfate, mg/i                          1,200

       Cost Evaluation of the Process - The development of cost data for
construction and operation of full-scale mine drainage treatment plants to
treat Class I coal mine drainage is difficult because of the wide  range of
flow and quality conditions included in Class I.  Furthermore, treatment
plant costs will vary based on the  availability of suitable land, soil condi-
tions,  and topography of the site.  For the cost analysis, it has  been assum-
ed that suitable land  is available to construct the treatment plant units,  the
topography of the proposed plant site is relatively level,  the proposed site
does not have a high  water table,  the depth to bedrock at the proposed site
is a minimum of 10 feet,  and soil  at the proposed site contains a high clay
content.   In addition,  it has  been assumed the proposed holding basin could
be constructed with a water  surface elevation sufficient to produce a gravity
flow condition through the plant complex;  therefore, the only pumping re-
quirements would be for recirculation and wasting of sludge.

       The treatment facility designed to treat coal mine drainage contain-
ing ferrous iron and  using limestone as the neutralizing agent,  consists of
the following unit operations, in flow-through sequence:  a) holding or equali-
zation lagoon; b) reactor  tank; c) aeration tank; d) settling basin, and e)
sludge dewater  basin.

       The cost evaluation has  been based upon the  sequence of treatment
units as  outlined and the plant operation procedures and assumptions as des-
cribed.  The coal mine drainage is conveyed to an earthen holding lagoon
providing a 12  hour  retention for the mine water.  The holding lagoon design
has a two (2) foot freeboard  and  1:1 sidewall slopes  with riprap on the upper
sidewalls.  To permit monitoring  and sampling of the holding basin overflow,
ai open  concrete flume connects between the holding basin and reactor tank.
The pulverized  limestone  and recirculated sludge is added to the reactor
tank and mixed  with coal mine drainage for a period of 60 minutes.  Rein-
forced concrete reactor tanks are  used in order to eliminate the erosion
                                 -140-

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problems caused by mixing action in earthen basins.  The reactor tanks are
constructed with vertical walls and a four (4) foot freeboard.

       Effluent from the reactor tank flows to an aeration tank where mixing,
aeration and sparging of carbon dioxide are accomplished by mechanical sur-
face aerators.  The aeration tanks are sized for a 60 minute detention period
for the total flow rate to the unit.  The aeration tanks are constructed of re-
inforced concrete and the  aerators are mechanical surface aeration units
which ensure  continuous mixing.  The aerator is secured with guy wires or
supported by structural steel members spanning the  tank walls.

       The aeration tank effluent flows into the settling basin,  providing a 12
hour detention period based upon the  flow rate to the settling basin.   The set-
tling basin is  provided  with an influent distribution trough and weir and de-
signed to minimize the possibility of  short circuiting.  The earthen basins are
constructed of well compacted clay-type soil to reduce leakage.  In addition,
the earthen settling basins are  constructed with a minimum of two (2) feet
freeboard, a minimum inside wall slope of 2:1 and riprap on the upper sidewalls
to prevent erosion by the surface wave action.  An open channel to the re-
ceiving stream permits visual observation and continuous pH monitoring of the
treated effluent.  The sludge from the settling basin  is pumped from  the set-
tling basin to  the sludge pump well.

       The sludge removal system has been designed to use portable floating
surface pumps secured to the basin crest by guy wires.  Recirculated sludge
is pumped at a rate equal  to the plant influent to the reactor tank.  The re-
mainder of the settled  solids is  pumped by the waste sludge pumps to the earth-
en sludge dewatering basins for additional concentration and disposal.  All
pumping systems  include a standby pumping unit to be used during maintenance
or breakdown.

       The construction costs for sludge dewatering facilities are based on
the assumption that basins can be located adjacent to the treatment complex
and do not reflect costs of pumping sludge through a  long pipeline.  The
supernatant from  the dewatering basin is discharged to the receiving stream.
A concrete sump, with pumps and appurtenances to pump the concentrated
sludge from the dewatering basin, provides a means  for  transfer of the  sludge
to tank trucks for ultimate disposal.  The dewatering basins have a capacity
to hold a three (3) month sludge accumulation.

       The design of the limestone treatment process units is based  on  single
unit operation and does not reflect the capital costs if duplicate units  are re-
quired.

       Facilities  for a minimum of four (4) days storage of bulk pulverized
limestone is provided at the plant site.  It is assumed limestone will be  de-
livered to the  plant site by pneumatic unloading trucks.   The limestone storage
bins are equipped with  level indicators, limestone  feeders,  and dust  collectors.
                                 -141-

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The limestone feeders are installed in duplicate to reduce the possibility of
plant  shutdown due to mechanical equipment failure and to permit routine
maintenance on the equipment.  This equipment should be located near the
reactor tank in order to reduce distance of conveying limestone.

       A control building  is required at the plant site to house the plant ser-
vices, administration facilities, and chemical feed systems.  The plant ser-
vices  and administration section of the  control  building  should contain 1 ) an
office for the plant operator; 2) a central control panel from which the  treat-
ment  plant operations would be monitored; 3) laboratory facilities for water
quality analysis and chemical dosage controls; 4) main motor control center,
and 5) maintenance shop.   The chemical feed equipment  section of the con-
trol building contains the limestone  and coagulant aid feed equipment.

       A paved access roadway should  be constructed to the plant site  to en-
sure delivery of the chemicals to the plant during all weather conditions.

       The operation and  control of the proposed mine drainage treatment
complex is based upon the  flow rate and acidity concentration of the specific
mine  drainage discharge to be treated.   The holding  basin effluent flow should
be continuously and automatically metered.  Acidity  concentration at this point
in the process must be manually sampled and analyzed to determine  the quan-
tity of limestone feed. In addition,  the pH should be continuously and auto-
matically monitored  by pH probes  located between the aeration tank and settling
basin and in the treated water discharge channel.  The recirculated sludge
flow shoald be automatically regulated by the plant influent flow rate at the
ratio  of 1:1.

       The following  assumptions  are made for the purpose of completing
plant  design  data and  material balances:

1,  The limestone requirement is twice the stoichiometric  amount based on
    acidity.

2.  A recirculated sludge  to mine drainage feed ratio of 1:1 is required.
    (Actually, a 1:1  ratio of slurry  to coal mine drainage. )

3.  Twenty five percent of the limestone feed remains unreacted  in the sludge.

4.  All but 7 mg/1 of the initial iron present is precipitated in the sludge as
    ferric hydroxide.

5.  All of the  initial aluminum is precipitated in the sludge as aluminum
    hydroxide.

6.  Calcium sulfate  (gypsum) is not precipitated in the  sludge.

7.  The sludge solids content is five percent.
                                 -142-

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8.   The sludge specific gravity is 1.05.

       The cost parameters on which Bituminous Coal Research,  Inc.  based
their costs  of limestone treatment are given in Table  3.  The  costs are up-
dated using Engineering News-Record (ENR) Construction Cost Index.  It is
assumed the cost  index was 1575 when BCR made their cost estimates (June,
1971) and the updated costs are based on the estimated April,  1972 ENR cost
index of 1700.  The updated cost  estimates are plotted in the form of cost
carves (Figures 5 to 15).

       Table 4 presents an estimate of capital cost for a limestone treatment
plant to treat South Greensburg coal mine drainage at  a 4. 0 mgd flow rate.
The  total capital cost of the plant based on June, 1971 prices is  estimated at
$658,960.   Using  the April, 1972 ENR cost index,  the total capital cost of the
plant is $711, 000.

       Figures 6 through 9 give the estimated costs for various plant facilities
based on plant capacity and chemical characteristics 01 the mine drainage  to be
treated.   The cost of site clearing, final grading, access roads, engineering and
contingencies should be  added to  arrive at the  total plant costs which are indi-
cated in Figure 5.

       The operating costs for plants of various capacities and chemical char-
acteristics  of mine drainage to be treated are  indicated on Figure  10.  Figures
11 through  14 give cost estimates for various elements of plant operation and
Figure 15 is an estimate of sludge accumulation  for one year for various size
plants with  differing chemical characteristics  of mine drainage.  The costs  of
coagulant aids, if needed, and  contingencies should be added to obtain the esti-
mated total operation cost of the  treatment plant.

       The BCR limestone process should be studied  on a larger scale since
bench scale studies have not sufficiently defined  the following:

1.   The mixing requirements in  the reactor tank

2.   The cost of grinding coarse limestone versus the  use of pulverized lime-
     stone

3.   The use of mechanical aerators

4.   The sludge recirculation ratio in an equilibrium condition and the effect
     of sludge properties such as  solids content,  alkalinity, etc. on process
     efficiency

5.   The effect on treatment plant systems in treating  coal mine drainage having
     sulfate concentrations  of up to 20, 000 mg/1 with resultant precipitation of
     gypsum

6.   The effect of coagulant aids on settling properties and on  recycled  sludge

7.   The effect of more concentrated coal mine drainage on sludge volume.

                                 -143-

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                              TABLE 3
     BASIS FOR ESTIMATED COSTS OF LIMESTONE TREATMENT
                 VARIOUS SIZE TREATMENT PLANTS

1.   Capital Costs
    The capital costs are amortized for twenty (20) years  at six (6) percent
    interest.

2.   Labor
    a.  0. 1 MGD Treatment Plant:
           1 Operator                                $  7, 500. 00
           1 Part Time Laborer                         3, 003. 00
                                                    $10,500.00

    b.  1.0 MGD Treatment Plant:
           1 Operator                                $  8, 000. 00
           1 Laborer                                   6,000.00
                                                    $14,000.00

    c.  7.0 MGD Treatment Plant:
           1 Operator                                $10, 000.00
           2 Laborers                                 15,OOP.00
                                                    $25,000.00

    d.  4. 0 MGD Treatment Plant:
           1 Operator                                $10,000.00
           1 Laborer                                   7,5_OQ.Oj)
                                                    $17,500.00

3.   Limestone
    (Pulverized limestone delivered to plant site by bulk trucks.)
           0 to 10 tons/yr          - $7. 00 per ton
         10 to 20 tons/yr          - $6.50 per ton
         Greater than 20 tons/yr   - $6.00 per ton
4.   Coagulant Aid
    $2.00 per pound

5.   Powe r
    a.  0. 1 MGD Treatment Plant: $85. 00 per horsepower per year
    b.  1.0 MGD Treatment Plant: $80.00 per horsepower per year
    c.  4.0 MGD Treatment Plant: $80.00 per horsepower per year
    d.  7.0 MGD Treatment Plant: $75.00 per horsepower per year

6.   Maintenance and Repairs
    a.  0. 1 MGD Treatment Plant: $  3,000 per year
    b.  1.0 MGD Treatment Plant: $  5, 000 per year
    c.  4.0 MGD Treatment Plant: $  8, 000 per year
    d.  7. 0 MGD Treatment Plant: $10, 000 per year

7.   Contingencies
    One percent of  construction costs

8.   Sludge Disposal Cost
    $10.00 per 1,000 gallons
                               -144-

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                                TABLE 4
   ESTIMATE OF CAPITAL COST FOR LIMESTONE TREATMENT PLANT
              SOUTH GREENS BURG COAL MINE DRAINAGE
                          4.0 MGD FLOW RATE

 1.  Site Preparation
     a.  Clearing & Grubbing                          $    500.00

 2.  Structures
     a.  Holding Lagoon                                76,000.00
     b.  Reactor Tank                                  43, ZOO. 00
     c.  Aeration Tank                                 43,200.00
     d.  Settling Basin                                 118,500.03
     e.  Sludge Dewatering Basin                        35,000.00
     f.  Sludge Pump Well                              12,000.00

 3.  Control Building                                    48,000.00

 4.  Mechanical Equipment
     a.  Mixers                                        25,500.00
     b.  Aerators                                       31,000.00
     c.  Sludge Recirculation Pumps                     11,250.00
     d.  Waste Sludge Pumps                             1,950.00
     e.  Settling Basin Sludge Pumps                     11,250.00

 5.  Chemical Feed Equipment                            6,000.00

 6.  Mechanical Piping                                  40,000.00

 7.  Control Equipment                                 24,000.00

 8.  Access Roadway                                     2,500.00

 9.  Final Grading                                       6,000.00

10.  Electrical                                         30,000.00

11.  Contingencies                                       56,150.00

12.  Engineering                                        36, 960. 00

     TOTAL CAPITAL COSTS                          $658, 960. 00
                                 -145-

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                              FIGURE 5
             ESTIMATE  OF CAPITAL COSTS Vs. PLANT CAPACITY
           BCR LIMESTONE TREATMENT W/SLUDGE DEWATERING
              EPA.WQO, CLASS I COAL MINE DRAINAGE (REF5)
0.1
02
0 3  O.4 05
     10        2O
CAPACITY-MGD
                                                 30   40  5.0
                                -146-

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                      FIGURE  6
     ESTIMATE OF CAPITAL COSTS Vs. PLANT CAPACITY
  BCR LIMESTONE TREATMENT W/SLUDGE DEWATERING
     EPA,WQO,CLASS I COAL MINE DRAINAGE (REF. 5)
1000
  O.I      0.2  0.3 0.4 0.5     1.0     2.0  3.0 4.0 5.0     10.0
                   CAPACITY-MGD
                       -147-

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                       FIGURE  7

      ESTIMATE OF CAPITAL COSTS Vs. PLANT CAPACITY

   BCR  LIMESTONE TREATMENT W/SLUDGE DEWATERING

      EPA.WQO.CLASS I COAL MINE DRAINAGE (REF5)
10,000!
5,000

4,000

3,000'
     SLUDGE REtitoULATING
                        CASE A
      WASTE SLUDGE PUMPS ( CASE B
                        CASE C
    01     02  03 04 05      1.0     20  30 40 50
                      CAPACITY-MGD
                         -148-

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                        FIGURE  8


     ESTIMATE OF CAPITAL COSTS Vs. PLANT CAPACITY

   BCR LIMESTONE TREATMENT W/SLUDGE DEWATERING

      EPA,WQO,CLASS I COAL MINE DRAINAGE (REE5)
1,000
     i) (2) (3) SETTLING BASIN

    41     CONTROL BUILDING
    5) (6) (7) SLUDGE PUMP WELL

    ®,(D,® CHEMICAL FEED EQUIPMENT
           CONTROL EQUIPMENT
           I    1  ._!  1 .1  I
          0.2
0.3 0.4 0.5     1.0     2.0

         CAPACITY-MGD
3.0 4.0 5O
10.0
                          -149-

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                        FIGURE  9


      ESTIMATE OF CAPITAL COSTS Vs. PLANT CAPACITY

    BCR LIMESTONE TREATMENT W/SLUDGE DEWATERING

       EPA.WQO.CLASS I COAL MINE DRAINAGE (REF5)
 1,000
  500

  400


  300
  200
CO
cc
  100
CO
Q
   50
co  40

O
X  30
co
O
O
2
0.

o
   20
   10
     -MECHANICAL PIPING:CASE
    O.I      0.2   0.3 04 0.5     1.0     2.0  3.0 4.0 5.0     10.0

                      CAPACITY-MGD
                          -150-

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10.0
 O.I
                                 FIGURE 10

              ESTIMATE OF OPERATING COSTS Vs. PLANT CAPACITY
              BCR  LIMESTONE TREATMENT W/SLUDGE DEWATERING
                 EPA.WQO.CLASS I COAL MINE DRAINAGE (REF5)
  0.1
0.2    03   04 05
                                                    3.0   4O  5.0
10.0
                              CAPACITY-MGD
                                   -151-

-------
I
  8
             _l  -I

             999
             o  o o
              ^t.
                                   O  Z> "" <
                                   <  O CO QL
                                        o
                                        o
                      8


                      s


                      s
                                        ii
                                        s§
                                        uj
                                        UJ
                                          or
                                          o
                                          m
              -152-

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                  FIGURE 12

   ESTIMATED COSTS (CENTS/THOUSAND GALLONS)
 BCR LIMESTONE TREATMENT W/SLUDGE DEWATERING
   EPA,WQO,CLASS I COALMINE DRAINAGE(REF5)
500
400
1S\f\
ER TREATED
5 i_J
u.
O
g 50
0 40
•J
4 30
0
z
COST-CENTS/THOUS/!
— ro ex -fc 01 o c









1


























• •


























=K

























i^iH








































cc

























)S

























CAS











*f\








c









E C


C Q 	






ASE



T




0




F







" —



LIMESTC





















— —


)NE





















«==

























——

























•—

























•~m
























































0.1
    1.0
CAPACITY-MGD
10.0
                    -153-

-------
                      FIGURE  13
     ESTIMATED COSTS (CENTS/THOUSAND GALLONS)
            BCR LIMESTONE TREATMENT OF
     EPA,WQO,CLASS I COALMINE DRAINAGE (REF.5)
100.0
                               POWER-CASE B
                                   POWER-
  0.1
02
0.3 040.5     ID     2.0
        CAPACITY-MGD
3.0 4.0 5.0
                       -154-

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                        FIGURE 14


       ESTIMATED  COSTS (CENTS/THOUSAND GALLONS)

              BCR LIMESTONE TREATMENT OF

       EPA.WQO, CLASS I COAL MINE DRAINAGE (REF5)
  1000
  500

  400

  300

Q
£ 200


Q:
I-

2]  100
O
CO  50

3  40
_l
%  30
<  20
CO
CO  10
O
8
    4

    3


    2-
    CASE B
     ;ASE c-
SLUDGE DISPOSAL COSTS

CAPITAL COST  	
    I
    0.1      02   0.3 0.4 0.5      1.0     20   30  4.0 5.0     100

                       CAPACITY-MGD
                         -155-

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                        FIGURE 15
  ipoo
LJ
Lu

LU

O




5
LU
LU


Q
O


O


§
§
300
   100
 10
    1.0
       ESTIMATED SLUDGE ACCUMULATION IN ONE YEAR

            FROM BCR LIMESTONE TREATMENT OF

        EPA.WQO,CLASS I COAL MINE DRAINAGE (REF5)
                                                 /
  O.I      02  0.3  04 05     1.0      2.0


                      CAPACITY-MGD
                                       3.0 4.0 5.0
10.0
                          -156-

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U. S. Bureau of Mines Limes tone _T r e atment Pro cess

       The U. S. Bureau of Mines initiated an effort in 1966 to develop a
low-cost practical neutralization process for treatment of acid mine water.
The  emphasis was on using limestone as the neutralizing  agent because of
its low cost and availability.  As a result of their effort '  ' '•  » '•   ',  a
limestone neutralization process was developed to  treat mine water of any
quality and preliminary plant design and total cost  estimates were develop-
ed.

       The general process for treatment of acid mine water effluent con-
sists of limestone neutralization,  aeration, solids  settling,  and sludge con-
centration.  Figure 16 is a flow sheet of the  mine water treatment process.
  From mine
                                                             Sludge settling
                                                                 and
                                                             storage ponds—/
       Automatic  k—'
        control    fcH
                                                                          Treated
                                                                          effluent
                               FIGURE 16

         FLOWSHEET OF MINE WATER TREATMENT PROCESS
         After  Mihok,  197()(8)
                                 -157-

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       Mihok^ ' describes the process as follows:

       Gravity flow in this plant design is utilized throughout the treatment
from holding pond to ultimate effluent discharge.   Mine water flows  from the
holding pond through pipes and flumes  and is mixed with limestone slurry
generated in an autogenous tube mill or grinder.  The resulting mixture enters
the primary section of the aeration pond where air is applied to remove CC>2
formed from the  neutralization of free acidity.  As the mixture flows into the
main section of the aeration pond,  additional limestone  slurry is added to
neutralize the remaining acidity formed by oxidation and precipitation of iron.
Air sparging is continued at a reduced rate  through the  main section of the
aerating pond. The neutralized mixture flows from the pond through flumes
to settling ponds  designed to provide sufficient time for the suspended solids
to settle  to  the bottom of the pond.  The clarified effluent  is discharged into
a stream or river.

       The  two settling ponds are designed  to hold 10 years of solids accumu-
lation.  When the sludge level in the pond approaches within 5 feet of the upper-
most water  level, solids settling is conducted in the other pond.  Water in the
first pond is drawn off and the sludge is air dried and allowed to remain in
place.  When the second pond fills with sludge,  the neutralized water is divert-
ed to the first pond which is air dried and settling continues uninterrupted.

       Design Criteria and Costs - Design criteria and costs are given for a
wide range  of volumes and quality of mine water.  Volumes range from 100, 000
gpd to  6  million gpd, acidity from 100  to 5, 000 ppm, ferrous iron from 50 to
1, 500 ppm,  and neutralized water suspended solids from 250 to 8,000 ppm.
Suspended solids concentrations typically consist of calcium sulfate, hydrated
metal oxides, silica,  unused limestone,  and inerts.

       Since design criteria and treatment methods affect the cost of construc-
tion and  operation of a treatment plant, a discussion of important factors affect-
ing costs follows:

       a) Holding Pond  - The holding  pond  capacity is at  least three times the
anticipated  maximum daily mine water flow.  This additional volume provides
safeguards  to prevent untreated or  inadequately treated water from  discharging
into streams or rivers in the event of unforeseen increase of acid mine drain-
age flow and temporary shutdown of neutralizing facilities.  It will minimize
fluctuations in raw water feed composition and reduce ferrous iron concentra-
tions.

       b) Neutralization Treatment -  The limestone autogenous tube mill and
aeration equipment is designed to treat continuously a 25 percent excess of the
anticipated  maximum daily mine water acid and ferrous iron load.   Process
control is maintained by raw mine water feed regulation.  Normal operation
consists of  maximum production of limestone for neutralization of total acidity
so that depletion of feed takes place at rated design capacity.  When a minimal
                                 -158-

-------
level of acid mine water in the pond is reached, the tube mill shuts down and
is reactivated when sufficient water volume has accumulated.

       c)  Limestone Storage and Processing - Limestone storage and pro-
cessing capacity is based  on the maximum daily total acidity to be treated.
Storage bins are designed to hold at least a five (5) day  supply of limestone.
A feeder mechanism is included to  meet maximum daily limestone require-
ments. The autogenous grinder provides limestone slurry containing  particles
of which 99 percent pass through a  400-mesh screen. A consistent uniform
slurry is produced when the tube mill operates under constant feed and grind-
ing speed coaditioiis.

       The storage bin and  feeder costs, including installation,  have been
obtained from manufacturers of these items.

       d)  Aeration - Aeration performs three functions in limestone treat-
ment of acid mine drainage; it mixes the reactants,  removes CO£ formed
from CaCC>3 reaction with acid, and supplies  oxygen for ferrous  iron oxida-
tioa.  MihokW believes that this can best be accomplished by diffused air or
air sparging.

       The design of the aeration system is based on winter  operating condi-
tions  (air and water temperature 0° to 10° C) when the lowest reaction rates
and highest concentrations of ferrous iron prevail.  The volume of acid mine
water, ferrous iron concentration,  and oxidation rate under these conditions
dictate the size  of the pond and bhe  volume of air to  be supplied.  Disregarding
catalytic oxidation,  ferrous  iron oxidation rates at pH range  of 6. 5 to  7. 5 and
10° C for various concentrations used in this  design  are as follows:





1
1
2
Fe++
concentrate
50 	 '
100 	
250 	
500 	
, 000 	
, 500 	
, 000 	
Oxidation
rate,
ppm per min
r 3
4
5
6
7.5
10
12.5
       Based on results of the pilot plant and laboratory tests, these rates
can be achieved with air rate volumes  approximately double the water volume
flow rate for a. period of up to a five (5) minute detention time in the primary
section of the aeration unit.  Subsequent air,  at rates approximately equal to
the water volume flow rate, is supplied in the secondary or main section of
the aeration unit. A centrifugal blower delivers  air at four (4) psi pressure
at rated capacity through a PVC pipe equipped with diffuser nozzels or orifices
mounted near the bottom of the aeration pond.
                                 -159-

-------
       Centrifugal blower, motor,  and piping costs have been obtained from
manufacturers and total costs including installation have been estimated.

       e)  Sludge Settling  and Concentration Ponds - Suspended solids  are sep-
arated from the treated water by means of duplicate settling ponds.  The al-
ternate use of the pond provides for sludge concentration and solids storage in
situ.  At least a 24 hour settling time is maintained at all times.   Capacity  is
based on the volume occupied by air-dried solids accumulated over a period of
10 years.  An average  bulk density of dried solids  of 50 Ibs./cu.  ft. has been
used to determine the settling pond capacity.  A ton of dried sludge cake con-
taining up  to 50 percent moisture occupies the volume of approximately 300
gallons of  water.

       f)   Excavation - Pond construction costs depend on many factors but
ultimately  are expressed in terms of cost per cubic yard of earth handled.
The capacity of the pond in gallons  equated in terms of cubic yards determines
the relative amount of work that must be performed. An estimate of one dollar
($1.00) per cubic yard  for excavation was used in determining construction
costs for holding, aeration,  and sludge settling ponds.  Aeration pond  costs
also include an additional  $1.00 per square foot for concrete slab lining of
the side walls.

       g)  Water Transport,  Flow Control, and Measurement - Mine water is
transported by means of open flumes throughout the process, except for water
discharged from the holding pond which flows through PVC pipes.  Piping and
valves are incorporated in the system  for a distance of 200 feet from pond to
neutralizer. Open, half round, corrugated galvanized pipe flumes carry the
water through the rest  of the process.   Weirs for measuring water flow are
located ahead of the neutralizer and at the effluent discharge from the  settling
pond.  Automatic controls are used to  regulate the mine water feed instead  of
regulating  the neutralizing agent feed,  because generation of limestone fines
can be controlled more efficiently and  economically with constant-speed grind-
ing.

       Hydraulic requirements dictate the size of valves, piping,  etc., and
the cost of these  items was obtained from manufacturers.  Included in the total
cost of water transport and control are labor and installation estimates.

       h)  Limestone Fines  Generation at Tube Mill - For limestone require-
ments  of up to 10 tons per day, the cost of limestone fines generation is related
to the cost of the pilot plant tube mill designed and constructed by the Bureau
of Mines.  Tube mill cost estimates for greater than 10 tons per day capacities
have been  obtained from grinding mill  manufacturers.

       i)   Auxiliary Equipment Costs  - Included in this item are pH meters,
turbidity meters,  and process controls.  The cost of these items  were obtained
from the manufacturers.  Table 5 gives the estimated costs of these items for
treatment  plants  of various capacities.
                                -160-

-------
       j) Other Factors Affecting Costs - The costs of land acquisition, site
improvement and  pumping water from the mine can be  highly variable.  It is
assumed for this  cost estimate that sufficient land is available and mine water
is discharging into the holding or equalization pond.  It also has  been assumed
that electric power is available at the site.

       k)  Capital Costs  - The total treatment plant capital costs include all
construction costs plus an allowance of 25 percent to cover contingencies.

       1) Fixed Costs -  Included in the annual operating costs is a. fixed charge
of 10 percent of the total capital costs.  It is expected that the useful life of the
plant equipment will  be greater than 10 years,  but the ponds storage capacity
sets this 10 year  limit.   The plant life can be extended by removing  the solids
from the pond.

       m) Operating Costs  -

            1.  Limestone - The cost of limestone (containing about  75 percent
               CaCOo) has been set at $2. 00 per  ton f. o. b.  for these calcula-
               tions .

            2.  Labor -  Labor costs  are based on $10, 000 per man-year.

            3.  Powe r - The power cost is  based on a 1 cent per kilowatt -hour
               rate,  with continuous consumption 24 hours per day and 365
               days  per  year.

            4.  Maintenance - Yearly maintenance costs, including tube mill
               liner  replacement, are estimated  at 10 percent of tube mill
               capital costs.

       The detailed breakdown of estimated  capital and operating costs for
limestone treatment  plants of various capacities used in the U. S. Bureau of
Mines publication "Mine  Water Research - Plant Design and Cost Estimates
for Limestone Treatment, "  1970,  by Mihok ' ' is  shown  on Tables 6 through
11.  The cost estimates  presented in these tables  were made in 1969.  It is
assumed that the ENR construction cost index was 1305 (December,  1969)
when these estimates were made.  The estimated  costs were updated using  an
ENR construction cost index of 1700  (April,  1972), and the updated costs were
plotted as cost curves on Figures 17 through 24.

       A preliminary study  conducted  by the U. S. Bureau of Mines  indicates
the aeration step might be supplanted by a catalytic oxidation step prior to
neutralization.  Extremely rapid ferrous iron oxidation rates have been attain-
ed with the use of granular activated carbon.  With all  the iron in the raw mine
water  converted to the ferric state, neutralization equilibrium can be quickly
established and subsequent aeration is unnecessary.  Promising aspects of  the
catalytic oxidation process are nonrecurring expense and long operational life
                                 -161-

-------
of the activated carbon.   Therefore, further  reduction of mine water treat-
ment costs and greater simplicity and control of neutralization are possible.

       Bituminous Coal Research,  Inc.* ' in their studies also indicated that
activated carbon is an effective catalyst and  reduces the time required for
ferrous iron oxidation to about 60 minutes.  However, the short duration (about
24 cycles) for which this activity  is maintained requires more frequent regen-
eration of the activated carbon making the process economically unattractive.
                               TABLE 5
                    AUXILIARY EQUIPMENT COSTS
Auxiliarv equipment
Piping, valves, etc....
pH meter. ...... ° . <> . . .

Electricity. . 0 .........
Weir and flumes .......
Automatic controls ....
Building .............
Total Cost ....

Plant capacity --gpd
100, 000
$ 1,000
1, 500
1, 500
1, 000
1,500
4, 500
1, 500
$12, 500
300. 000
$ 1,500
1, 500
1, 500
1, 000
1, 500
4, 500
1, 500
$13, 000
500, 000
$ 2, 000
1, 500
1, 500
3, 000
3,000
5, 000
2, 000
$18, 000
1, 500, 000
$ 3,500
1, 500
1,500
3, 000
3, 000
5, 000
2, 000
$19, 500
2. dOO.OOO
$ 5, 000
1, 500
1, 500
6, 000
4,500
6, 000
2, 500
$27, 000
6, 000.000
$ 8, 000
1, 500
1,500
o, 000
4, 500
6, 000
2,500
$30, 000
                                 -162-

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                                     -168-

-------
                              FIGURE 17
             ESTIMATED  CAPITAL COSTS Vs. PLANT CAPACITY
     FOR LIMESTONE TREATMENT PLANT-US. BUREAU OF MINES (REF8)
                        IRON AS Fe+*=50 PPM
                                        	 EXTRAPOLATED CURVE
ICH
 QI
02
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CAPACITY-MGD
30  40 50
                                                                  100
                                -169-

-------
                         FIGURE 18
        ESTIMATED CAPITAL COSTS Vs. PLANT CAPACITY
FOR LIMESTONE TREATMENT PLANT-U.S. BUREAU OF MINES (REF 8)
                   IRON AS  Fe-1"1^ 100 PPM
                                   	 EXTRAPOLATED CURVE
   0        20
CAPACITY -MGD
                                            30  40  50
100
                           -170-

-------
ipoo-
  20-
  IOJ
                                  FIGURE 19

                ESTIMATED CAPITAL COSTS Vs. PLANT CAPACITY
       FOR LIMESTONE TREATMENT PLANT-US BUREAU OF MINES (REF8)
                           IRON  AS Fe++=500PPM
                                      	EXTRAPOLATED CURVE
   O.I
0.2
0.3   0.4  0.5
     1.0
CAPACITY-MGD
2.0
3.0  4.0  5.0
                                                                       10.0
                                    -171-

-------
10
                              FIGURE 20

             ESTIMATED CAPITAL COSTS Vs. PLANT CAPACITY
     FOR LIMESTONE TREATMENT PLANT-US. BUREAU OF MINES (REF8)
                        IRON AS Fe++=1000PPM
 Ql
20    30  40 50
10.0
                             CAPACITY-MGD
                                -172-

-------
                            FIGURE  21

              ANNUAL OPERATING COSTS Vs. PLANT CAPACITY
        FOR LIMESTONE  TREATMENT-U.S. BUREAU OF MINES (REF8)
                        IRON AS FE++=50 PPM
  70r
  60-
co
                                   	EXTRAPOLATED CURVE
0.2
0.3  0.4  0.5
                                  1.0       2.0
                               CAPACITY-MGD
30  40 50
10.0
                              -173-

-------
                           FIGURE  22

            ANNUAL OPERATING COSTS Vs. PLANT CAPACITY
      FOR LIMESTONE TREATMENT-U.S. BUREAU OF MINES (REF8)
                      IRON AS FE++ = IOOPPM
70r
60r
                                  	EXTRAPOLATED CURVE
          0.2    0.3   0.4  0.5        1.0        2.0    3.0  4.0  5.0
                           CAPACITY-MGD
10.0
                             -174-

-------
                             FIGURE  23

              ANNUAL OPERATING COSTS Vs. PLANT CAPACITY
        FOR LIMESTONE TREATMENT-U.S. BUREAU OF MINES (REF 8)
                        IRON AS FE++=500PPM
  70r
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co
O
                  	EXTRAPOLATED CURVE
            0.2
0.3  0.4 05
    1.0        2.0
CAPACITY-MGD
30  4.0  5.0
10.0
                               -175-

-------
                              FIGURE  24


               ANNUAL OPERATING COSTS Vs. PLANT CAPACITY

         FOR LIMESTONE TRE AT MEN T-U.S. BUREAU OF MINES (REF 8)

                          IRON AS  FE++=1000 PPM
  70r
  60-

-------
Combination Limestone - Lime Treatment Process

        The major disadvantages of using limestone as a neutralizing agent in
treating acid mine drainage are:

        1.   The relatively inefficient reaction rate, which in many cases,
            makes lime more economical to use, and

        2.   The pH's in excess of 7 which are necessary for rapid oxidation
            of ferrous iron are not produced.

        Thus,  in spite of recent work to increase the reaction efficiency of
limestone,  it can only effectively compete with lime when treating ferric iron
mine drainage  or mine drainage in which the ferrous iron can be  cheaply oxi-
dized to ferric iron  by biological oxidation or other methods prior to lime-
stone neutralization.

        The logical step would be to combine the limestone and lime  processes.
Since limestone is highly reactive at low pH's, it should be added first to the
acid mine drainage.  Lime being highly reactive to pH 9 and higher,  should be
used to "polish" the limestone treated water.  In this manner, combination
limestone - lime treatment enables both limestone and  lime to be employed as
neutralizing agents in their most efficient ranges of reactivity.  The lower
cost of limestone and the improvement in sludge characteristics as a result
of using this material are  advantages which should lead to an overall cost re-
duction when both limestone and lime are employed in neutralizing acid mine
water.

        This approach was investigated by the Environmental Protection Agency^   '
at the Norton Mine Drainage Field Site, Norton, West Virginia.   The mine drain-
age used in the batch scale studies and in the later pilot plant operation was from
a heavily polluted stream in which it is estimated  that 90 percent of  the flow is
from abandoned mines; about 70 percent of the pollution flows directly out of
underground mines.  The mine drainage has the following significant chemical
characteristics:

                                                   Mean
              pH          2.5 to 3.4            2.8*
              Acidity      134 to 640 mg/1       430 mg/1
              Calcium       18 to 170 mg/1       106 mg/1
              Magnesium   21 to 120 mg/1        35 mg/1
              Aluminum     18 to  69 mg/1        33 mg/1
              Sulfate       76 to 1200 mg/1       590 mg/1
              Total Iron     14 to 170 mg/1        92 mg/1

              *Median Value

       Virtually all the  iron present in this  mine drainage was in the ferric
state.

                                 -177-

-------
       In order to obtain the smallest particle size commercially available,
the "rock dust" form of limestone was used.  The cost of the limestone was
$6 per ton and lime was $18 per ton.

       The combination limes tone-lime treatment provided greater than 25
percent reduction in material cost for treatment to pH 6.5  of the Norton acid
mine drainage as  compared to straight lime or limestone treatment.  In add-
ition to the materials cost advantage,  combination treatment produced a
sludge whose  solids contents were up to five times higher than sludge produced
by lime neutralization, though not as  high as sludge from limestone neutrali-
zation. The volume of sludge produced by combination treatment was  roughly
one-third that of lime treatment and slightly less than limestone  sludge volume.

       Although the study was performed on ferric iron water, the combination
limestone-lime treatment should be applicable to virtually  all acid mine drain-
age situations.  Whether or not an economic advantage can be realized is a
matter which  can  only be determined  by evaluating each individual site and its
required process  parameter.  The variables which must be considered are:

       1.   Raw material costs of "rock dust" limestone and hydrated lime.

       2.   Effectiveness of limestone in acid mine drainage treatment
            (composition of limestone).

       3.   Reaction time.

       4.   Treatment pH

       To determine the effects of raw material costs  for lime and limestone
on process economics, the data on Table 12 was chosen by Wilmoth, et. al. ^  '
as an example.  Both the lime and limestone raw material  costs  were  varied
and the cost reduction calculated. Their plot of the resulting data is shown on
Figure 25.  When the lime /lime stone raw material cost ratio is less than
1.8:1,  the cost  advantage of combination treatment over  lime treatment no
longer exists.  As the lime/limes tone ratio increased, so did the advantage
of combination, treatment.

       In an example, they assumed the water treated in Table 12 was all fer-
rous iron mine  drainage  and a pH in the range of 9. 0 would be required for
efficient oxidation by aeration.   In this example, roughly 20 percent more lime
would  be required (verified by titration tests) to affect the pH increase from
6.4 to  9.0.  Thus, side 2 in Table 12 would require an additional 0.727 Ibs./
1, 000  gallons of lime (20%  of 3.634) for a total of 4. 361.  The amount of lime-
stone required by side  1 would  not change but the amount of lime would be
increased by  the same  0. 727 pounds to 2, 078  Ibs. /I, 000 gallons  of water.  The
cost reduction due to combination treatment would decrease to 21.4 percent
(lime/limestone raw material cost ratio of 3:1 when limestone =  0. 30/lb.  and
lime = 0.90/lb.)
                                 -178-

-------
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                     -179-

-------
       If 70 percent more lime were  required to increase the pH from 6.4
to 9. 0,  then the  cost advantage of combination treatment over lime would
decrease to 15. 1 percent (lime/limestone raw material cost ratio of 3:1).

       The combination treatment appears to offer nearly as great an eco-
nomical advantage in ferrous iron situations as in  ferric ones.  Although
combination treatment requires a higher initial investment in equipment, it
appears  the advantage  realized in reagent cost reduction can quickly offset
this increased initial expenditure.
       2.000
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                                 FIGURE  25
               LIME/LIMESTONE COST RATIO AND PROCESS COST REDUCTION
                                                                      Z
                                                                      ui
                                                                      u
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                                                                      Z
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           After Wilmoth,et al., 1972
                               (u)
                                  -180-

-------
Combination Lime-Limestone Neutralization with Rotary Precoat Filtration
for Sludge Dewatering

        The combination lime-limestone neutralization process was  employed
                  M 9  1 "2 \                                               J
by Davis, et, al. , I   '   ' in conjunction with rotary precoat filtration for de-
watering the sludge produced from neutralization of mine drainage.   Pilot
plant operation was performed at five  sites. A schematic flow-diagram of the
process used at Hollywood,  Penisylvania, the  fourth site,  is shown in Figure
26.  The raw water was obtained from the pump well of the Proctor 2 pumping
station feeding the Hollywood, Pennsylvania experimental mine drainage treat-
ment facility.  The chemical characteristics of the mine drainage treated  at
this site are: pH - 3. 0,  total iron  - 653 mg/1,  ferrous  iron - 445 mg/1, total
acidity - 1, 560 mg/1 and total solids - 4, 110 mg/1.

        The pilot plant treatment system was fabricated from the following
equipment:

1.   U.S.  Bureau of Mines' four foot diameter  by 24 foot long tube mill'  ' which
     was used to produce a fine limestone slurry from one-half to two inch rock.

2.   The Pennsylvania Department of Environmental Resources' Operation Yellow-
     boy Trailer.  This trailer contains a variable capacity feed pump, a 50 gallon
     flash mixer with agitator  and screw feeder, a. 1,200 gallon agitated aerator
     tank with a 17 cfm blower-sprayer unit, a 1, 000 gallon thickener, and a
     variable speed sludge recycle/discharge pump.

3.   A Johns-Manville rotary  vacuum precoat filter (6  inch face and 36 inch
     diameter) with a variable speed drum drive,  variable speed  knife advance
     and 30  and 50 percent submergence ports in the filter bowl.
                                                              (13'
       The conclusions reached as a result of this investigation1  '
were:
1.  The sedimentation and filtration unit processes were  found to be the major
    factors contributing to treatment costs for systems using chemical neutra-
    lization followed by solids  concentration and dewatering via rotary vacuum
    precoat filtration.

2.  The optimum economic system design for a given chemical process can
    be found by optimizing the  individual unit processes with the  exception of
    the sedimentation and filtration processes.  Due to the interaction between
    these processes,  they should be considered as a single-unit process  in
    optimizing the design of the system.

3.  The use of polyelectrolytes appeared to offer  an economic means  of in-
    creasing sludge concentration,  thereby reducing the sludge volume and the
    respective filtration costs.
                                 -181-

-------
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-------
4.   The presence of unreacted limestone appeared to enhance the settleability
     and filterability  of the sludge.

5.   Chemical neutralization with a combination of limestone and lime offers a
     definite cost advantage over lime alone and operational advantages over
     limestone alone.

6.   Production  of fine  limestone  slurry by attrition of rock in a wet mill on-
     site appeared to be the most  economical method for feeding limestone.

7.   Optimum conditions for operation of the rotary  vacuum filter are a drum
     speed on one revolution per minute,  30 percent submergence,  a CELITE 501*
     precoat and a knife advance of 0. 001 inches per drum revolution.

*A proprietory diatomaceous earth filter.

        Cost estimates  based on the system shown in Figure 26  are presented
in Tables 13 and 14.  These cost  estimates  were computed from values found
in the literature and updated to 1970 economics by use of the Marshall and
Stevens Equipment Cost Index.  For this  study,  it is assumed the updated cost
estimates were  equivalent to an ENR  Cost Index of 1425  (1970) and they are
further updated  to reflect an ENR Cost Index of 1700 (April,  1972).  The  1972
cost estimates were plotted and the resulting curves are shown on Figures  27,
28 and 29.
                                -183-

-------












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                            FIGURE 27

         ESTIMATED CAPITAL COSTS FOR VARIOUS SIZE PLANTS
     USING INCREASED EFFICIENCY LIMESTONE-LIME PROCESS (REF12)

         ROTARY PRECOAT FILTRATION FOR SLUDGE DEWATERING

            FOR MINE DRAINAGE CHARACTERISTICS SEE TEXT
   60
   5.5
   5.0
   4.5
   4.0
o

-------
                               FIGURE  28
ESTIMATED CAPITAL COSTS FOR VARIOUS SIZE PLANT COMPONENTS
 USING INCREASED EFFICIENCY LIMESTONE-LIME PROCESS(REF12)

      ROTARY PRECOAT FILTRATION FOR SLUDGE DEWATERING

          FOR MINE DRAINAGE CHARACTERISTICS SEE TEXT
   icpoo
§     ROTARY PRECOAT FILTER  	
     INSTALLATION AND PIPING 	
     CONTINGENCIES AND ENGINEERING
 " (4) THICKENER AND SLUDGE PUMPING
 _ © SLUDGE DISPOSAL
  © INSTRUMENTATION
	(?) LIMESTONE STORAGE BIN, FEEDER a REACTOR
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-------
                           FIGURE  29


         ESTIMATED OPERATING COSTS FOR VARIOUS SIZE PLANTS

      USING INCREASED EFFICIENCY LIMESTONE-LIME PROCESS(REF 12)



         ROTARY PRECOAT FILTRATION FOR SLUDGE DEWATERING


            FOR MINE DRAINAGE CHARACTERISTICS SEE  TEXT
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                          CAPITAL AMMORTIZED
                              3        4

                         PLANT SIZE-MGD
                             -188-

-------
Electrochemical Oxidation Followed by Limestone Neutralization

        Tyco Laboratories, supported by the Environmental Protection Agency,
has developed an electrochemical oxidation process to oxidize ferrous iron be-
fore subjecting the mine drainage to limestone neutralization, Gaines, et. al,
1972'-*-'*'  -*>.  The logic being.that unlike most waste liquids,  the high acid con-
tent of acid mine drainage produces  a material of reasonable ionic conductivity.
In addition to accomplishing the desired oxidation,  electrolytic hydrogen is pro-
duced as a by-product.  At high AMD treatment rates,  the  recovery of this
hydrogen can produce a significant cost savings for  the overall treatment process.

        Basic Electrochemical Parameters  - An acid mine  water can contain on
the average 500 mg/1 of Fe^+ and 1, 000 mg/1 H+. Also present are variable
amounts of aluminum,  calcium and manganese. As  such, AMD is an electroly-
tically conducting solution and is capable of being treated electrochemically
without resort to additional additives.   The pertinent electrochemical reaction

        Fe2 +—- Fe3+ + e"

is carried out at an inert (nonconsumable)  anode.  Concurrently,  on an inert
cathode, the reaction

       H4" +  e" 	-1/2 H2

will result in the removal of  1 mole  of acid (and the  generation of 1/2 mole of
hydrogen gas) for every mole of iron that is oxidized.

       Carbon anodes, formed from a packed bed of activated carbon (4  x 10
mesh granules),  were employed since  carbon is inexpensive, readily available
in a variety of forms, resistant to chemical attack,  and has a wide potential
range over which it is electrochemically stable (i.e. does not evolve QZ,  1^2 or
dissolve).  As a cathode, 316 stainless steel perforated sheet was used since
this readily available material  is highly resistant to corrosion  in  dilute sulfuric
acid solutions.  The  perforations in  the cathode sheet allow the generated hydr-
gen bubbles to leave  the reactor without obstructing  electrode area.

       Reactor Configuration - Treatment of 6, 000  gal. /hr.  of AMD containing
500 mg/1 Fe^+ is considered  as the base design of the packed bed reactor.  The
ferrous concentration is to be reduced to five percent (5%) of its original value.

       The proposed reactor configuration developed from experimental data
is outlined in Figure 30.  The reactor  is constructed in two series-connected
vertical tanks,  each  8 feet high by 3 feet wide.  Each tank is  partitioned  by
perforated stainless  steel sheet into 35 flow channels, 1 inch wide,  each treat-
ing 170  gal. /hr.  of AMD.  Each unit would thus be about 5 feet long for a total
reactor volume of 240 cu. ft.
                                 -189-

-------
         8 FT.
                              UNTREATED
                             1 AMD     GENERATED
                                     HYDROGEN
                                            CATHODE
                                                 .PACKED BED ANODE
                                                 '" WIDE
                            -OXIDIZED AMD
                            (TO NEUTRALIZATION)
                           FIGURE 30
         Oxidation Unit for Treating  6,000 gal./hr.
                      of  500 mg/1 Fe* + AMD


From:  Gaines,  et  al. , 19?z(14)
                               -190-

-------
       Devices capable of treating more than 6, 000 gal. /hr.  of AMD would be
simple multiples of the proposed design.  Thus the oxidation  reactor  for a large
AMD treatment plant operating at a peak process flow of 1, 000, 000 gal. /day
would occupy approximately 1,650 cu, ft.

       Capital Costs - The capital cost analysis for a 6, 000 gal. /hr. , 95% con-
version, oxidation reactor are as follows:

       Reactor
            Stainless steel tank       $10,000   Vendor Quote
            Carbon bed @ 0.50/lb.       2,100
            Other                       1,400
                                       13,500
       Installation and start-up costs    6, 700
               Total Cost             $20,200

       Net  Capital Cost: 2.6^/1,000  gal. treated (25 yr. life, 4-1/2% interest
                         charge)

       Due  to the modular nature of electrochemical devices, the  capital charge
of 2.6^/1,000 gal. is generally applicable to all situations where a conversion
of 95% is desired.  The capital costs  for conversion of 90% and 99%,  i.e., for
initial Fe   concentrations  of  50 mg/1 and  1, 000 mg/1 treated to final ferrous
content  of 5 mg/1 are:

                   Conversion,        Capital Charge,
                                           OOP gal.
                       90                   1.9
                       95                   2.6
                       99                   3.8

       Not included in the capital charges are the initial costs associated with
the AC -DC rectifying  and control circuits required for the operation of the oxi-
dation reactor.  These costs  are sensitive to both AMD flow rate and initial
Fe    concentration, as well as the desired conversion.

       In addition to the capital charges  described above,  the only other cost
peculiar to the direct  oxidation concept is the power cost associated with the
oxidation reaction.  Labor and maintenance  charges are not significant.  The
electrochemical treatment step requires no  operating  labor and is easily con-
structed in a failsafe configuration.

       The cost of the electrochemical oxidation step  is compensated by cost
reductions in other parts of the treatment scheme.  These cost reductions
accrue from the elimination of aeration equipment, the use of cheaper lime-
stone rather than lime to precipitate iron, and a reduction in equipment size
and disposal problems due to the denser  more rapidly settling  sludge produced
by the limestone treatment.
                                 -191-

-------
       The clarifier and/or settling pond requirements for limestone treat-
ment of ferric mine water, containing less than 5 mg/1 Fe^ + were estimated.
Primary settling, performed in a conventional clarifier-settler with a 1 hour
residence time, would discharge  10% of the total stream flow to a settling
pond/storage  basin for final compaction and disposal.  The use of a primary
clarifier, by reducing the sludge volume and increasing its solids content to
6 to 10% by weight,  facilitates sludge disposal in shallow lagoons or abandoned
mine shafts.  The costs associated with the final storage volume required are,
of course,  dependent on the initial acidity and iron content of the AMD.

       AMD Treatment Plant Design and Economics  - Since AMD  varies  widely
in composition as well as flow rate, three flows and three ferrous iron concen-
trations were selected by Tyco Laboratories in order to represent a variety of
possible situations.

                    AMD Compositions and Flow Rates

       Flow Rate,       Fe2 + Concentration,        Total Acidity
        gal, /day        ______ S3&/I __        _ mg/1
          250,000              1,000                   2,000
        1,000,000                500                   1,000
        6,000,000                 50                     500

       The basic  treatment scheme proposed was the same in all cases.  Under
the conservative assumption that no ferrous iron will precipitate during  lime-
stone treatment, the oxidation reactor was designed for a final maximum Fe
concentration of 5 mg/1.  Since the flow of mine drainage will vary to some ex-
tent,  even on a daily basis,  a holding pond with a controlled output was provided.
For plants with a  low flow rate,  the holding pond would also be used for AMD
storage, thereby reducing labor charges since continuous plant operation would
not be necessary.

       Limestone slurry would be produced by loading a tumbling  mill with bulk
limestone and providing a flow of water to give the slurry concentration desired.
Limestone containing 75% CaCC>3 costing  $5 /ton F.O.B.  was used as a basis for
estimating equipment size and operating costs.

       The AMD from the holding pond is fed to the electrochemical oxidation
reactor.  Following oxidation, the limestone slurry is added  to the ferric mine
water in a simple  neutralization reactor.   In the  absence of ferrous iron, the
precipitation  is  rapid and in a form favorable to rapid settling. A primary clari-
fier is used to separate the  rapidly settling dilute sludge (about 10% of the total
stream flow)  from the iron free  supernate.  The  underflow from the primary
clarifier is sent to settling lagoons for final compaction and storage.
                                  -192-

-------
       The investment costs for the AMD treatment plants are listed in Table
15.  Sizing of the process equipment was based on operating times of 8 hr. /day
for the 250, 000 gal. /day rate, 16 hr. /day at the 1, 000, 000 gal. /day rate, and
continuous operation at 6, 000, 000 gal. /day.  Holding pond capacities were ad-
justed to provide a 30 hour retention volume.  Process stream flows are thus
41, 600 gal. /hr. , 104, 000 gal. /hr.  and 250, 000 gal. /hr. ,  respectively.  The
capital costs associated with final sludge disposal are considered by Tyco Lab-
oratories to be too variable to be included without reference to a specific lo-
cation, this investment requirement is not included in the analysis.

       The estimated operating expenses (exclusive of final sludge costs) are
shown in Table 16.  For 500 mg/1 Fe2+,  the operating costs range from 20£/
1, 000 gal. at 6, 000, 000 gal. /day to 55£/l, 000 gal.  at 250, 000 gal. /day.  Tyco
Laboratories found that comparable figures  for current approaches to AMD
treatment were not readily available.  In the one case where operating data was
available(16), a lime cost alone of 13^/1, 000 gal.  was reported for a plant treat-
ing about 3, 000, 000 gal. /day of 200 mg/1 Fe2+,  700 mg/1 H+ AMD. They found
reported values for  total treatment  costs (including capital charges) range from
    to $2/1,000 gal.  treated.
       The data in Tables 15 and 16 were updated to reflect prices in April,
1972 (from an ENR Construction Cost Index of 1575 to 1700).  The updated
costs were plotted and the resulting cost curves are shown in Figures 31 and
32.

       Credits for hydrogen production can only be estimated.  Treatment  of
1, 000 gal. of AMD containing 500 mg/1 Fe2 + will result in the generation of
15 cu. ft.  of hydrogen.   Optimized electrolytic hydrogen plants  can produce
H2 at about 30^/100 cu.  ft.  Shipping charges will range from 20£ to  $1/100
cu. ft. depending on distance and method.  If the  by-product hydrogen can be
sold at a credit (after collection and packaging costs) of 40^/100 cu.  ft., the
credit to the treatment process would be 6£/l, 000 gal. of AMD  treated.  At
AMD flow  rates of 6, 000, 000 gal. /day, this by-product return would repre-
sent a savings  of 30% on total treatment costs.  For streams  containing 1,000
mg/1 Fe2"^, the savings approach 50% of total costs.

       Although the cost of electrochemical oxidation of ferrous iron followed
by neutralization appears attractive,  it must be understood that these are esti-
mates developed from bench scale experiments with no supporting data from
full scale operations.
                                 -193-

-------







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                              TABLE 16
               ESTIMATED OPERATING EXPENSES FOR
   DIRECT ELECTROCHEMICAL OXIDATION TREATMENT PLANTS,
                               , 000 GAL.*
Flow Rate, Gal. /Day
Fe2+, mg/1
Acidity, mg/1
Treatment Power, 5 V
Plant Power
Limestone
Labor + Overhead
Depreciation
Total Costs
250, 000
50 500 1000
500 1000 2000
0.5 5.3 11
333
248
16 16 16
15 27 34
37 55 72
1, 000,000
50 500 1000
500 1000 2000
0.5 5.3 11
333
248
888
8.2 16 19
22 36 49
6,000,000
50 500 1000
500 1000 2000
0.5 5.3 11
333
248
222
367
11 20 31
Basis: Power at 1^/KWhr.
       Depreciation at 10% of investment
       Limestone at $6.67/ton (10% of basis)
       Labor + overhead at $5/hr.
       Plant On-Stream 8, 12 and 24 hours/day respectively

*Lime treatment range 20£ to $2/1,000 gal.

After Tyco Laboratories, Inc.,  1972(15)
                                -195-

-------
                                 FIGURE 31
                ESTIMATED CAPITAL COSTS Vs. PLANT CAPACITY
  FOR ELECTROCHEMICAL OXIDATION AND LIMESTONE NEUTRALIZATION TREATMENT
                  AFTER TYCO LABORATORIES, INC (REF 15 )
100
  O.I
0.2
0.3  04  0.5
   1.0         2.0
CAPACITY-MGD
                                                        4.0 5.0
10.0
                               -196-

-------
                                FIGURE 32

          ESTIMATED ANNUAL OPERATING COSTS Vs. PLANT CAPACITY

 FOR ELECTROCHEMICAL OXIDATION AND LIMESTONE NEUTRALIZATION TREATMENT

                 AFTER TYCO LABORATORIES,INC.(REF. 15 )
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                               -197-

-------
Biochemical Oxidation Followed by Limestone Neutralization

       The existence  of certain bacteria, commonly known as the acidophilic
iron bacteria, that specialize in the oxidation of ferrous to ferric iron at low
pH values has been known for years (^).  In fact,  these micro-organisms have
been isolated from many mine discharge waters.

       Acidophilic iron  bacteria are autotrophic (do not require organic sub-
stances for growth) and  are  classified as  the Thiobacillus-Ferrobacillus group.
These  bacteria utilize carbon dioxide as their source of carbon and oxidize
ferrous iron to the ferric state in order to obtain  energy to drive their cell
machinery.  In addition  to carbon dioxide, oxygen and ferrous iron,  these  or-
ganisms also require  lesser quantities  of nitrogen and phosphorous and trace
amounts of other minerals ( •"•").
                  demonstrated that this microbial catalytic activity can be
economically utilized to satisfactorily prepare ferrous acid mine drainage
water for limestone treatment.  His studies indicated that complete  treatment
of an acid mine drainage could be achieved by preliminary  biochemical oxi-
dation  to convert ferrous salts to ferric, followed by neutralization with lime-
stone.   A pilot plant was constructed in Great Britain to demonstrate the whole
process.  A flow diagram of the plant is shown in Figure 33 and a dimensioned
sketch in Figure 34. The plant includes biochemical oxidation reactors, a new
upflow expanded bed limestone reactor, a sedimentation vessel, and a sludge
filter.   The typical  operating characteristics are summarized in Table 17.

       Glover's patented process employs recirculation of active  sludge con-
taining an active biological culture  of acidophilic bacteria and in this respect
is similar to the activated sludge treatment of municipal sewage and certain
industrial wastes.   On  the pilot scale, it was possible to find sufficient de-
posited sludge in the mine drainage feed tank and in the limestone reactor
pump feed tank to start the biochemical reactors at a high rate.   On the large
scale,  it should be possible to start a plant by agitating the deposits in the
feed channels of the acid mine drainage and by driving  the suspension forward
into the process where it would be retained'  "'.

        The neutralized drainage discharged from the limestone  reactors was
foand to have relatively poor  initial settling characteristics. Lime settling did
not occur and it was necessary to design sedimentation basins on a basis of
retention time for coagulation.  Retention for four hours without any special
flocculating equipment  or reagents  produced a supernate having  a suspended
solids  content of less than 20 rng/1  which would be adequate to meet most re-
quired standards for discharges to  inland watercourses in Great Britain. The
supernate  contained most of the manganous salts which had been present in
the original mine drainage although some of the manganese  had been absorbed
by the  limestone neutralized sludge (Table 17).
                                  -198-

-------
                                FIGURE  33

             Flow Diagram of Complete Biochemical  Oxidation
                  and Limestone Neutralization Process
Acid Mine
Drainage
Air
Limestone
  Grit


Biochemical
Oxidation
,

—

Sedimentation

                                                                       Treated
                                                                       Effluent
                           Active
                           Sludge
   After Glover, 1967(I9)
                                      Cake To
                                      Waste
                                   -199-

-------
                           FIGURE 34
  Acid Mine
   Drainage
                                     Air Supply
                               Main, 8gal./min., 5lb/in2
                                 Air Lift,0.5tol.3gal./min.
              Meterings
               Pump       Oxidizing Reactors
             0 to l.3gal./min.    3x26.4 gal.
                       Active Sludge
                 •LT^ Recovery 39.6 gal.
   Rest level of
   Limestone
           Float
           Switch
                                  -Attritor
                                                        -Sludge Rake
                               Purified
                               Effluent
   Pump Feed     Feed Pump
Tank approx.2IOgal.  5gal./min
   f                6lbs./in.2
Two Limestone Grit
Reactors,IOft. high
6in I.D.
       Dimensioned sketch of experimental pilot
     scale biochemical oxidation and limestone
     neutralization plant for acid mine drainage
     treatment. The volume proportions of the
     unit items of equipment are not necessarily
     in the optimum ratio.
     Volumes converted to U.S. gallons from
     liters and imperial gallons.
     After Glover, 1967 09)
                                                        Clarifier/Thickener
                                                         I2OO gal. approx.
                                      Filter
                                      Cake
                      Rotary Vacuum
                      Drum Filter
                      I ft.2Active Area
                           Not To  Scale
                             -200-

-------
                              TABLE 17

      TYPICAL OPERATING CHARACTERISTICS OF PILOT SCALE
BIOCHEMICAL OXIDATION AND LIMESTONE NEUTRALIZATION PROCESS
     (COMPONENTS IN SOLUTION UNLESS OTHERWISE SPECIFIED)
Parameter
pH value
Ferrous mg/1 Fe
Ferric og/l Fe

Aluminium QgA Al
Manganese mg/1 Un
Calcium mg/1 Ca
Magnesium mg/1 Mg
Sodium mg/1 Na
Potassium mg/1 K
Sulphate mg/lSO,
Chloride mg/1 Cl
Silica mg/1 Si02
Carbon dioxide mg/1 C02
Combined Nitrogen mg/1 N
Arsenic mg/1 As
Total solids (dissolved)
mg/1
Suspended solids mg/1
Plow rate, max 0°C 1/min

Flow rate, max 10 C
1/min
Flow rate, max 20°C
1/min .
Influent
3.0
100-300
100-300

20-50
20
200
150
100
15
1500-2000
40
30
200
1-3
<0.02
2500
0-10,000
0.5
(cont)
2
(cont)
5
(cont)
After
oxida-
tion
and
Sedimen-
;ation
2.8
< 5
200-600

20
20
-
-
-
-

-
-
1
-
-
-
10
M

—

•.

After
Neutra-
lisation
5.8-6.5
< 5
0

0
16
-
-
-
-
-
-
-
-
-
-
-
1000
18
(int)
18
(int)
18
(int)
TJater
Phase
after
Second
Sedimen-
tation
6.0-6.5
< 1
0

0
11
-
-
-
-
-
-
-
-
-
-
-
<20
18
(int)
18
(int)
18
(int)
Sludge
Phase
after
Second
Sedimen-
tation
_
-
-

-
-
-



-
-
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-
-
-
-
9-12J8
0.005
(cont)
0.02
(cont)
0.05
(cont)
Sludge
Phase
after
filtra-
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—
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-
-
-
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 After Glover,
                               -201-

-------
       After consolidation for a few days, the sludge from the neutralization
process had a relative volume of about one percent (1%) of the volume of mine
drainage processed,  and a solids content of 9 to  12 percent.  This was a con-
siderable improvement compared to the  sludge accumulation from lime treat-
ment of the same acid mine drainage which had a relative volume of about ten
percent (10%) and a solids content of about one percent (1%).  The tenfold re-
duction in the volume of sludge produced is considered to be the main advantage
of the biochemical  oxidation/limestone neutralization process.

       The filtration rate of the sludge  averaged 7 gal. /ft.  /hr.  From this
data it was calculated that vacuum filters of a total filtration area 250 ft.
operating 10  hr. /day, 7 days/week, would be sufficient to dewater the sludge
produced by biochemical oxidation/limestone  neutralization 01 1, 000, 000  gal. /
day of  acid mine drainage containing about 300 mg/1 of dissolved  irom '».

       The lower limit of acidity of an acid mine drainage which  can be treated
by this process  is determined by the pH  value of the drainage after  it has been
oxidized.   The pH value of the drainage as discharged from the mining oper-
ation may be an insufficient guide since, for example,  ferrous sulfate solutions
containing  hundreds of mg/1 of iron are stable at almost neutral pH values.
The process  should be applicable to mine drainages which contain at least 10
to 20 mg/1 of dissolved iron and a total acidity of 25 mg/1 (CaCO^) or more.

       The upper limit of acidity which can be treated  by the process would be
determined by the sulfate tolerance of the limestone process.  It  would prob-
ably be safe to assume that the upper limit will be  5, 000 mg/1 804, but it is
possible that higher limits may be  acceptable due to the effect of  the attritors( *9)
Higher limits would be possible if the reaction temperature was less  than 15° C.

       The extreme  temperature limits  for the complete process are expected
to be 0° C  to 35° C,  with a preferred working range of 5° C to 25° C. Tem-
peratures up to 30° C would increase the activity of the biochemical oxidation
stage,  but  temperatures  down to  5° C would raise the  sulfate tolerance of the
limestone stage.

       The inability  of the process to remove manganese salts  from an acid
mine drainage is a distinct disadvantage which would be more acute at some
sites than others.  In general,  manganese salts are as much a pollutant as are
ferrous salts, although manganese  salts do not produce such an obvious dis-
coloration  of the stream bed.

       The physical  limitations of Glover's process are:  1) the mine drainage
must be at least slightly acidic, but not seriously contaminated with acidity,
2) the temperature must not be extreme,  and  3) the manganous  salt content
should not  be excessive.
                                 -202-

-------
        A  cost estimate was made by Glover'^' for treatment of an acid mine
 drainage discharge from a shallow underground coal mine.  The discharge
 having a peak flow rate of 840, 000 gal. /day*,  a maximum consecutive period
 of 21 days at peak flow,  and an average flow rate of 240, 000 gal. /day*.   The
 quality of the influent, effluent and cake from  the biochemical limestone pro-
 cess are as shown in Table 17.  The quality of products from the lime process
 are as near as possible  similar.

 **Estimated Costs $ I/Year    Lime Process    Biochemical/ Limes tone Process

        Highest Probable
                Capital           $332,575            $154,760
                Operating           53,000              31,005
        Lowest Possible
                Capital             52,470              31,138
                Operating           58,035              33,920

 *Converted from imperial to U.  S. gallons
**Converted from British Pounds - One Pound  Sterling = U.S.  $2.65

        It  is evident  the process, based on the  above cost  estimate,  would have
 a distinct cost advantage over the lime treatment process at the particular de-
 gree of contamination represented by the sample mine drainage. It is expected
 the cost advantage would increase as the mine drainage became less contamin-
 ated since the lime process becomes progressively more difficult to operate
 with the less contaminated mine waters.  Conversely, the lime  process  in-
 creases in efficiency as the degree of contamination rises.  The break point
 at which the lime process becomes cheaper than the biochemical limestone
 process is not known, but it may be above the  upper limit for the sulfate  con-
 tent of the biochemical limestone process,  in  which event it could conceivably
 be cheaper to dilute  the  acid mine drainage to  bring it within range of the bio-
 chemical  limestone  process, although this would increase the load  of dissolved
 calcium salts discharged from the process.

        As a generalization,  it may be concluded that  the biochemical limestone
 process will find its application  in the purification of  the less contaminated acid
 mine drainage, and  that the conventional lime  process will  be more applicable
 to the most highly contaminated  acid mine drainages.  The  two processes are
 thus to some extent  complementary rather than competitive' ''.

        Continental Oil Company* °' conducted studies to determine the abilities
 of acidophilic bacteria to oxidize ferrous iron  or to convert sulfate to hydrogen
 sulfide and reached  conclusions  similar to that of Glover.   They also found that
 series multistaging  of microbial oxidation vessels offers operational efficiency
 over a single oxidation vessel.  However, attempts of Continental to go from a
 1-1/2 gallon bench size  microbial oxidation system to a 1, 000 gallon pilot plant
 oxidation  vessel were not successful. As a result of  their experiments,  they
 also found that although  sulfate-reducing bacteria are present in acid mine drain-
 age water, they will not grow or produce E^S  at pH values below 5. 5.
                                  -203-

-------
       Lovelr   ' conducted studies at the Pennsylvania State University Ex-
perimental Mine Drainage Research Facility, Hollywood, Pennsylvania, and
effectively treated waters containing up to 100 mg/1 iron II in a limestone
system without a separate iron oxidation  step.  Waters containing between
100 and 500 mg/1 iron II were successfully oxidized biochemically to levels
well below 100 mg/1 iron II and subsequently they responded  satisfactorily to
the limestone reaction.

       A bacterial strain, designated "Z, " was cultured from Hollywood waters
and utilized in these studies.  It was presumed to be Ferrobacillus ferrooxidans.
Advantages  in initiating the biochemical oxidation system were experienced
from inoculation with laboratory cultures, but continued  introduction of inocu-
lant need not be maintained.  Similarly, the addition of bacterial nutrients was
helpful to initiate growth but  need not be continued.  A bacterial culture at a
minimum level of 10" cells /ml appeared  necessary and was maintained for the
study.
       At Hollywood,  Lowell\    employed an oxidation reactor in the form of
a trickling filter similar in design to a conventional sewage trickling filter
(Figure 35).  It was filled with inert, minus four inch (-4") argillite to a depth
of five (5) feet.   Hydraulic loading rates to this reactor were maintained at
levels up to 0. 16 GPM/square foot.   There were no power or labor require-
ments for this operation which is an obvious advantage.  A disadvantage to
using a stone -filled trickling filter is that it is liable to get plugged with sludge
build up; experimental work on plastic filter media with high void ratio is  ex-
pected to solve  this problem.  A rotary tube mill is utilized as the limestone
reactor and the water retention time  in the reactor was slightly over two min-
utes.  Reactor power  requirements ranged between 0.5 and 1.2 cents/ 1000
gallons with power priced at  1.7 cents /KWH.  The rotary reactor was contin-
uously charged  with limestone.  The  most satisfactory limestone  appeared to
be a quarry waste which was relatively soft and degradable.  Effluent from
the limestone reactor goes to an upflow clarifier.  Frequently limestone sludges
with solids  content as high as 15 percent  by weight were obtained.  Porous bot-
tom sludge drying beds dry  this sludge to one -fourth of its original volume,
95 percent of  the drying taking place  in the first 48 hours.  Similarly, the dry
solids rate  of limestone sludges from precoat vacuum filtration ranged from
300-1, 200  Ibs. /ft. 2/24 hours.   At 25 - 50 percent moisture in contrast to
30 - 40 Ibs. /ft. 2/24 hours obtained with lime-produced sludges.  Detailed cost
estimates have  not been developed for these facilities.
                                  -204-

-------
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-205-

-------
Ozone  Oxidation Followed by Limestone Neutralization

       An engineering design and economic study to evaluate the feasibility
of ozone oxidation and limestone neutralization of acid mine  drainage was
performed by Seller, Waide and Steinberg'  ^' at Brookhaven National Lab-
oratory.  The chemistry of using ozone for oxidation in low pH solutions is
expressed by the following equations:

       (1) Oxidation

                2 Fe+2 + 03 + 2 H + ^1 2 Fe+3 + H2O + O2

       (2) Hydrolysis

                Fe + 3 + 3

       (3) Neutralization

                3 H++ 3 OH" T~*" 3 H2O

       Because acid  mine waters range widely in flow rate and composition,
three flows and ferrous  iron compositions were selected for the study which
generally encompass the conditions at typical acid mine drainage  sites.  The
acid mine drainage flow rates  chosen are 250, 000,  1, 000, 000 and 6, 000, 000
gallons per day,  containing ferrous iron contents of  50,300  and 1,000  parts
per million.  The Fe+2  and  total acidity used for the study are summarized
below.  For  simplicity,  any acid resulting from the hydrolysis of metal ions
other than iron was ignored.

            Fe+2 Cone,  ppm     p_H     Total Acidjmg/l CaCOs)

                 1,000          2.5             1,900
                   300          2.5               650
                    50          2.5               200

       Figure  36  shows the  acid mine drainage oxidation neutralization pro-
cess system using ozone for oxidation of ferrous iron.  The  ozone is pro-
duced  as a mixture containing  1.7 percent by weight of ozone (1%  by volume)
in a gaseous oxygen stream.  It is supplied to the oxidizing contactor,  and
after reacting with the AMD, is recycled to ths ozone production unit.  A
turbine type  mixer is used in the oxidizing vessel as  the contact device.

       Ozone requirements  for the various cases on which the study was based
are as follows:
                                 -206-

-------
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-207-

-------
                 Ozone Requirements for AMD Streams
                            Ibs. /day Ozone

                                 AMD Stream Flow-gal. /day
          Fe   Cone, -ppm    250.000    1,000,000    6,000,000

                   50              52         208         1,248
                 300             312       1,248         7,488
               1,000           1,040       4,160        24,960

       The ozone requirements are based on the sto.ichiom.etry of the oxida-
tion reaction:

       2 Fe+2 + O3 + 2 H+—— 2 Fe+3 + H2O + O2

       The following methods of ozone production were  examined in the study
for their economic  feasibility.

       1.  Electric discharge in oxygen.

       2.  Electric discharge in air.

       3.  Chemonuclear (Fission Fragment)

       4.  Isotopic sources (Gamma)

       Tables 18 through 24 present the cost estimates  worked out  by Seller
et al.'"),  which are plotted in the form of cost curves in Figures  37 through
40.

       Beller et al.   ',  also worked out the investment cost necessary to
treat the entire acid mine drainage of southwestern Pennsylvania,  estimated
at 486, 000, 000 gal. /day.  The cost of $182, 000, 000 is based on the use of
a 200-ton per day central chemonuclear ozone plant.  The investment cost in-
cludes ozone storage and shipment facilities and AMD treatment equipment
at each of the approximately 2, 160 sites in the region.  Each site was assumed
capable of handling an average flow of 250, 000 gallons per day.  A central
electric discharge plant would  require an investment of about $191, 000, 000.
Table 25 gives  this cost breakdown.

       The cost estimates in this  study were made  about March, 1970 (U.S.
Average ENR Construction Cost Index 1314). They should be multiplied by
a factor of (1700/1314) = 1.3 to arrive at the ENR Construction Cost Index of
April,  1972.

       The study consisted of an analysis  of available methods of ozone pro-
duction and theoretical assumptions of acid mine drainage oxidation by ozone.
The  conclusions reached in the  study were not verified by actual laboratory
                                 -208-

-------
or plant scale tests.  Therefore, the cost estimates arrived at as  a result of
the study, provide at the best, an indication of the probable costs should ozone
oxidation materialize as a proven and tested method for acid  mine drainage
treatment.
                                 -209-

-------
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                           -210-

-------
                         TABLE 19


      AMD TREATMENT PLANT  OPERATING COSTS* - C/IOOO GAL.
AMD F3.0W                   666
Gal./Day         0.25 X  10         1 X 10          6 X 10

Fe++, ppm.     J50   300   1000   J50   300  1000   J30_  300  1000

Depreciation
 f> 1.3%       5.1   5.2    5.2   3.8   4.0   4.3  3.2  3.4   3.6

Power @
 8 mil.Kw-Hr  3.2   3.3    3.5   3.2   3.3   3.5  3.2  3.3   3.5

Limestone
 @ $5/Ton     0.5   1.6    4.4   0.5   1.6   4.4  0.5  1.6   4.4

 TOTAL        8.8  10.1   13.1   7.5   8.9  12.2  6.9  8.3  11.5
*Not including ozone.
After Beller et al, (23)
                            -211-

-------
                         TABLE 20

             AMD TREATMENT TOTAL OPERATING COST

                         fr/1000 Gal.
AMD FLOW, GPD
Fe  ,  ppm
                       0.25 X 10
                                     1.0 X 10
                                                     6.0 X 10
                    50  300  1000   50  300  1000   50  300  1000
    OZONE GENERATED ON SITE-ELECTRIC DISCHARGE OZONIZERS

           A. ONCE-THROUGH AIR FEED. 7.25 KW-Hr/lb
OZONE
AMD PLANT
  TOTAL
OZONE
AMD PLANT
  TOTAL
OZONE
AMD PLANT
  TOTAL
OZONE
AMD PLANT
  TOTAL
 3.6 20.1
 8.8 10.1
12.4 30.2
                             61.1
                             13.1
3.4 18.1
7.5  8.9
                                             55.0
                                             12.2
2.8 16.0
6.9  8.3
                             74.3 10.9 27.0  67.2  9.7 24.3
           B. ONCE-THROUGH AIR FEED, 9.75 KW-Hr/lb
                   4.2 24.8
                   8.8 10.1
                  13.0 34.9
                             75.3
                             13.1
                 4.2 22.2
                 7.5  8.9
                             88.4  11.7  31.1
          67.9
          12 ; 2	
          80.1 10.6 27.9
3.7 19.6
6.9  8.3
           C. OXYGEN FEED WITH RECYCLE,  3.75 KW-Hr/lb
                   4.9 21.2
                   8.8 10.1
                  13.7 31.3
                              56.5
                              13.1
                 3.7 16.5
                 7.5  8.9
                              69.6  11.2  25.4
          45.7  2.7 12.6
          12.2  6.9  8.3
          57.9  9.6 20.9
           D. OXYGEN FEED WITH RECYCLE.  5.0 KW-Hr/lb
 5.5 24.1
 8.8 10.1
14.3 34.2
                             65.2
                             13.1
4.3 19.1
7.5  8.9
                                              52.9
                                              12.2
3.2 14.5
6.9  8.3
                             78.3  11.8  28.0   65.1  10.1 22.8
51.7
11.5
63.2
62.5
11 ._5
74.0
           35.8
           11.5
           47.3
42.1
11.5
53.6
 After Beller, et al, (23)
                              -212-

-------
                        TABLE 21




OZONE GENERATED IN 40 TON/DAY CENTRAL PLANT, SHIPPED TO AMD SITE




                        e/1000 Gal.
AMD FLOW, GPD
++. ppm
Fe
0.25 X
50 300

A. ELECTRIC DISCHARGE
1. 5
OZONE
AMD PLANT
DISTRIBUTION
LABOR
TOTAL
2. 6
OZONE
AMD PLANT
DISTRIBUTION
LABOR
TOTAL
io6

1.
1000 50



OZONIZERS,
MIL./KW-Hr POWER
1.2 7.0
8.8 10.1
0.9 5.4
2.0 2.0
12.9 24.5
23.
13.
14.
2.
52.
MIL./KW-Hr POWER
1.5 8.0
8.8 10.1
0.9 5.4
2.0 2.0
13.2 25.5
B. CHEMONUCLEAR OZONE
1. G
OZONE
AMD PLANT
DISTRIBUTION
LABOR
TOTAL
2. G
OZONE
AMD PLANT
DISTRIBUTION
LABOR
TOTAL
= 15, E = 0.
1.0 5.8
8.8 10.1
0.9 5.4
2.0 2.0
12.7 23.3
= 10, E = 0.
1.3 6.8
8.8 10.1
0.9 5.4
2.0 2.0
13.0 24.3
26.
13.
14.
2.
55.
COST
3 1.
1 7.
0 0.
0 1.
4 10.
COST
0 1.
1 7.
0 0.
0 1.
1 10.

2
5
9
0
6

5
5
9
0
9
, RECYCLED 0
20
19.
13.
14.
2.
48.
20
22.
13.
14.
2.
51.

5 1.
1 7.
0 0.
0 1.
6 10.

5 1.
1 7.
0 0.
0 1.
6 10.

0
5
9
0
4

3
5
9
0
7
0 X
300

io6


1000
RECYCLED

7.0
8.9
5.4
1.0
22.3

8.0
8.9
5.4
1.0
23.3


5.8
8.9
5.4
1.0
21.1

6.8
8.9
5.4
1.0
22.1

23.
12.
14.
1.
50.

26.
12.
14.
1.
53.


19.
12.
14.
1.
46.

22.
12.
14.
1.
49.
0.,

3
2
0
0
5

0
2
0
0
2


5
2
0
0
7

5
2
0
0
7


1
6
0
0
9

1
6
0
0
9


1
6
0
0
9

1
6
0
0
9
6
50

5

.2
.9
.9
.5
.5

.5
.9
.9
.5
.8


.0
.9
.9
.5
.3

.3
.9
.9
.5
.6
.0 X
300

io6
1000

KW-Hr/lb

7.0
8.3
5.4
0.5
21.2

8.0
8.3
5.4
0.5
22.2


5.8
8.3
5.4
0.5
20.0

6.8
8.3
5.4
0.5
21.0

23.3
11.5
14.0
0.5
49.3

26.0
11.5
14.0
0.5
52.0


19.5
11.5
14.0
0.5
45.5

22.5
11.5
14.0
0.5
48.5
 After Beller et al, (23)
                          -213-

-------
                          TABLE 22




OZONE GENERATED  IN  200 TON/DAY CENTRAL  PLANT. SHIPPED TO AMD SITE




                        C/1000 Gal.
AMD FLOW, GPD
Pe , ppm
0.25 X
50 300
A. ELECTRIC DISCHARGE
1.
OZONE
AMD PLANT
DISTRIBUTION
LABOR
TOTAL
2.
OZONE
AMD PLANT
DISTRIBUTION
LABOR
TOTAL
106

1000
1.
50
OZONIZERS,
5 MIL./KW-HR POWER
1.1 6.4
8.8 10.1
0.9 5.4
2.0 2.0
12.8 23.9
21.
13.
14.
2.
50.
6 MIL./KW-HR POWER
1.2 7.2
8.8 10.1
0.9 5.4
2.0 2.0
12.9 24.7
B. CHEMONUCLEAR OZONE
1.
OZONE
AMD PLANT
DISTRIBUTION
LABOR
TOTAL
2.
OZONE
AMD PLANT
DISTRIBUTION
LABOR
TOTAL
G = 15, E = 0
0.7 4.1
8.8 10.1
0.9 5.4
2.0 2.0
12.4 21.6
G = 10, E = 0
0.9 5.2
8.8 10.1
0.9 5.4
2.0 2.0
12.6 22.7
24.
13.
14.
2.
53.
0 X 10
300
6

1000
RECYCLED
0^,

6.
50
, 5
0 X 10
300
6
1000
KW-Hr/lb
COST
3
1
0
0
4
1.1
7.5
0.9
1.0
10.5
6.4
8.9
5.4
1.0
21. .7
21
12
14
1
48
.3
.2
.0
.0
.5
1.
6.
0.
0.
9.
1
9
9
5
4
6.4
8.3
5.4
0.5
20.6
21.3
11.5
14.0
0.5
47.3
COST
0
1
0
0
1
1.2
7.5
0.9
1.0
10.6
7.2
8.9
5.4
1.0
22.5
24
12
14
1
51
.0
.2
.0
.0
.2
1.
6.
0.
0.
9.
2
9
9
5
5
7.2
8.3
5.4
0.5
21.4
24.0
11.5
14.0
0.5
50.0
, RECYCLED 0.
.20
13.
13.
14.
2.
42.
.20
17.
13.
14.
2.
46.

7
1
0
0
8

3
1
0
0
4

0.7
7.5
0.9
1.0
10.1

0.9
7.5
0.9
1.0
10.3
i
4.1
8.9
5.4
1.0
19.4

5.2
8.9
5.4
1.0
20.5

13
12
14
1
40

17
12
14
1
44

.7
.2
.0
.0
.9

.3
.2
.0
.0
.5

0.
6.
0.
0.
9.

0.
6.
0.
0.
9.

7
9
9
5
0

9
9
9
5
2

4.1
8.3
5.4
0.5
18.3

5.2
8.3
5.4
0.5
19.4

13.7
11.5
14.0
0.5
39.7

17.3
11.5
14.0
0.5
43.3
  After Beller et al,  (23)
                             -214-

-------
                         TABLE 23

          TOTAL INVESTMENT  COSTS  FOR AMD  TREATMENT
       USING ON-SITE OZONE  WITH RECYCLED  OXYGEN FEED

                        5.0 KWH/LB OZONE

                        COSTS  IN  THOUSANDS OF DOLLARS
AMD FLOW,
GAL. /DAY
Fe+2 CONC'N
ppm
OZONE PLANT
AMD PLANT
TOTAL $
250,

50
14
52
66
000

300
60
53
113
1

1000 50
190 40
53 156
243 196
,000,

300
220
163
383
000

1000
530
175
705


IP.
220
790
1010
6,000,

300
810
830
1640
000

1000
2130
855
2985
After Seller et al,  (23)
                            -215-

-------
                          TABLE  24

           COMPARISON OF AMD TOTAL  TREATMENT COSTS

                              COSTS IN CENTS PER 3000 GAL.

                                AMD FLOW - GAL. PER PAY


                       0.25 X 106          1.0 X 106        6.0 X 1Q6
Fe''"1' CONTENT-ppm     .50   300   1000   £0   300   1000   j>0   300   1000

1. ELECTRIC DISCHARGE WITH RECYCLED OXYGEN FEED, ON-SITE OZONE GENERATION

   @> 3.75 Kwh/lb.    14    31     70   11    25     58   10    21     47
   @ 5.00 Kwh/lb.    14    34     78   12    28     65   10    23     54

2. ELECTRIC DISCHARGE WITH ONCE-THROUGH AIR FEED. ON SITE OZONE GENERATION

   g> 7.25 Kwh/lb.    12    30     74   11    27     67   10    24     63
   @ 9.25 Kwh/lb.    13    35     88   12    31     80   11    28     74

                    CENTRAL OZONE PLANTS WITH DISTRIBUTION SYSTEMS

3. ELECTRIC DISCHARGE. 40 TON/DAY OZONE

   @ 5 mil/Kwh power 13    24     52   11    22     50   10    21     49
   g> 6 mil  "     "   13    26     55   11    23     53   10    22     52

4. ELECTRIC DISCHARGE, 200 TON/DftY  OZONE

   @ 5 mil/Kwh power 13    24     50   10    22     48    9    21     47
   @ 6 mil/ "     "   13    25     53   11    23     51    9    21     50

5. CHEMONUCLEAR,  40 TON/DAY OZONE

   G=10. E=0.20      13    24     52   11    22     50   10    21     48
   G=15. E=0.20      13    23     49   10    21     47    9    20     45

6. CHEHONUCLEAR,  200 TON/DAY OZONE

   6=10. E=0.20      13    23     46   10    21     44    9    19     43
   6=15, E=0.20      12    22     43   10    19     41    9    18     40
After Beller et al, (23)
                              -216-

-------
                    FIGURE 37
   80
   70
   60
   50
   40
 *
<  30
o
8  20
I  '0
fe   °
O
O
H
5  90
2
£  80
   60
   50
   40
   30
   20
   10
   0
ON-SITE OZONE GENERATION
RECYCLED OXYGEN FEED
        0.25 x I06GPD
                              1.0 xlO GPD J
                              6.0 x!06GPD J
                     3.75 KW-HR/LB
                     5.0  KW-HR/LB
ON-SITE OZONE GENERATION
ONCE-THROUGH AIR FEED
                                            xlO GPD
                            HR/LB
                            HR/LB
         I
I
          200    400   600    800   1000
                     Fe*+ CONTENT-ppm
          TOTAL AMD TREATMENT COSTS USING OZONE
               ELECTRIC DISCHARGE OZONIZERS
  After Seller et al, (23)
                       -217-

-------
                    FIGURE 38
UJ

h;

S
on



i
<
   60


   50


   40


<  30
o


8  20
o

^  10
i
h-
co
o
o
60




50
40


30


20


10
                         0.25-j   6

                          1.0  UlOGPD
                         6.0 J
                                          ___

                                          °'Z5\
                                          1.0

                                             J
                                       1.0    lO GPD.

                                       6.0
                        OZONE CAPACITY-40TON/DAY


                        	6MIL/KW-HR POWER

                        	5MIL/KW-HR POWER
                                               xlO GPD
                           OZONE CAPACITY-200 TON/DAY


                                -6MIL/KW-HR POWER

                                -5MIL/KW-HR POWER
                1
                      j_
   0    200   400    600    800    1000


                    Fe++CONTENT-ppm


TOTAL AMD TREATMENT COST USING ELECTRIC-DISCHARGE OZONE


  CENTRAL PLANT OZONE GENERATION.SHIPPED TO AMD SITE

            5KW-HR/LB 0,  POWER CONSUMPTION
   After Beller et al, (23)
                      -218-

-------
                     FIGURE 39
O
O
o

-------
                 FIGURE 40
3000

2800
 200
        RECYCLED OXYGEN  FEED
        5.0 KWH/LB OZONE
                      6x I0  GAL/DAY  AMD
                       I x I06 GAL/DAY AMD
                      0.25 x I06 GAL/DAY AMD
           200     400     600     800
                   Fe++ CONTENT - ppm
                                          1000
    TOTAL  PLANT INVESTMENT COST FOR AMD TREATMENT
    USING ON-SITE  ELECTRIC  DISCHARGE OZONE


After Seller et al,  (23)
                    -220-

-------
                     TABLE 25
       COST, BREAKDOWN FOR TOTAL AMD TREATMENT
             OF  PENNSYLVANIA AMD STREAMS

             486 MILLION GALLONS PER DAY

               Investment Costs - Million Dollars

                 Central   Central   On-Site
                   Chemo-    Elec.     Elec.
                 nuclear    Disch.    Disch.
Ozone Plants
AMD Neutrali-
zation*
Total Investment
26.0

156.0
182.0
Operating


Central
Chemo-
nuclear
Depreciation-7.3% 9.1
Nucl. Fuel Cycle 0.9
Labor 2 . 1
Power
Maintenance
Purchased Oxygen
Distribution
Limestone
Total Operating
Costs
3.9
0.1
0.8
1.2
18.1
34.8

156.0
190.8
Costs -
99.5

113.0
212.5
C/1000 Gal.
Central On-Site
Elec. Elec.
Disch
9.6
2.1
6.3
0.1
0.8
1.2
20.1
Disch.
10.6
1.0
7.2
1.0
5.4
1.2
26.4
Annual Operating
      Costs      $26.4x10   $29.3x10   $38.5x10
*
 Assumes 2,160 AMD treatment  sites with  average  flow
 rates of 250,000 gpd.
 After Beller et al, (23)
                      -221-

-------
Neutralization of Mine Drainage with High Ferric Iron Content

       Neutralization of mine drainage with high ferric iron content can be
accomplished more easily and at less cost compared to treatment of mine
drainage high in ferrous iron.  Equipment, chemicals and methods  necessary
for oxidation of ferrous iron can be eliminated with consequent  reduction in
cost and simplification of treatment.

       Wilmoth and Hill'  ' conducted continuous flow and batch test studies
utilizing lime, limestone and soda ash to  treat acid mine drainage having a
high ferric/ferrous ratio.  Some of their  conclusions and recommendations
were:

1.   Chemical costs for treating by the three methods were:  soda ash  -  0.049
     cents, limestone - 0.010 cents, and lime - 0.005 cents  per mg/1 acidity
     per  1,000 gallons.   These  costs updated to April, 1972, using the  ENR
     Construction Cost Index, would be respectively: 0.075 cents, 0.015 cents
     and  0.0075 cents per mg/1 acidity per 1, 000 gallons.

2.   Lime is a very reactive material and the  neutralization reaction goes to
     completion in less  than half an hour.  The limestone reaction requires  24
     to 48 hours to  go to completion and therefore, requires  a long detention
     time before discharge, however, aeration will reduce the detention  time
     to one comparable  to lime.

3.   The limestone reaction is not very sensitive quantitatively,  i.e.,  small
     changes in limestone feed rate or  water quality do not cause  large changes
     in product water quality so the accuracy with which constituents are fed
     into the  reactor need not be controlled with the precision required by lime.
     Accidental overtreatment is not the pollution problem with  limestone that
     it would be with lime.

4.   Lime is capable of attaining high pH's which may be necessary in  so.tne
     cases for desired water quality, whereas with limestone, pH's  above 7.0
     are  very difficult to attain.

5.   All three neutralizing agents were capable of treating the high ferric acid
     mine drainage.  Lime costs were  half that of limestone  for treating the
     same acid mine drainage because  of the low  utilization of limestone. How-
     ever, the  characteristics of the limestone sludge were superior; it occupied
     approximately two-thirds of the volume of lime sludge and  had  a higher
     solids content. The limestone sludge also had a large residual alkalinity
     which would be beneficial when disposed into an acid environment  (although
     this residual alkalinity is expensive and of questionable  value to the treat-
     ment process).
                                 -222-

-------
6.   Studies should be made to develop methods of increasing the efficiency
     of limestone as a neutralization agent in acid mine drainage treatment
     because of the lower initial cost and low sludge volume. Studies should
     be made on:

     a)   Sludge return to take advantage of the residual alkalinity within the
         sludge.

     b)   Increasing the detention time in the reactor to allow more limestone
         to go  into solution.

     c)   Increasing the shearing action in the reactor to break the calcium
         sulfate and iron coating of the limestone.

     d)   Combination lime stone-lime to  utilize the strong points of each, i. e,
         limestone for low pH's to around pH 5 (the most efficient portion of
         the limestone curve) and then the use of  lime  to further increase the
         pH.

     e)   Developing methods to produce  a rapid settling and dense sludge,
         e.g.,  the use of coagulating aids.

       Calhoun^  ' in discussing the design and operation of a limestone  treat-
ment plant for  the Rochester & Pittsburgh Coal Company, Indiana, Pennsyl-
vania, expressed  the opinion that the  limestone treatment method should  always
be investigated prior to installation of a  permanent treatment plant because
some types of  mine drainage can be treated with a limestone system.   The
reasons  given  are:  1)  most economical,  2) a lesser  volume of sludge for dis-
posal, and 3) there is no danger of overtreatment. He also said,  it appears
a combination  limestone-lime treatment method would be most economical
for treatment of a difficult water with a high ferrous  iron content.  These
statements are in agreement with the studies of Wilmoth and Hill.

       At the Rochester & Pittsburgh Coal Company treatment site the mine
drainage has the following average characteristics: pH - 3. 1,  acidity - 350
mg/1, iron - 56 mg/1 (less than 10% in the  ferrous state), dissolved solids -
1,600 mg/1,  and a volume of 150/gpm.

       The treatment facility consists essentially of a rotating drum as a re-
actor to  tumble the limestone and a settling pond.  The average quality of the
effluent from the settling pond in 1967 was:  pH -  6.9,  alkalinity - 18 mg/1,
and iron -1.4  mg/1.

       It is estimated  capital costs for new equipment for the treatment plant
would be close to $20, 000.  Actual costs were somewhat lower because second
hand equipment was utilized.  Operating costs,  including limestone, power,
maintenance and labor was estimated to  be about 6^/1,000 gal.  treated (esca-
lated to 1972 price levels  it would be about 10^/1,000 gal.  treated).
                                 -223-

-------
Mine Drainage Treatment Using Hydrated Lime

       In 1970, Heine and Giovannitti^  ' said, "The science  and technology
of mine drainage treatment is  in its infancy in the United States with the most
significant recent advancements occurring in Pennsylvania."  This is still the
case two years later.  Mine drainage  technology  is undergoing a period of rapid
growth.  The pace of research and development is so rapid,  that some treat-
ment plants can be said to be obsolete before they go into operation.

       There are now probably close  to three hundred plants  treating mine
drainage.  Most of these  plants are in Pennsylvania and many of them have
been in operation for less than three years.  The majority of  the treatment
plants  use  lime as the neutralizing agent.  In the  next few years, this dom-
ination by lime neutralization  could conceivably change as  the results of re-
cent limestone and lime stone-lime treatment technology are put into effect.

       In estimating costs for mine drainage treatment, it should be recog-
nized  that much of the actual cost data developed  to date is based on lime
neutralization.  Because  of the newness of mine drainage treatment technology
the capital and operating  costs of existing treatment plants may not be an  indi-
cation of future costs in mine drainage treatment.  It is obvious  when one re-
views  recent research and development that if the information was available
at the  time many of the existing plants were planned, the design and operation
would  be considerably different.  Although most of the lime neutralization
plants  in operation today  are effectively treating  acid mine drainage at costs
that are relatively economical, they are at best primitive examples of mine
drainage treatment in the dawn of a developing technology.  Further econo-
mies  can accrue  from more efficient  operation and design as  a  result of the
progress being made in mine drainage treatment technology.

       Hydrated  Lime Process - Basically this process involves four steps
in treating acid mine drainage.

1.  Neutralization which entails the conversion of

     a) Sulfuric  acid to calcium sulfate

        Ca(OH)2 + H2SO4	*-CaSO4  +  2 H2O

     b) Ferrous sulfate  to ferrous  hydroxide  and calcium sulfate

        Ca(OH)2 + FeSO4	*-Fe(OH)2  + CaSO4

2.  Aeration - The oxidation of ferrous hydroxide to ferric hydroxide

        O2 + 4 Fe(OH)2 + H20	*-4  Fe(OH)3

3.  Clarification - Thickening
                                  -224-

-------
4.  Sludge Dewatering and Disposal

       The  advantages of lime treatment are:  1) removal of acidity, 2) re-
moval of iron and aluminum salts,  3) reduction in sulfate ion concentration,
4) relative simplicity  and control, and 5) ready availability of lime.

       The  disadvantages are:  1) addition of hardness to effluent,  2) gypsum
scale on plant equipment and possibly in effluent, 3) difficulty in sludge hand-
ling and dewatering, 4) volume of sludge production and disposal,  and 5)
possibility of overtreatment with detrimental effects.

       Engineering Cost Factors - The following engineering  cost factors
should be considered in estimating costs of lime treatment facilities.

1.  Treatment Plant Capacity - The capital cost of a plant is  determined by
    its construction cost which to some  extent is affected by the acidity and
    iron content of mine drainage to be treated. The  operating costs are more
    affected by the acidity  and iron content than by the plant size.

2.  Lime Storage  Facilities  - These facilities depend for their sizing on acid-
    ity characteristics as well as the volume of mine  drainage to be treated.

3.  Mixing  and Aeration -  The purpose of mixing is two fold:  1)  it must dis-
    perse the solid hydrated lime in mine water and 2) it must produce tur-
    bulence  of high intensity around the  hydrated lime particles in  order to
    promote a mass transfer between the two phases.  Dorr-Oliver, Inc.
    reports(27» 28) tnat with  a separate flash mixing operation, a detention
    time of one minute was found sufficient to  ensure  neutralization.

4.  Aeration - "Operation  Yellowboy" data^"' indicates a detention time of
    about 30 minutes with efficient aeration equipment is sufficient.

5.  Settling  and/or Thickening -  Sludges formed in lime treatment are typi-
    cally slow in settling from solution.  In this respect,  lime treatment is
    at a  disadvantage  in comparison with limestone treatment, which pro-
    duces a  more rapidly settling sludge of less volume.  "Operation Yellow-
    boy"^ ') used a thickener to separate the iron oxide-gypsum  sludge
    mixture, and subsequent centrifugation as a sludge dewatering process.
    Also, according to "Operation Yellowboy" data, settling and  thickening
    may represent a significant cost in capital plant expenditures.

    The  sludge volume typically produced in lime treatment represents a
    high percentage of the  influent volume and the solids content  ranges
    from 1  to 10%. The solids contentdoes  increase with time.  Polymeric
    flocculants  improve the settling characteristics of sludge, but  they do
    not increase the solids concentration.
                                  -225-

-------
    Kostenbader and Haines^  '   ' report the development of a high-density
    sludge (HDS) process which,  in addition to the usual lime treatment pro-
    cess, involves recycling a controlled volume of the settled sludge and
    mixing the recycled sludge with lime slurry in a reaction tank prior to
    the neutralization and separation steps.  Figure 41 shows the flow dia-
    gram of  the HDS process.  Depending mainly on the oxidation state of
    iron in the mine water,  the sludges produced can contain 15 to 40% solids.
    The HDS process is claimed to be inherently well-suited for treating acid
    mine  drainage with high ferrous/ferric iron ratios.

    If land space is available, lagoons could be used for sludge settling as an
    alternative to mechanical thickening.  Two or more lagoons or basins
    could be used, and after sludge settling, the supernatant may be removed
    by pumping,  or the sludge may be allowed to dry in the lagoon.

6.  Sludge Dewatering - The "Operation Yellowboy" projects employed various
    dewatering techniques,  including  centrifugation and filtration.   A drum
    filter process  increased solids concentrations from initial ranges of  0.9
    to 5 percent to final solids concentrations  of 21 to 27 percent.

    Rotary precoat filtration, centrifugation,  pressure filtration,  freezing,
    cycloning, CC>2 pretreatment, and other methods  of sludge densification
    and dewatering have also been studied^   > ^  '.

7.  Sludge Disposal - The disposal of sludge is a major problem in mine drain-
    age treatment.  Holland et al. (^), estimated costs of disposing of sludge in
    lagoons.  These estimates show costs may amount to  13  to 15  percent of
    the total annual plant operating costs for treating highly acid mine drainage,
    11 to  13  percent for moderately acid discharges  and 7.5  to 10  percent for
    weakly acid discharges.  Holland points out that the cost could be  higher
    because  the cost of sludge disposal in lagoons is markedly affected by land
    availability,  soil type,  underlying rock, ground water, etc. He also sug-
    gests the possibility of using nearby abandoned mines  for sludge disposal.

    Where possible, sludge should be pumped  to abandoned mines.  Deep in-
    jection wells cannot be used where the subsurface geology is unfavorable
    and it is questionable whether this method is practical for acid mine  drain-
    age sludge disposal.  Evaporation ponds are not functional in areas where
    annual rainfall exceeds  annual evaporation.  Rinne(^ ' provides costs for
    evaporation ponds  and for deep well disposal of brine  (Tables 26 and  27).
    Steinman^35'  reports that at the Thompson Mine Drainage Treatment Plant
    of Jones and Laughlin's Vesta Shannopin Coal Division,  it was found more
    economical to  truck the sludge rather than acquire land and construct a
    large sludge lagoon.  Dean(3°) describes  methods of sludge disposal  in
    detail.   Osman et al. (^'), investigated mine drainage  sludge utilization.
    Their research covered:  1) additives used in the building materials in-
    dustry,  2) recovery of iron,  3) the application of gypsum technology to
    the sulfate portion of the sludge,  and 4) separation of  the major chemical
    components.  They found that manufacture  of synthetic light-weight aggre-
                                  -226-

-------
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-------
                              TABLE 26
         COST OF BRINE DISPOSAL IN EVAPORATION PONDS
               (Assuming PVC Liner at $0. 30 per sq. ft. )
                            1. 0 MGD Brine

                                 Arkansas     Gallup,     Midland,
                                City, Ark.     N.M.        Texas

Net Avg. Annual Pond Evapo-       14          30          40
  ration (inch)
Pond Area (acres)                960         468          343
Pond Construction Cost             15.27         7.34         5.38
  ($ x  106)
Total Annual Operation Cost          1.73         0.84         0.62
  ($/yr. x 106)
Cost per 1, 000 gals, of brine       $5.20         2.50         1.92
90% recovery of feed                 0.52         0.25         0.19
  ($/l, 000 gallons)
  fresh water
                              TABLE 27
             ESTIMATED COSTS OF DEEP WELL DISPOSAL

                                 Arkansas City   Midland    Ft. Morgan

Prod. Vol. (MGD)                     7.0           5.0         3.0
Brine Vol. (MGD)                     1.27          0.8         1.0
Well Construe. Cost($xl06)          0.195         0.157       0.787
Total Cap. Cost ($ x 106)              0.258         0.401       1.775
Total Annual Cost ($/yr. x 106)        0.063         0.120       0.384

Product Water Bases

  Total Unit  Cap. Cost                0.369         0.080       0.591
    ($/gal./day)
  Total Unit  Oper.  Cost               0.025         0.066       0.35
    ($/l, 000 gallons)
After Rinne,  1970(34)
Costs not updated to 1972.
                                -228-

-------
gates and structural bricks utilizing small percentages of sludge was
technically feasible and recovery of iron was also generally successful.
The high-iron content sludge (alkaline) can be pallatized and used directly
as a blast furnace feed after dewatering.  The high-sulfate sludge (acid),
when pre-reduced at high temperature to decompose the calcium sulfate,
can be agglomerated into a blast furnace feed.  Additional research is
needed before these results  can be  considered commercially attractive.

"Operation Yellowboy" projects^27'28> 29» 38'39), Holland, et al. (3) and
Selmeczi' 0' provide useful design  information for lime neutralization
treatment plants.

Tables 28, 29 and 30 give the actual costs  of five "Operation Yellowboy"
projects. Tables 31, 32 and 33 give the estimated costs using hydrated
lime as taken from the work of Holland, et al.'-5).  These  costs were up-
dated to  April, 1972  price levels using the ENR Construction Cost Index
and plotted as cost curves in Figures 42,  43 and 44.
                             -229-

-------

















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                                    TABLE 31
       Estimated Costs of Neutralizing Highly Acid Mine Water Using Hydrated Lime
               (All Costs in Cents per 1000 Gallons of Water Treated)

Plant
Capacity
Gallons /Day
300,000
900, 000
2,700,000
8, 100,000

Labor
10
5
2.5
2

Lime
28
26
25.5
25.5
Plant Cost
Except
Sludge
Disposal
9.5
8.5
7.25
7.25

Sludge
Disposal
Cost
8
7
7.75*
7.50*

Repair
4
3
2.5
2.5

Misc.
3
3
3
3

Total
62.5
52.5
48.5
47.75
Accumulation of
Sludge in
One-Year
Acre-Feet
9.8
30. 1
91.0
273.0
Acidity 2800 - 4000
Iron 900 - 1200
Bag Lime $24,00/Ton
Bulk Lime $22.00/Ton
                                    TABLE 32
   Estimated Costs of Neutralizing Moderately Acid Mine Water Using Hydrated Lime
                (All Costs in Cents per 1000 Gallons of Water Treated)
Plant
Capacity
Gallons /Day
300,000
900,000
2,700,000
8, 100,000
Labor
8
4
2
1.6
Lime
12.9
11.5
11
11
Plant Cost
Except
Sludge
Disposal
9.5
8.5
7.75
7.25
Sludge
Disposal
Cost
4
3.5 *
3.75*
3.75*
Repair
3
2.5
2
2
Misc.
3
3
3
3
Total
34.8
33.0
29.5
28.6
Accumulation of
Sludge in
One-Year
Acre-Feet
4.9
15.4
45.5
136.5
Acidity around 1400 PPM
Iron around 600 - 700 PPM
Bag Lime $24.00/Ton
Bulk Lime $22.00/Ton
                                    TABLE 33

      Estimated Costs of Neutralizing Weak Acid Mine Water Using Hydrated Lime
               (All Coats in Cents per 1000 Gallons of Water Treated)
Plant
Capacity
Gallons /Day
300, 000
900,000
2,700,000
8, 100, 000
Labor
6
3
1.8
1
Lime
6.1
5.7
5.5
5.5
Plant Cost
Except
Sludge
Disposal
8.5
7.5
6.75
6.5
Sludge
Disposal
Cost
2
1.8
1.9*
1.9*
Repair
2.5
2
1.5
1.5
Misc.
2.5
2.5
2.5
2.5
Total
27.60
22.50
19.95
18.90
Accumulation of
Sludge in
One-Year
Acre-Feet
2.8
7.7
23.1
68.6
Acidity around 600 - 700,
Iron 322,
Bag Lime $24. 00/Ton
Bulk Lime $22. 00/Ton
 After Holland, et al <3'
*These costs allow for excavating some hard rock.
                                      -233-

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                           FIGURE 42
                   CAPITAL COST Vs. PLANT CAPACITY
         HYDRATED LIME TREATMENT PLANT WITH SLUDGE DISPOSAL
                        REFERENCES^ 29 a 41
01
                                                                IOO
                              -234-

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                               FIGURE 43
                 TOTAL CAPITAL COST Vs. PLANT CAPACITY
                   HYDRATED LIME TREATMENT PLANT
                   (WITHOUT SLUDGE DISPOSAL) REF 3
O.I
0.2    0.3  0.4 0.5
   1.0         2
CAPACITY-MGD
345
10
                                -235-

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                                       FIGURE 44
                      TOTAL OPERATING COST (Including Capital Costs)
                         HYDRATED LIME TREATMENT (REF 3 )
  100-r

  3O-
_J
CP
o
Z 2.0-
                       _L
LIRON-PPM
ACIDITY-PPM
           •HIGHLY ACIDIC
            MODERATELY ACIDIC
            WEAKLY ACIDIC
  50
  4O - ---
900-1200
600-700
   322
 2800-4800
    1400
  600-700
    /— HIGHLY ACIDIC (WITH SLUDGE DISPOSAL)	
    2— HIGHLY ACIDIC (WITHOUT SLUDGE DISPOSAL)
    J- MODERATELY ACIDIC (WITH SLUDGE DISPOSAL)   j
    4 -MODERATELY ACIDIC (WITHOUT SLUDGE DISPOSAL)
    5 —WEAKLY ACIDIC (WITH SLUDGE DISPOSAL)
    6 - WEAKLY ACIDIC (WITHOUT SLUDGE DISPOSAL)
                                          1.0
                                       CAPACITY-MGD
                                                                                100
                                         -236-

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       Cost of Lime Neutralization of Mine Drainage  - Mine drainage is a
complex waste which varies in quality,  quantity and inherent characteristics
from mine to mine and even within the same mine from place to place and
with time. The cost of treating  mine drainage, therefore,  will vary with
the quantity of drainage requiring treatment, the initial quality and the de-
sired final quality, and other factors,  such as,  availability of land for the
treatment plant and methods of sludge disposal.

       More than two hundred mine drainage treatment plants are presently
in operation in Pennsylvania alone and many of the plants are operated by
captive coal companies.  Because coal mining  is a highly competitive  indus-
try, most companies have shown reluctance to supply information on their
treatment costs for use in this study.  Treatment costs are  available for
some plants built for the  Commonwealth of Pennsylvania and a few cost fig-
ures are available in the  literature  on mine drainage treatment for plants
operated by coal companies.

       Since little actual cost data is available, a case history approach will
be used in describing selected lime neutralization plants, their characteris-
tics and  costs, in order to get an idea of the present cost of mine drainage
treatment by lime neutralization.  The case histories are as follows:

1.   Duquesne Light Company, Warwick Mine No. 2

       In 1969i  the Duquesne Light Company began operating a 3 MGD mine
     drainage treatment plant at  the Warwick Mine No. Z, Greene County,
     Pennsylvania.  Figure  45 is a flow sheet for this  plant.   According to
     Draper'   ',  mine drainage discharges  from this Pittsburgh Seam mine
     were consolidated to the area of lowest seam elevation and all mining in
     this area was completed so  that it could act as a natural sump.

       Draper describes the plant operation as follows:

       Three deep well turbine pumps with a capacity of about 4,400 gpm
     were installed from the surface through boreholes into the area.  The
     raw mine water is discharged from the mine pumps into a flume,  which
     conducts it  to a four  million gallon raw water equilization pond.  To pre-
     vent leakage of raw water into the ground or into  the nearby stream,
     this pond was lined with over three feet of a compacted  special imper-
     vious clay trucked from some distance. The mine water is pumped from
     the equalization pond into the reaction and aeration tank where it is re-
     tained some ZO minutes.

       Lime is  delivered to the plant lime bin in pneumatic  tank trucks of
     approximately 2Z to*is capacity.  When the pH control probe signals for
     lime, the rotary and screw feeders under the bin start to feed lime into
     the lime slurry tank, the water pump starts  to put water into the same
     tank and the lime slurry pump starts  to pump milk of lime  from the tank
                                 -Z37-

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    DUQUESNE  LIGHT  COMPANY
   WARWICK  MINE  PORTAL  NO. 2
  MINE WATER  TREATMENT  PLANT
          FLOW  SHEET
                PNEUMATIC TRUCK UNLOADING
                                                           SPLITTER BOX
                                                           OVERFLOW  MIN6 pgups
                                                         RAW WATER      J—1
                                                           PUMPS, ?L"ME-fl
                                                       EQUALIZATION
                                                          POND
     UNDERFLOW TO
    ABANDONED MINE
PRESENT PLANT
   2100 gpm
After Draper,  1972
                          FIGURE  45

                           (42)
                              -238-

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    into the mine water as  it enters  the reaction and aeration tank.  When the
    pH of the water rises to the preset level, the control shuts off both lime
    feeders and both pumps.

       The limed and aerated mine water discharges into a flume, passes by
    the pH control probe and is discharged into the center well of the 200 foot
    diameter earthen wall thickener.  The overflow from this thickener is col-
    lected in a trough near the  periphery and conducted in a flume either di-
    rectly to the stream or to a polishing pond, which will retain the water for
    some 12 hours before discharging it to the stream.  The underflow of the
    thickener is  pumped to a shaft or one of  several boreholes for disposal in
    an abandoned mine in the Sewickley Seam.  The discharge from  this seam
    percolates to the Pittsburgh Seam, which is  100 feet below and from which
    the raw water is pumped.

       The total  cost of the plant in 1969 was $582, 000 including the  polishing
    pond which was installed in December,  19&9. For the purpose of deriving
    cost, a life  of 10 years was assumed.  The annual operating costs are about
    19£ per thousand gallons.  The mine drainage treated in  1971 had an aver-
    age chemical analysis of:  pH - 4.20, acidity - 1, 557 mg/1,  and  total iron -
    573 mg/1 (Fe+2 - 424 mg/1).

       The low cost of the plant operation can be attributed to:  1)  sludge dis-
    posal in abandoned mines,  2) completely automated operation of the plant
    eliminating most of the labor costs and,  3) favorable topography and ground
    conditions permitting construction of earthen walled tanks and ponds thus
    eliminating costly construction of tanks of concrete or other structurally
    strong walls.

2.  Slippery Rock Creek Mine Drainage  Treatment Plant

       Probably  the most interesting studies made to date on the effect of acid
    mine drainage on an entire watershed, are those studies made for Slippery
    Rock Creek.  In addition to construction of a mine  drainage treatment plant,
    as a result of these studies,  mine sealing  and strip mine reclamation pro-
    jects were completed.  The latter projects are discussed in the  appropriate
    sections of this report.

       In 1963,  the basin was chosen by  the Pennsylvania Department of Health,
    Division of Sanitary Engineering (now Pennsylvania Department  of Environ-
    mental Resources,  Bureau of Water Quality  Management) for its first in-
    tensive mine drainage study of a large watershed''*^).  One of  the reasons
    for choosing Slippery Rock Creek was the  complete change in water quality
    that occurred downstream within months after the closing of a limestone
    processing plant. Although the large number of mines in the watershed
    had an adverse effect on  stream quality,  particularly in the headwaters
    which were  extensively mined, the highly alkaline discharge of waste water
    from the limestone plant effectively  neutralized the stream's acid load,
                                 -239-

-------
making it alkaline downstream of the limestone plant discharge.  Figure
46 shows  the effect that closing the  limestone processing plant had on
Slippery Rock Creek water quality.

   In July, 1964, a high runoff occurring as a result of heavy rainfall
caused a serious fish kill in Slippery Rock Creek.  The acid condition of
the stream during and immediately  following the runoff was the direct
cause of death of fish and other aquatic life.  Approximately two  million
fish were killed over the entire length of the  stream.  It was concluded
that the slugs of acid responsible for the fish kill were flushed out  of
swamps and impoundments in the extensively mined headwaters of  North
Branch Slippery Rock Creek and that acid mine discharges from  other
sources contributed to  and prolonged the acid condition of the stream^   '.

   Drainage from Slippery Rock Creek normally has  a high natural alka-
linity because much of  the watershed is  underlain by 20 or more  feet of
Vanport Limestone, a high calcium limestone.  This availability of CaCC>3
is responsible for the chemical character of the mine drainage which is
weakly acidic in spite of the extensive mining which has  occurred in parts
of the watershed.  The  mine drainage has a pH of around 4, acidities of
less than  100 mg/1,  a low  iron content,  a manganese concentration equal
to or greater than iron, and a relatively high solids content when compared
to other water quality parameters.  The mine drainage can be  classified
as Class II and some of the tributaries may have  Class III  mine drainage
(Table 1).

   The mine  drainage treatment plant is located near the headwaters of
North Branch Slippery  Rock Creek,  which is  in turn the  headwaters for
Slippery Rock Creek drainage area, a watershed  of some 400 square miles.
Tributaries which comprise less than 25 percent  of the total watershed are
responsible for mine drainage pollution in the main stream,  and  the bulk of
this  acid load is from the headwaters.  More than 83 percent of the acid
mine drainage originates in abandoned mine workings.

   The treatment plant is designed not only to improve the  water quality of
the headwaters of North Branch Slippery Rock Creek, but also to minimize
the effect of acidity  contributed by acid tributaries  at some distance down-
stream.   Table 34 showing treatment plant operating data for 1971  has  a
tabulation of pH ranges in  the stream below the treatment plant.

   To accomplish the objective  of making  North Branch Slippery  Rock Creek
a clean stream, it was  necessary to neutralize all the acid mine  drainage
and in addition,  to remove all the insoluble by-products  of that neutraliza-
tion.  According to Lisanti,  et al. (44>,  the treatment of a  major portion of
a stream watershed of  three square miles and the removal of settleable
solids was not done  before this undertaking.
                            -240-

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                          FIGURE 46

EFFECT OF THE CLOSING OF THE MICHIGAN LIMESTONE CO. PLANT
     AT BOYERS IN DECEMBER 1957 ON  WATER QUALITY IN
                    SLIPPERY  ROCK CREEK
   r 80T
     60--
     40--
      20--
   E
   >s
      0
                    KEY:
                     I. April 4,1951
                     2. May 11, 1955
                     3. February 25,1958
                     4. March 18,1963
                     5. June 17,1963

     -20--
    -40--
    -60--

   --80--
                       5
         Above Limestone
         Plant
         Station 4 Boyers
I Mile Downstream
From Limestone Plant
Station 5 West of Boyers
5 Miles Downstream
From Limestone Plant
Station 7 Bovard
        After Pennsylvania Department of Health, Division of Sanitary
        Engineering, 1965(43)
                               -241-

-------










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                                              -242-

-------
   The flows, acidity,  iron and manganese concentrations in the stream
may vary considerably with intensity of rainfall, therefore, average fig-
ures in design have little meaning.  The peak flow of the stream is in the
order  of 1, 550 MGD.  The treatment plant objective is satisfied if 6, 000
Ib. /day of acidity is neutralized and as much as 50, 000 Ib. /day of solids
is removed from the neutralized water.  The peak design flow rate was
set at  10 MGD and a median flow rate of 3 MGD was the basis of design
for the treatment  plant.  An average  lime  use of 1, 900 Ibs. /day was
estimated.

   A flow diagram of the plant is  shown in Figure 47 and the principal unit
processes are as  follows:

a) Flow Diversion - A concrete dam  to divert the peak design flow to the
   plant.  The dam, spillway and downstream channel are designed to take
   peak stream flow,  i«e.,  3,450  cfs.

b) Equalization -  A 2  million gallon impoundment lagoon serves to lessen
   shock loads to  the plant.

c) Neutralization  - The stream flows by gravity to a well agitated tank
   where  lime slurry  is automatically added under pH control.   A back-
   up pH and lime feed system is provided at the clarifiers center wall
   for  emergency use.  Dry hydrated lime delivered in tank trucks is
   made into a 30 to 35 percent by weight slurry by pneumatically un-
   loading and mixing it with water in a storage tank provided with a
   turbine mixer.  The specific gravity of the slurry is  controlled in  a
   dilution tank and fed to the treatment tank by means of proportioning
   weirs.

d) Waste water Pumping - The head loss through the plant made  it neces-
   sary to lift stream water.  This is accomplished with screw pumps
   because they are essentially surge-free, will handle  highly variant
   flow rates,  have non-clogging characteristics, and have an efficiency
   of about 85 percent which remains relatively constant regardless of
   variations in volume.  The pumps  are located between the flash mix
   neutralization tank and the clarifier.

e) Clarification -  A 75 ft, diameter,  solids-contact type clarifier is used
   which is  capable of handling the varying loading and settling  rates.  A
   200, 000 gallon lagoon is provided for emergency use.

f)  Solids Handling - A 30 ft. diameter thickener is provided.to  reduce the
   water content of the clarifier  sludge and to temporarily store the sludge.
   The thickened sludge is  pumped to one of two sludge lagoons, each
   150,000 gallons,  for further dewatering and storage.
                            -243-

-------
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-------
     g)  Miscellaneous - Also included in the plant are: a polymeric flocculant
        feeding system;  filtration of treatment plant effluent for potable water
        use; process  water system which uses the plant effluent without further
        treatment; compressed air system;  and a sanitary sewage treatment
        system.

        The plant is manned by two operators during the day shift, usually one
     during the second shift,  and  is unattended during  the night shift, operating,
     therefore, completely automatically.

        Construction  of the plant was  completed in December,  1969 and the total
     cost was  $750, 000.  Engineering costs were $53, 000.  The annual operating
     cost is about $51,000 (chemicals - $5,000,  electricity - $7,000, wages  -
     $34,000,  telephone and alarm services  - $1,500, and the balance for  mis-
     cellaneous items.

3.   Mountaineer Coal Company Mine  Drainage Treatment Plant

       Kosowski and  Henderson*   ' reported some of  the design features and
    capital expenditures for a mine drainage treatment plant at the Mountain-
    eer Coal Company operation  in Harrison County,  West Virginia, The  mine
    drainage is an alkaline type discharge containing substantial amounts of
    dissolved iron.   A typical analysis of the influent  is:  pH - 6.5,  alkalinity -
    252 mg/1  and iron - 109 mg/1.

       The treatment plant is designed to treat 0.72 MGD of mine drainage on
    a 24 hour basis.  A schematic flow sheet is presented in Figure 48. The
    steep mountainous terrain in the immediate vicinity of the discharge to-
    gether with other natural and man made obstacles, limited the available
    land for a treatment plant to  a single tract of land approximately 100 feet
    below  and 2, 000  feet away from the discharge.

       The design features of the treatment plant are  as follows:

    a) The mine drainage flows from the Levi Moore  borehole discharge in an
       open ditch to a 300, 000 gallon  earthen holding pond.  The Georgia V-type
       ditch is approximately 1,450 feet long, 16 feet wide and has a fall of 1/2
       percent.  The ditch also serves as an access road to the discharge  pump.

    b) From the holding pond, the mine  drainage flows by gravity through  a  10
       inch pipe, down the side of the mountain, across a railroad track, and
       across a creek, a total length  of 520 feet to the treatment  building.

    c) At the  treatment building the mine drainage is  mixed with  a lime slurry
       prepared from bulk hydrated lime.   The lime system is a  standard  unit
       consisting of a pneumatic  bulk lime storage bin of 30 ton capacity, a bin
       shaker, screw feeder, lime slurry tank with mixer and a flash mix tank
       with mixer.
                                 -245-

-------
LEVI MOORE
  PUMP
 500 GPM
           SETTLING   LAGOONS
         SLUDGE TRANSFER
            SYSTEM
                                      BINGAMON CREEK
                             ""•^B"
                            SLUDGE LAGOON

   MOUNTAINEER COAL CO. -  WILLIAMS  MINE
           LEVI  MOORE   DISCHARGE
                  FIGURE 48

From Kosowski and Henderson, 1968*   '
                     -246-

-------
d) The treated drainage then flows into an earthen aeration lagoon of about
   100, 000 gallon capacity. Aeration is accomplished by spraying the water
   into the air using a floating surface aerator.

e) The water then flows into two earthen settling lagoons  arranged in series
   where the  insoluble iron compounds drop to the bottom of the lagoon while
   the clear treated water  overflows  into the creek.   The settling lagoons
   have a combined capacity of almost 3 million gallons.

f) Flocculating chambers of reinforced  concrete construction were built into
   the inlet of each of the settling lagoons.   The mechanical flocculator  is a
   standard unit, equipped  with  one five-blade flocculating turbine with sta-
   bilizing ring and powered with a 1. 5 HP motor with variable speed drive.
   Only one flocculator is used since it is physically moved from one settling
   lagoon to the other. According  to Kosowski and Henderson^   ', this  is
   a unique feature  of the treatment plant design and probably the first of its
   kind in the mine drainage field.  The  flocculating  units are expected to re-
   duce significantly the retention time,  therefore, huge lagoons are not
   needed to provide retention time for precipitation of iron compounds  as
   under normal circumstances.

g) A concrete sludge sump, with sludge  pumps  and piping was installed  be-
   tween the two settling  lagoons to permit draining the contents  and pump-
   ing the  sludge into a sludge lagoon.

h) Transfer of treated water from the treatment building  to the aeration
   lagoon, through the two  settling lagoons  and  into the creek is by open
   flared concrete  flumes.

   Another unique feature of this treatment plant is the installation of a  com-
plete  bulk lime system,  even though the  water is not acidic.  The lime  sys-
tem is used to obtain basic information on a large-scale treatment plant under
a variety of actual  operating conditions and seasonal fluctuations.

   The treatment facilities  are capable of discharging treated mine drainage
containing no more than 10 mg/1 of iron,  30 mg/1 of  aluminum,  200 mg/1 of
suspended solids and having a  pH of 5. 5  to 8. 5.

   The estimated capital  expenditures at the Levi Moore treatment facilities
are $120, 000. A breakdown of these expenditures  are:

a) Excavation and Grading                             $23, 000
b) Mechanical Equipment including Electrical          13, 000
c) Concrete,  Piling, Erection of Steel and Bridge       59,000
d) Piping                                               6, 000
e) Sludge Pump and Piping                              15, 000
f)  Contingencies                                        4, OOP

   Total                                             $120,000
                             -247-

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4.  Little Scrubgrass Creek Lime Treatment Plant

       Based on the results obtained from research using the lime neutraliza-
    tion technique with the "Operation Yellowboy" trailer, the Pennsylvania
    Department of Mines and Mineral Industries (now part of the Pennsylvania
    Department of Environmental Resources) decided that from a technical and
    economic viewpoint,  it would be most effective if neutralization of "low iron"
    streams was accomplished using a fully automated neutralization process
    (46,47).

       A prototype treatment plant was designed and installed on Little Scrub-
    grass Creek, Venango County,  Pennsylvania.  The plant did not include
    any  facility for liquid solid separation and this type of installation may
    only be used in those cases where  iron, aluminum,  manganese and other
    precipitable salts are present in low  or insignificant quantities.   There
    does not appear to be a  limit to the acid content of the mine water which
    can  be treated by the plant.  It may be possible to operate a plant of this
    type at  sites where the stream velocity is such that any  precipitates which
    might form would be carried away and dispersed and would not create any
    appreciable sedimentation or siltation problems.

       The  treatment plant operated 24 hours per day, 365 days per year and
    treated the  entire flow of Little Scrubgrass Creek.  A schematic  diagram
    of the plant is shown on Figure 49. A float mechanism suspended from the
    treatment plant into the creek rises and falls with the flow  of the  water be-
    neath the plant.  The stream flow  is highly variable, but the  quality of the
    water remains nearly constant, therefore,  the float mechanism needs only
    to feed  a quantity of lime directly proportional to the quantity of water flow
    beneath the plant.

       Similar plants were later  constructed on other streams  in Pennsylvania.
    The capital costs have ranged from $40, 000 to $54, 000 depending on site
    conditions and the specific  requirements of the mine drainage.

       The  Little Scrubgrass Creek mine drainage has an iron  content of approxi-r
    mately  1 mg/1 and an average acidity of 68  mg/1.  Neutralization is  the only
    treatment required of this stream. Aeration and dewatering were not war-
    ranted.  Costs for treating 1, 000 gallons  of this  specific water by lime
    neutralization varied between $0.0068 (high flow) and $0.0573 (low flow).
    Table 35 gives the monthly operating  expenses for high and low flows.
                                 -248-

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                                 FIGURE 49


                          SCHEMATIC DIAGRAM
               LITTLE SCRUBGRASS  TREATMENT PLANT
                  VENANGO COUNTY, PENNSYLVANIA
                           Filter
                                            Manhole
             Line for
             pneumatic
             loading
From Charmbury,  et al.,  1968
                                (46)
                                   -249-

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                       TABLE 35

LITTLE SCRUBGRASS CREEK LIME TREATMENT PLANT
              Monthly Operating Expenses

                              Low Flow*    High Flow**

Lime  (Tons @ $15.65/Ton)     $116.46       $557.50

Electricity                        12.35         18.00

Man Hours                       160.00        160.00

Repairs                           5.50          5.50

Total                          $300.31       $741.00


 *Summer-Fall Low Flow

**Winter-Spring  High  Flow
                         -250-

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5.  Rausch Creek Mine Drainage Treatment Plant

       A report submitted by the Anthracite Research and Development Com-
    pany'^9) to the Pennsylvania Department of Environmental Resoruces in-
    dicated there are  28 active mining operations on the east and west branches
    of Rausch Creek together with six abandoned workings on the west branch
    and an overflow from a mine pool on the east branch contributing  to mine
    drainage pollution of the stream.

       A treatment plant was designed to treat the entire  flow of Rausch Creek
    located in Schuylkill County, Pennsylvania and  construction is nearing com-
    pletion.  Figure 50 is  a flow sheet of the treatment plant.  Operators of
    active mines contributing mine drainage to Rausch Creek are required to
    pay a fee for operating expenses of the treatment plant.

       The plant is designed for a  flow of 10 MGD with a hydraulic capacity of
    20 MGD and is  provided with flash mixing, aeration,  flocculation  and clari-
    fication, and thickening and polishing lagoons.  Flows larger than 20 MGD
    are automatically bypassed to  Polishing Lagoon No. 1. In the event of such
    large flows, facilities have been provided for addition of sodium hydroxide
    to the polishing lagoon.  Also the  large holding capacity of the lagoons should
    be able to absorb  excess flows without any appreciable change in alkalinity
    of the effluent.  Provision has  been made for trucking the sludge for final
    disposal.  The  total construction cost of the project is $1,747,380 and engi-
    neering design costs amount to an  additional  $314, 700. Since the  plant has
    not gone into operation yet,  no operating costs  are available(50).

6.  Altoona Mine Drainage Treatment  Plant

       The treatment  plant was designed by  Gwin, Dobson &  Foreman, Inc. ,
    to eliminate acid mine drainage contamination of the area west of Altoona,
    Pennsylvania and  to improve the supply  of potable  water  to the Altoona
    Water System^51).

       The major sources of potable water for the City of Altoona are located
    in drainage areas  west of the city.  One stream, Kittanning Run is bypassed
    because it is highly contaminated with acid mine drainage.  Glen White Run
    is contaminated to a lesser extent  and is used for  water supply.  Sugar Run
    was formerly used as  a supply of potable water, but it is now highly  con-
    taminated by acid mine drainage.   Two other drainage areas, Mill Run and
    Homer's Gap, are not affected by mine drainage.  A general summary of
    water quality parameters of the streams is as follows:
                                -251-

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                                 Acidity    Iron    Manganese
                          pH     mg/1    rag/I       mg/1
       Glen White Run    3.8       60      5.5         3.3
       Kittanning Run     2.9      420     70.0        11.0
       Sugar Run         3.5      140     12.0         2.0
       Mill Run           7.1        0      0.2         0.0

       On the basis of laboratory and field investigations, it was decided that
    these flows could be neutralized with a combination of lime  treatment,
    mixing, aeration and sedimentation.  Additional studies were carried out
    to determine the most feasible means of further treatment to render the
    water potable for use in the Altoona Water System.  The studies  indicated
    that a lime-soda process be used as it provided more flexibility and is  more
    adaptable to  changing conditions which might occur.   The  combined water
    treatment plant is under  construction  and has  separate facilities for neu-
    tralization and for  softening and filtering a water supply.   Neutralization
    facilities are designed  for a capacity of 15 MGD and the softening and fil-
    tration portion is designed for a capacity of 7 MGD.  A  schematic flow
    diagram is shown in Figure 51.  Sludge will be  disposed of in abandoned
    deep mines.

       The total  construction cost of the project as  contracted will be about
    $4, 590, 000.  Engineering design and supervision costs  are  about $172, 000.
    The operating costs  for the treatment plant,  excluding capital ammortiza-
    tion, are expected  to be about $156, OOO^50).

7.   Shirley Machine  Company "Mixmeter"

       A package slurry making and discharging plant is available in several
    models  with  the trade name "Mixmeter" from the Shirley  Machine Com-
    pany, a Division of Tasa Corporation, Pittsburgh, Pennsylvania^   '.  The
    plant comes  complete with pH recordings and controlling  instruments.  A
    typical installation arrangement of one of the models  is  shown in Figure
    52.

       The Mixmeter provides  continuous  variable  feed under automatic con-
    trol and is capable of feeding 500 to 3, 000 Ibs. /hr. of hydrated lime in
    slurry form  with 20 percent solids.  Plants with higher feed capabilities
    have been designed  and are available on order.   The Mixmeter system
    monitors the result of treatment downstream of the treatment plant,  re-
    lays a signal to the  Mixmeter which responds to maintain  the desired pH
    of the effluent.  In  this concept the pH (a specific and constant pH) of the
    treated  effluent is the object of the treatment process.  It automatically
    compensates for volume  and quality of the influent and the quality of neu-
    tralizing agent being used.

       Coal operators and other industrial sites in Pennsylvania, West Vir-
    ginia and Ohio with  acid pollution problems have a number of these plants
    in operation.
                                -253-

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                            -254-

-------
                                     Continuously Recording Controller
       Charging Tank
            Slurry Feed Hose
                      Raw Water
     Suction Hose
Sump
                                   Plan View
                             Continuously Recording Controller
                                                     pH Sensor
                   Charging Tank
              Jfl
                                                       Water Line
                                End View
                                 FIGURE  52
 MIXMETER MODEL 65AE - TYPICAL INSTALLATION ARRANGEMENT
From Shirley Machine Company, Information Manual,  1972*   '
                                   -255-

-------
FLASH DISTILLATION PROCESS

       Flash distillation is a vaporization and  condensation process.   The
feed in liquid state is heated to the vaporization point in an enclosed chamber
and subsequently flashed,  in a series of chambers or columns, operated at
successively low pressures and temperatures (Figure 53).  The basic  process
has been utilized for years by the chemical industry for the processing of
petroleum,  organic chemicals, and inorganic chemicals.  The principal items
of equipment include evaporators,  deaerators,  air ejectors, heat exchangers,
pumps, air compressors and stream generating systems.

       Within the last five years, the process  has been investigated,  evaluated
and used for processing saline  and brackish waters for production of potable
water for domestic use.  Recently the process  has been investigated as a method
for the treatment of acid mine waters and at the same time for the production of
high quality potable water.

       The basic idea of a concentrating evaporator is  to reduce the volume of
contaminant ions by removing the H^O as vapor and leaving all the contaminants
behind.  Drastic reduction in volume of material to be disposed of is the chief
benefit of this method,  with the production of ultrapure water being a close sec-
ond.

       Westinghouse Electric Corporation under a contract with the Coal Re-
search Board,  Commonwealth of Pennsylvania, evaluated the flash distillation
process for treating of acid mine water(^'> 54,  ", 56)<  Preliminary tests were
made with a small scale pilot plant to determine the optimum operating condi-
tions and  to assess the engineering and economics of the process as applied to
acid mine water.  The data obtained from these tests were used to design a 5
MGD treatment plant.   Capital investment and  operating costs were estimated
for the plant based on  the  data from the pilot plant operation (Tables 36,  37,
and 38).

       The operating costs in Tables 37 and 38 do not include  capital cost
amortization and cost  of sludge disposal.   The  demineralization plant was
scheduled to be completed about January, 1973.  Since  the new U.G.I, steam
plant  was not  scheduled to be completed until  at least  June, 1975,  it would
have been necessary to operate the flash distillation plant for at least two years
on temporary oil-fired boilers.

       The disposal of solid wastes  from the Westinghouse Plant posed many
problems.  Each day of full operation would yield about 150 tons of residue
which would be  extremely caustic.  Plans called for the disposal of this mat-
erial in a plastic-lined pit at  the plant site but  because  of the chemical com-
position of the  plant residue,  the Pennsylvania Department of Environmental
Resources felt contamination of the groundwater could  occur if the plastic
lining failed.

       Because of projected excessive operating costs  and questions about en-
vironmental impact, plans to construct a plant have been abandoned.


                                 -256-

-------
   Cooling Water
  Product Water
<10 PPM
   IDS)
                    1st Stage Heat
                    Rejection Unit
1st Stage Heat
Recovery Unit
                                                 2nd Stage Heat
                                                  Recovery Unit
                             2nd Stage Heat
                             Rejection Unit
1st Stage Recycle
  Feed Heater
Steam
Ik k
* *
FeS04 Recovery
or Feed to
Wet Chemical
Recovery Unit
                2nd Stage Recycle  steam

                                                               (FeSO.-7
                  4"H2rj)
          for
\izer/

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-------
                              TABLE 36

               MULTIPLE STAGE FLASH DISTILLATION
             ACID MINE DRAINAGE TREATMENT PLANT
                             Cost Estimate
                                (1971)

1.  Principal Items of Equipment
       Evap.  & Brine Heater                              $  6,024,000.00
       Air Ejector                                             10,000.00
       Pumps and Drivers                                     425, 124. 00
       Misc.  Tanks                                            50,000.00
       Crystalizer                                                	
       Evap.  Field Erection                                   567,000.00

2.  Process Facilities
       Site Development                                       567,000.00
       Piping                                                 655,200.00
       Electrical                                              459,527.00
       Instruments                                            195,300.00
       Insulation                                              126,000.00
       Painting                                                50,400.00
       Building                                               264, 600. 00
       Equipment Erection                                     347, 760. 00

3.  Other Plant Costs
       Engineering (Purchases)                                577,041.00
       Interest During Construction
       Start-Up Expenses                                     214,200.00
       Engineering W                                         446, 000. 00

4.  Other Facilities
       AMD Pumping System                                  597, 996. 00
       Cooling Tower                                         432,180.00
       Temporary Boiler (s)                                1,007,760.00
       Prod.  Water Post-Treat                                 63,000.00
       Sludge Disposal                                          6, 300. 00
    Plant Cost Total                                       13,086,388.00

5.  Operation and Maintenance                                 447, 000. 00

6.  Plant + Operational Cost                               13,533,388.00

7.  Contingency on Prototype Plant                             666,612.00

8.  Grand Total Plant + Operation for 1st Year             $14, 200, 000. 00
 After Westinghouse Electric Corp.,
                                 -258-

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                              TABLE  37

                   SUMMARY OF OPERATING COSTS

                 Plant Capacity = 1, 750, 000 KGAL/year
                                              1971 Engineering Cost Estimate
                                                 Yearly      Cost/1000 Gal.
Direct Operating Costs
    1.  Steam Cost                            $  505,050.00          28.
    2.  Electric Cost                             344,064.00          19.
    3.  Maintenance                               69,600.00           4.
    4.  Oper. Labor/Supv.                         93,600.00           5.
           Subtotal                            $1,012,314.00          58.

Indirect Operating Costs

    1.  General and  Administrative
        Payroll                               $   28,080.00           1.
    2.  Payroll Extras  for Op. Labor               12,500.00            .
           Subtotal                            $   40,580.00           2.3£

Total                                         $1,052,894.00          60. 3£


"Interim Cost of Water" is presented in Table 38.  This  cost can be anticipated
until operation with the  U.G.I,  plant commences.

 After Westinghouse Electric Corp. ,
                                -259-

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                              TABLE 38

                     INTERIM OPERATING COSTS
                                              1971 Interim Cost Estimate
                                                  Yearly          Cents/1000 Gal.
Direct Operating Costs
    1.  Steam Cost                            $3,968,800.00         226.
    2.  Electric Cost                              602,760.00          34.
    3.  Maintenance                                75,000.00           4.
    4.  Operating Labor and
        Supervision                                126,880.00           7.
           Subtotal                            $4,773,440.00         272.

Indirect Operating Costs

    1.  General and Administrative Costs       $   125,000.00          7. l
    2.  Payroll Extra for Operating Labor           17,472.00          1.0
           Subtotal                           $   142,472.00          8. l£

Total                                         $4,915,912.00         280.7^

                                                                     $2.81

 After Westinghouse Electric Corp.,  1971   '
                                 -260-

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ION EXCHANGE PROCESSES

        The basic process for the treatment of acid mine water by ion exchange
(deionization) consists of the reaction of metal salts and hydroxides in water
with specific anionic and cationic resins.

        Various forms of ion exchange processes can be used to remove un-
desirable constituents from mine drainage. Either alone or in combination
with neutralization, softening, and aeration, ion exchange can produce water
of high quality suitable for either domestic or industrial use.  There is an
indication that the sludges and other  residues produced by this  process may
be more amenable  to disposal than those produced by neutralization.

        Burns and Roe, Inc. , in a proposal to the Pennsylvania Department
of Environmental Resources'-5 ' >,  describe the two fundamental reactions in-
volved in the ion exchange process.  They can be expressed by the following
equilibrium equations:

        cl  + Rfc2+ = c2+ + RX'C^

        AX- + R2+A2~ = A2~ +RZ+AI"

        Where C^ ,  C2  are cations of different  species

              A,",  A ~ are anions of different species

              R!~,  RO  are cationic and anionic exchange materials.

        The normal sequence in the treatment of industrial waters by the ion
exchange process is  to pass the flow first through a cation exchanger and then
through an anion exchanger. If softening is the desired objective, the following
reaction applies:
       Ca++              Ca++
       Mg++              Mg++
                                     2 Na
       After the resin is exhausted; i.e., all of the exchange sites have been
used, it  is regenerated with concentrated salt solution as follows:

                              Ca++
                l +2 Na+—   ++ >+Na2R1
       Mg                    Mg   J

       The calcium and  magnesium ions  are contained in the waste regenerant
as the chlorides.  The treated water contains sodium ions and all of the anions
originally present.
                                -261-

-------
       Applied to mine drainage, the  softening reaction has several limitations.
The process removes  none of the anions, specifically, sulfates, and the waste
regenerant contains the same cations,  still in soluble, albeit more concentrated,
form.  A third limitation is that the ion exchange reactions involving iron and
manganese cations may not be as easily reversible as those involving calcium
and magnesium.  Finally, the total waste problem is actually  aggravated by the
load represented by the regenerant.

       If_ the conventional demineralization process is utilized, the reactions
are as follows:
       2 Na
         Ca
         Mg
         Fe
         Mn
         Al
       SO4
 2 Na
  Ca
  Mg

  Mn
  Al
     H2S04
                                      2HC1
                                           2 H2O
H2S04                        S04
        >+ 2 R2OH	-R2 <^
2 HC1 J                     [ C12

The  regeneration  reactions are as follows:
       2 Na
         Ca
         Mg
         Fe
         Mn
             HS0
             SO,
             C12
                  + 2 NaOH
 2 Na
  Ca
- Mg
  Fe
  Mn
                           2 Na
SO
                                  SO,
                R(OH)2
       The limitations of the normal demineralization sequence are the same
as those of the softening process, plus the relatively high cost of the regener-
ation chemicals, which makes the process uneconomical as compared to alter-
nate processes as soon as the total solids level exceeds 500-1,000 mg/1.

       The criteria used in selecting  ion exchange processes for the treatment
of mine drainage are therefore the following:

        1.  To convert the contaminating soluble ions present in mine drainage
           into insoluble forms.

       2.  To achieve this  conversion either utilizing low cost chemicals as
           regenerants or to  develop process  sequences which allow for the
           recovery and reuse of the regenerant.
                                -262-

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        A promising process for treatment of acid mine drainage wastes was
 described by Pollio and Kunin'^°'*.  The principal process steps are expressed
 in these  reactions:

        Treatment:

             M (SO4) + 2 RHCO3	-R2SO4 + M(HCO3)2

        Regeneration:

             R2SO4 + 2 NH4OH	 2 ROH + (NH4)2SO4

             2 ROH + 2 H2CO3	*• 2 RHCO3 + 2 H2O

        The ion exchange process is followed with aeration and coagulation with
 lime to precipitate iron, manganese and aluminum and to reduce calcium  and
 magnesium hardness.

        The advantage of this process is that most of the metallic sulfates  are
 converted into soluble bicarbonates which pass through the  resin bed without
 forming  precipitates.   The insoluble salts then are formed  downstream in the
 aerator and softener and are removed by coagulation and  sedimentation.   The
 regenerants used  in this process are ammonia  and  carbon dioxide, both of
 which are relatively low cost bulk  chemicals.   Furthermore, the process  ap-
 pears to  be suited to either regenerant recovery and reuse  or the development
 of marketable by-products from the spent regenerant.  The process therefore
 has the potential of meeting the objectives of elimination of pollution and of the
 ultimate  disposal  of the waste products.

        Another promising ion exchange process for treatment of acid mine
 drainage waters takes advantage of sulfate-bisulfate equilibria and is  currently
 being explored for processing brackish  waters.  This process** uses 1) a strong
 acid cation exchange resin, and 2) a strong  base anion exchange resin which
 operates on the sulfate-bisulfate cycle.

        The fundamentals  of this process are as follows:  In the first step, the
 water is  contacted with a strongly  acidic ion exchange resin,  converting the
 salts to their corresponding free acids.  These  are passed  through the sulfate
 form of a strong anion exchanger.   The divalent sulfate counter ions remove
 hydrogen ions from the water and are converted to  the monovalent bisulfate
 ion.  This frees half the anion exchange sites for absorption of anions from
 solution.  The water is thereby effectively demineralized.  For example,  a
 solution  of ferrous sulfate passed through the resin acids  will react as follows:
 *Desal Process^
**Sul-biSUL process1
                                 -263-

-------
       Cation Exchanger

           FeSO4 + 2 RH .^  *  R2Fe + H2SO4

       Anion Exchanger

           H2SO4 + RzSO4 «.     2 RHSO4

       Regeneration is a simple process.   The anion resin is regenerated with
water, or water made slightly alkaline with lime, which, because of its higher
pH, reverses  the sulfate bisulfate reaction:

                    H20

           2 RHSO4 - - RzSO4  + H2SO4

       The liberated acid is partially recovered using it to regenerate the
cation resin.

           R2Fe + H2SO4 - «- 2 RH + FeSO4

       The regenerant chemicals are inexpensive; i.e.,  sulfuric acid and
lime.  This  process is reportedly more  efficient at higher salt concentrations,
and it could be very economical if the natural acidity of mine waters could be
used as a source of regeneration acid.  It seems possible that this process
could be more  economical than bicarbonate cycle processes for certain acid
mine drainage  waters.  Therefore,  the choice of ion exchange process would
depend on the  concentration and composition of the acid mine drainage water
to be processed.

       Burns  and Roe, Inc.^'»  "', designed an ion exchange treatment plant to
treat acid mine drainage at Hawk Run near Philipsburg,  Pennsylvania.  The plant
utilizes the "Modified desal process"® developed by Rohm and Haas  Company,
Philadelphia,  to remove mineral acidity.  This is followed by aeration, softening,
and filtration to remove iron, other metals and hardness to produce water meet-
ing the U.S. Public Health Service standards for drinking water.  A schematic
flow diagram of the treatment plant is shown on Figure 54.  Burns and Roe,  Inc.'  '
gives  a summary of operating data and the design water quality as shown  in
Table 39.

       The estimated construction cost of the  plant is  about $2,485,000 including
engineering design costs.
       Chester Engineers^*' °*> designed a 0.5 MGD ion exchange treatment
plant for Smith Township about 20 miles west of Pittsburgh.  The capital costs
of the plant is borne solely by  the Commonwealth of Pennsylvania and the Smith
Township Municipal Authority  in conjunction with the Smith Township Supervisors
will operate and maintain the plant.
                                -264-

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                               TABLE 39

     SUMMARY OF OPERATING DATA AND DESIGN WATER QUALITY

                      Summary of Operating Data

Nominal Plant Capacity, Normal Operating Conditions       500, 000 GPD

       AMD Water Treated                                684, 000 GPD

         In-Plant Use and Waste                            64, 000 GPD

         Treated Water Produced                          620, 000 GPD

Maximum Output of Ion Exchange Resin When Supplied
with AMD Water of Design Conditions                       820, 000 GPD

Chemical and Fuel Requirements

         Ammonia (5% Makeup)                                 160 Lb. /Day

         Carbon Dioxide                                     6, 180 Lb. /Day

         Lime                                               6,430 Lb. /Day

         Fuel Oil                                              350 GPD

Waste  Products (Dry Basis)                                 19, 160 Lb. /Day

                         Design Water Quality

Sulfate
Hardness
Total Iron
pH
Total Solids
AMD Feed
1, 000 mg/1
550 mg/1
250 mg/1
3 - 4
1,000 mg/1
Product
50
70
0.3
8.5
300
mg/1
mg/1
mg/1

mg/1
                                 -266-

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       The water in Dinsmore Reservoir,  the source of potable water for the
Township,  is alkaline but contains more than 1, 000 mg/1 of sulfates, largely
calcium sulfate,  and  several hundred mg/1 of carbonates. Mine drainage from
strip mines within the area flows through limestone and calcareous  shales.
This results in the production of a calcium sulfate near -neutral water product
as the  acidity and iron is removed.  A typical analysis of raw water in the res-
ervoir would indicate  a pH of 6.5 to 8.4, sulfates from 400 to over 1, 300 mg/1,
and total dissolved solids of 1, 500 to 2, 000 mg/1.

       Prior to the installation of the ion exchange treatment plant, raw water
was  treated by coagulation to remove turbidity, some soda lime softening fol-
lowed by filtration and chlorination.  Hardness was only partially removed by
this  treatment and the high total dissolved solids discouraged industrial use.
Water  treatment costs using the lime and soda ash process was about 0.50£/
1, 000 gal.  and it is believed that water treatment costs using the new ion ex-
change process  will be brought  down to 0.20^/1, 000 g
       The ion exchange process for the treatment plant is based on
technology of the Dow Chemical Company and on a resin handling system devel-
oped by Chemical Separations, Inc.  It employs two ion exchange steps and an
intricate method for regenerating and transporting  ion exchange  resins.  Figure
55 is a flow diagram of the process. A product water with a pH  of 8 to 9, a
dissolved solids concentration of less than  500 mg/1, and a total hardness of
150 mg/1 should result from treatment.  The total capital  cost of the project
including engineering design is estimated at $730,000.

       The Culligan International Company'"^) made an extensive study for  the
Environmental Protection  Agency on treatment of mine drainage using ion ex-
change processes.   They studied two complete processes in detail for production
of potable water.  One process,  the utilization of a strong  acid cation exchanger
(H+ form) with a weak base anion exchanger (free base form) is a conventional
ion exchange process which has never been applied to the treatment of mine
drainage.  The process utilizing a weak base anion in the bicarbonate form with
lime treatment had been studied  before.  Their study compared the  two pro-
cesses.  It is demonstrated that  these processes are capable of producing a
potable effluent from acid  mine drainage and that the chemical costs are  about
the same.  Wastes  from the conventional ion exchange process will  contain acid
materials while the  bicarbonate form-weak base process does not.  Three plant
sizes for each process are being designed for production of 0.1,  0.5 and 1,0
MGD of potable water so that a comparison can be made  of each  of the two pro-
cesses.
                                -267-

-------
-268-

-------
REVERSE OSMOSIS PROCESS

       A concise definition of the fundamentals  of reverse osmosis is  included
in "Treatment of Acid Mine Drainage by Reverse Osmosis, " a study by Rex
Chainbelt, Inc. for the Environmental Protection Agency^  '.

         "Osmosis occurs if two solutions  of different concentrations in the
same solvent are separated from one another by a membrane.  If the mem-
brane is semipermeable, i.e., permeable to  the solvent and not to the solute,
solvent flow  occurs from the  more dilute to the  more concentrated  solution.
This solvent flow continues until the two solutions are of equal concentration
or the  pressure on the more concentrated side of the membrane rise to a value
called  the  osmotic pressure.   If a pressure in excess  of the osmotic pressure
is applied  to the more concentrated side of the membrane,  the solvent can be
caused to flow into the more dilute solution.   This is termed reverse osmosis."

       Golomb and Besik' "°) describe five broad categories of osmotic mem-
brane modules as  follows:

       Tubular Units - There are several design concepts of tubular modules
on the  market.  Their chief advantage over other systems is  that they  can
handle liquids  containing suspended particles  or dissolved substances likely to
precipitate out as  the feed solution becomes more concentrated.  In the tubular
unit, provision is  made  for maintaining a good flushing action throughout  the
system during operation.  As the solution becomes more concentrated, it is
often possible  to prevent fouling or  plugging of the membrane simply by ad-
justing the proper hydrodynamlc conditions.   This is an easy operation in
tubular systems, but hardly possible in others.  Nevertheless,  there are also
some disadvantages:  1) the large number of connectors with the resulting ex-
pense in making and assembling the  array; 2) the small membrane  surface
area/unit volume ratio;  3) the necessity for enclosing  the tube exteriors to
protect the purity of the permeate; and 4) the  expensiveness of the support
media.

       Spiral-Wound Units  -  Developed by Gulf General Atomic Co. ,  the  spiral-
wound  unit consists of a "sandwich"  arrangement consisting of two  layers of
membrane, with a porous backing material at the center, at one end of which
is a perforated plastic pipe.  The edges  of the membrane are sealed, with the
porous backing material inside the resulting  envelope,  which with suitable mesh
spacers  is rolled spirally around the central pipe.   The whole is placed inside
a cylindrical pressure container, thus completing the  modular unit. Typically,
several modules can be placed in series. The feed  liquid flows axially,  and as
water permeates the membrane it flows  through the porous backing material to
the central pipe which acts as collector for the product water.  The concentrated
solution continues to flow axially  through the roll, emerging at  the  mesh spacer
gaps at the other end.
                                 -269-

-------
       A principal advantage of this design is that it has a high membrane
surface area/unit volume ratio compared with the tubular configuration.
Disadvantages  in comparison with tubular units  are:  1) severe problems  in
handling high-solids feed; 2) short feed flow paths; 3) high pressure  losses;
and 4) difficulty in recirculating concentrate.

       Plate and Frame Units - The plate and frame concept, the earliest
design of RO unit,  has  an obvious similarity to  the filter press,  and provides
a convenient solution to the pressure-containing problem.  A system of this
type has been developed by Aerojet-General Corp.  It is particularly attrac-
tive  for small, low-pressure plants.

       The membrane  is supported on a flat circular plate,  and plates are
stacked on top  of each other.   Product water emerges at the edge of the plates
in the smaller  units; in the larger units (over 1, 000 gpd* capacity) product
water is channelled to a central shaft.  Feed and product liquid streams are
kept separate by O-ring seals.  Turbulent flow  of the feedstream. is  induced
by means of baffles located near the membrane  surfaces.

       The following disadvantages can be ascribed to  the plate and  frame
design:  1) expensive to install and maintain (labor costs); 2) distribution and
short circuiting problems;  3) narrow flow channels; 4)  multiple membrane
handling, which increases the probability of failure;  and 5) low surface area/
unit  volume ratio.  Notwithstanding these limitations, large numbers of com-
plete units have been used for water purification on a scale up to  40, 000 gpd.

       Plate and Frame (Ultrafiltration) Units - Dorr-Oliver, Inc. has devel-
oped a somewhat unique ultrafiltration module,  less  costly and easier to main-
tain  than other devices  now available in regard  to membrane replacement.  The
membrane is supplied in the form of replaceable cartridges, which are inserted
into  a polyester/fiberglass molded rectangular  shell-and-cover arrangement.
The  unit has typical operating pressures of 10-50 psi.  The  Dorr-Oliver unit
utilizes high flux, non-cellulosic anisotropic membranes, developed by the
Amicon Corp., and tailor-made for  retention of large molecules  and colloids.
These membranes are  well-suited to operation  under more strongly acidic or
alkaline  conditions than the cellulosic membranes can withstand,  and also at
higher temperatures.   Currently,  this system is being developed for industrial
and domestic wastewater purification.

       Hollow-Fiber Units -  A somewhat novel approach to  RO equipment is
being pursued  by the DuPont Co.  and by Dow Chemical Co. , who  have pioneered
the use of fine  hollow fibers as osmotic membranes.

       Modules based on this  concept contain an astronomically large number
of hollow filaments, ca. 50/* o.d.  and 25^, i.d., assembled  into a cylindrical
bundle, the open ends of which have  been potted into  a plug of resin serving as

*Gallons of Permeate per Day
                                 -270-

-------
a header.  This bundle is inserted into a cylindrical shell which serves as
a pressure vessel.  Pressurized liquid is pumped into the shell side of the
assembly, permeate being collected from the ends of the hollow fiber  bundle.
These units contain an enormous membrane surface  area/unit volume ratio,
so that high intrinsic membrane permeabilities (in terms  of gfd) are unim-
portant.   Present systems are designed primarily for water demineralization.
Dow's fibers are spun from cellulose acetate; DuPont's from nylon and other
polymers.

       Advantages of the hollow fiber configuration are: 1) enormous surface
area/unit volume ratio; and 2) the hollow fibers withstand the high operating
pressures required for RO and eliminate the need for space-consuming porous
support media essential to other module designs.

       The disadvantage of this configuration is  that it is  not applicable where
an appreciable level of suspended  solids is  present in the  feed solution.  Fil-
tration is necessary to prevent clogging of the fiber bundle.

       The DuPont hollow-fiber unit, based on nylon fibers,  is  operational in
the pH range 1.5 - 12.0, as compared with the recommended pH range 3-8
for modules utilizing cellulose acetate membranes.
       A reverse osmosis plant for treating acid mine waters would consist of
a raw water  intake, pumps, and filters for removal of particulate matter from
the raw water.  Filter effluent passes to the reverse osmosis pressure vessel
and is  exposed to the membrane cells.  The concentrated brine after completing
its circuit through the reverse osmosis unit passes to a collection pond or tank
for disposal  by deep well injection or by a lime neutralization process.  Product
water is collected and held in storage tanks for ultimate utilization.

       A plate and frame  type reverse  osmosis unit was  briefly operated on
acid mine waters at two mines near Kittanning, Pennsylvania in 1965, by Gulf
General Atomic, Inc.'   '  under the  sponsorship of the  Office of Saline Water in
cooperation with the Bureau of Mines.  The spiral-wound configuration was then
extensively tested by Gulf General Atomic, Inc.^   ' at the Environmental Pro-
tection Agency mine drainage treatment laboratory in Norton, West Virginia.
These tests showed utilization of reverse osmosis with acid mine drainage feed
was feasible  and that the product water was of potable quality.  On the basis of
the test results,  it was reasonable  to conclude the process would be most appli-
cable for Class  I acid mine waters  which  are highly acidic and have low pH's,
and that Class III mine waters which contain no iron and are  alkaline would be
suitable.

       The principal advantage of reverse osmosis for acid mine drainage treat-
ment is the recovery of potable water as a byproduct.
                                 -271-

-------
       Disadvantages  are:  1) high cost of acid mine drainage treatment and
brine disposal; 2) reverse osmosis by itself does not eliminate acid mine
drainage water; 3) fouling of membranes with consequent necessity of periodic
replacements; 4) operation with the acid solutions required for the prevention
of scaling makes it necessary to construct the plant of corrosion resistant
materials which significantly increase  capital cost requirements; and 5) pre-
filtration of acid mine drainage is required for feed to a reverse osmosis
process unit.

       Cyrus Wm. Rice and Company in their report to the Appalachian Reg-
ional Commission^*/  developed tabulated costs  and plots based on the studies
of Keilin(69) and Schroeder, et al.C^O).   Tables  40 to 52 and Figures 56 to 59
show the tabulated costs and cost curves as worked out by this company. No
attempt has been made to update these  cost figures for  the present study be-
cause of rapid technological developments in the  reverse osmosis field with
resulting reductions in the  cost of RO units.

       Cyrus Wm. Rice and Companyl'*!) list the elements of capital and op-
erating costs which must be considered in design, construction and operation
of reverse osmosis treatment plants.

                        Elements of Capital  Cost

                  1.   Principal Items of Equipment

                      a)  Reverse Osmosis Cells
                      b)  Filters
                      c)  Pumps
                      d)  Pressure Vessels

                  2.   Process Facility  Costs

                      a)  Site Development
                      b)  Piping
                      c)  Electrical
                      d)  Instruments
                      e)  Buildings
                      f)  Others

                  3.   Other Plant Costs

                      a)  Contingencies
                      b)  Engineering
                      c)  Interest during construction
                      d)  Startup expense
                      e)  Cost of Site
                                -272-

-------
4.  Other Facilities  Costs

    a)  Raw Water Intake
    b)  Product Water Storage
    c)  Deep well or  lime neutralization
        facilities for  brine disposal
    Elements of Operating Costs
   (Excluding Taxes and Insurance)

1.  Reverse Osmosis Processing

    a)  Power
    b)  Membrane Replacement
    c)  Operating Supplies
    d)  Operating and  Maintenance Labor
    e)  G & A and Overhead
    f)  Fixed Charges
        (Amortization and Interest)

2.  Lime Neutralization Brine Disposal

    a)  Hydrated Lime
    b)  Limestone

3.  Deep Well  Brine Disposal
               -Z73-

-------
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                              TABLE 42

 ESTIMATED CAPITAL COSTS FOR REVERSE OSMOSIS PROCESS WITH
  LIME NEUTRALIZATION FOR BRINE DISPOSAL IN THOUSANDS OF
  DOLLARS (FOR A AND B SERIES CASES CITED IN TABLES 40 & 41)
Total RO plant
(Items I-IV, Table B)

Total Capital Cost
for Lime Neutralization
Facility^

Total
                         A-.l   A-l    A-10   B-.l   B-l
                                   B-10
162    917   6600    261    1485   10,690



200    240    480    200     290    1,000

362   1157   7080    461    1775   11,690
Note:

5.  Costs obtained from curves developed by Cyrus Wm.  Rice  & Co. ,  1969
From Cyrus Wm. Rice & Co.,
                                            (41)
                               -276-

-------
                               TABLE 43

    ESTIMATED CAPITAL COSTS FOR REVERSE OSMOSIS PROCESS
   WITH DEEP WELL BRINE DISPOSAL IN THOUSANDS OF DOLLARS

                            Special Case-A^          Special Case-B7
Total RO plant
(from plotted data)                 560                       416

Total Capital Cost
of Deep Well Brine
Disposal Facility                   600                       600

Total                             1160                      1015
Note:
    Special Case A is based upon data obtained from as follows:
    TDS = 1500 ppm, well depth = 4000 feet,  total cost basis =
    $150/ft., injection pressure = 700 psi, injection flow = 100 gpm.
    Data developed on the foregoing is as follows: AMD treated =
    720, 000 GPD  (from 1500 ppm inlet solids and 100 GPM disposal
    flow),  product flow = 575, 000 GPD,  Total well cost = $600, 000.

    Special Case B is based upon data in 6 above with the exception:
    TDS = 5000 ppm.  Data developed on the  foregoing is  as follows:
    AMD  treated = 358, 000 GPD (from 5000 ppm inlet solids and 100
    GPM  disposal flow),  Product flow = 214, 000  GPD, Total well
    cost = $600,000.
From Cyrus Wm.  Rice & Co.,
                                 -277-

-------
                             TABLE 44

          ESTIMATED CAPITAL COSTS VS. CAPACITY FOR
   REVERSE OSMOSIS PROCESS WITH DEEP WELL BRINE DISPOSAL
                 (FromSchroeder,  et al. ,  1966(70)  )

               Product Flow
                  in gpd                 Capital Cost

                   100,000                  $248,000

                 1,000,000                $1,407,000

                10,000,000               $10,120,000

               Total Dissolved Solids in Feed - 1638 ppm
From Cyrus Wm. Rice & Co.,
                                -278-

-------
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                            TABLE 46

  ESTIMATED OPERATING COSTS FOR REVERSE OSMOSIS PROCESS
       WITH LIME NEUTRALIZATION FOR BRINE DISPOSAL IN
       DOLLARS PER THOUSAND GALLONS OF AMD TREATED
   (FOR  CASES CITED IN TABLES 40 & 42 USING HYDRATED LIME)

                  A-.. 1   A-l    A-10   B-. 1     B-l    B-10

Sub-Total
(Table A)          .785   .137   .080   .618   .122   .078

Neutralization
Operating Costs    .182   .180   .161   .605   .595   .500

Fixed Charges      .507   .162   .099   .484   .186   .123

Total             1.474   .479   .340   1.707   .903   .701
                             TABLE 47

  ESTIMATED OPERATING COSTS FOR REVERSE OSMOSIS PROCESS
       WITH LIME NEUTRALIZATION FOR BRINE DISPOSAL IN
       DOLLARS PER THOUSAND GALLONS OF PRODUCT WATER
   (FOR CASES CITED IN TABLES 40 & 42 USING HYDRATED LIME)

                  A-. 1   A-l   A-10   B-. 1    B-l   B-10

Total             1.840   .599   .425   2.856    1.510  1.171
From Cyrus Wm. Rice & Co., 1969^ l'
                               -280-

-------
                            TABLE 48

  ESTIMATED OPERATING COSTS FOR REVERSE OSMOSIS PROCESS
       WITH LIME NEUTRALIZATION FOR BRINE DISPOSAL IN
       DOLLARS PER THOUSAND GALLONS OF AMD TREATED
   (FOR CASES CITED IN TABLES 40 &  42 USING  LIMESTONE)

                 A-. 1    A-l   A-10   B-.l   B-l   B-10

Sub-Total
(Table A)          .785   .137   .080    .618   .122   .078

Neutralization
Operating Costs    .140   .139   .121    .312   .305   .230

Fixed Charges      .507   .162   .099    .484   .186   .123

Total            1.432   .438   .300   1.414   .613   .431
                            TABLE 49

  ESTIMATED OPERATING COSTS FOR REVERSE OSMOSIS PROCESS
        WITH LIME NEUTRALIZATION FOR BRINE DISPOSAL IN
       DOLLARS PER THOUSAND GALLONS OF PRODUCT WATER
     (FOR CASES CITED IN TABLES 40 & 42 USING LIMESTONE)

                 A-.l    A-l   A-10  B-.l    B-l   B-10

Total             1.791   .548   .375   2.360    1.023  .720
From Cyrus Wm. Rice & Co.,
                              -281-

-------
                              TABLE 50

  ESTIMATED OPERATING COSTS FOR REVERSE OSMOSIS PROCESS
                WITH DEEP WELL BRINE DISPOSAL IN
        DOLLARS PER THOUSAND GALLONS OF AMD TREATED
              (FOR SPECIAL CASES A  & B IN TABLE 42)

                                Special Case A       Special Case B

Power (@ $.007/kw-hr)14            .063                 .069

Membrane replacement              . 006                 . 009

Operating supplies                   . 005                 . 007

Operating and maintenance
labor                               .095                 .190

G and A and overhead                . 030                 . 067

Well maintenance                    .025                 .051

Fixed Charges                       .282                 .497

Total                               .506                 .890


                              TABLE 51

  ESTIMATED OPERATING COSTS FOR REVERSE OSMOSIS PROCESS
                WITH DEEP WELL BRINE DISPOSAL IN
      DOLLARS PER THOUSAND GALLONS OF PRODUCT WATER

                                Special Case A, /     Special Case Bj

Total                             .634                1.49

Note:

14.    Deep well injection pump power added to reverse osmosis power.
15.    Based upon $6, 000/year maintenance estimated  by
16.    Product flow = 575, 000 GPD
17.    Product flow = 214, 000 GPD
From Cyrus Wm. Rice fe Co.,
                                -282-

-------
                             TABLE 52

         ESTIMATED OPERATING COSTS VS. CAPACITY FOR
 REVERSE OSMOSIS PROCESS WITH DEEP WELL BRINE DISPOSAL IN
      DOLLARS PER THOUSAND GALLONS OF PRODUCT WATER
               (FROMSCHROEDER,  et al.,  1966(70))

                Product Flow
                   in gpd                    Cost

                   100,000                  $2.57

                 1,000,000                  $1.09

                10,000,000                  $0.77

                Total Dissolved Solids in Feed - 1638 ppm
From Cyrus Wm. Rice & Co.,
                              -283-

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       Studies were conducted by Rex Chainbelt, Inc.  and the Environmental
Protection Agency(°^» ' *• '^» '3) with tubular,  hollow fiber and spiral-wound
systems  of reverse osmosis and the following conclusions were reached:

1.  Under proper operating conditions, reverse osmosis can be used to treat
    ferrous iron acid mine drainage without major iron and calcium sulfate
    fouling problems.

2.  Flux declines observed during optimized flow schemes were tolerable for
    all three units but the spiral wound and hollow fiber were slightly superior
    in flux stability.

3.  Although salt rejections were near  99 percent for  all three units, product
    water would still  need further treatment for iron and manganese removal
    and  pH adjustment before potable standards could  be met.

4.  An intolerable flux decline  rate was observed for  the tubular system when
    high salt passage (1.5 percent) membranes were utilized, while lower salt
    passage (0.4 percent) membranes  had significantly improved flux stability.

5.  Oxidation of ferrous iron by bacteria can be inhibited by ultraviolet disin-
    fection and/or by lowering  the pH to 2.9 by acid injection.

6.  Water recovery was limited to slightly  above  75 percent due to calcium
    sulfate precipitation which  occurred when brine CaSO^ molar solubility
    product values were in the  range 35-50 x 10~5.

7.  No observable loss in membrane salt rejection capability occurred during
    a six-mo nth study.

8.  The  tubular  system had significantly lower productivity and higher initial
    cost as compared to the hollow fiber and spiral-wound system in this
    application.

       Table 53  shows the typical raw  water quality characteristics  of the
Mocanaqua discharge  at Mocanaqua,  Pennsylvania,  where the three systems
of reverse osmosis were  evaluated.  Tables 54 and 55 compare the water
production capabilities and relative cost of the three reverse osmosis systems.
                                 -288-

-------
                      TABLE 53
TYPICAL RAW WATER QUALITY CHARACTERISTICS OF
               MOCANAQUA DISCHARGE
  pH

  Conductance

  Acidity

  Calcium

  Magnesium

  Total Iron

  Ferrous Iron

  Aluminum

  Sulfate

  Manganese

  Silica

  TDS

  Dissolved Oxygen

  Temperature
3.4

1100 Mmhos/cm.

 230 mg/1 as CaCO3

 120 mg/1

  90 mg/1

  80 mg/1

  68 mg/1

  11 mg/1

 800 mg/1

  15 mg/1

  10 mg/1

1200 mg/1

<  1 mg/1

  54° F.
                        -289-

-------
                           TABLE  54
                   Comparison af Uater Production Capaoilities
System

Spiral Wound
(Phasp I)
Spiral Wound
(Phase II)
hollow Fiber
(Phase II)
Tubular
(Phase II)
Pressure
Vessel
Volume
ft3


1.13

1.13

0.65

0.63
Enclosed
Membrane
ftraa ft2


150

166

1500

16.9
Memarana
Packing
Density
ft2/ft3


133

165

2308

26. 6
Aug. Flux
GF^O S
77° F &
(.00 psi
net
(19.28 @ 600)

12.86

12.31

2.1.6
(15.60 @ 600)
10.1.0
Total Vssael
Flux pe."1 Day
Gal/Day
® 77" F &
1*00 psi net
(2892 *S 600)

1929

2290

3720
(26<4 e 600)
Output psr Cubic Foot
of Vassal Volume
per day @ 77°F
& COO psi net
(2559 S 600)

1707

2026

5723
(1.18 S 600)
176 | 280
8
i
per Win. @ 77"F
S tOQ psi nei;
(1.76 & 600)

1.19

l.<4l

3.97
(0.29 8 600)
0.19
                           TABLE  55





                               Relative Cost
System
Spiral Uound
Phase I
Spiral Wound
Phase II
Hollow Fiber
Phase II
Tubular Phase II
Cost for One
Pressure Vessel
and Membrane
» 850.(11)
1 850.(11)
J100D.(1Z)
J 2SS.(13)
Obseruea Output (Gal. per
Vessel per day @ 77° F
X Indicated Net Pressure)
2892 e 600
2290 8 UOO
3720 9 <.00
261* @ 600
Initial Cost
per Unit Out-
put (^al/day)
80.29
$0.37
$0.27
$1.00
From Wilmoth,  et al. ,  1972(73)
                               -290-

-------
        In a report for the Environmental Protection Agency,  Rex Chainbelt,
 Inc.('  ) worked out  cost estimates for a 0.75 MOD reverse osmosis acid mine
 drainage treatment plant.  Figure 60  shows the flow sheet used for the cost
 estimates.  The following assumptions were made to arrive at costs:

 1.  Hollow fiber RO modules are utilized.

 2.  RO product water capacity is  0.75 MGD,

 3.  Chemical additive costs are based on field testing results.

 4.  Diatomaceous earth filtration is utilized.

 5.  No costs for buildings or land are included.

 6.  The  product water from the plant meets USPHS standards.

 7.  No costs are included for  disposal of  residuals.

 8.  Operating manpower includes a plant  manager  and a three man crew.
     (Total salary and  administrative  costs  - $50,000 per year.)

 9.  Power costs are 1.0^/kwh.

10.  Chemical additives include acid,  diatomaceous earth, lime, chlorine,
     flushing chemicals for RO  membranes, potassium permanganate.

11.  RO module  life  is  four years - replacement cost is 28£/gpd  capacity.

12.  The  brine treatment  system is of concrete construction with high speed
     floating aerators.

13.  The  product water treatment system utilizes a portion of the sedimen-
     tation tank overflow for  neutralization and potassium permanganate for
     manganese  oxidation, followed by filtration and chlorination.

        Table 56 shows the major cost items for the treatment system.  The
 cost estimates were based on vendor quotations  or  purchase prices at the time
 the  report'^) was written.  Advancement in reverse osmosis technology is
 likely to  bring about price reductions  in RO equipment.  Also it must be con-
 sidered that two tasks  are being performed,  i.e. , treatment of acid mine
 drainage and production of potable water.
                                  -291-

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                        TABLE 56

           MAJOR COST ITEMS FOR 0.75 MGD
         REVERSE OSMOSIS TREATMENT PLANT

1.   CAPITAL COSTS

     A.  Pretreatment

         Filtration (diatomaceous earth)
         pH Control
         Disinfection                             $ 29, 000

     B.  RO System

         Modules
         Pumps and Plumbing
         Instrumentation                         $385,000

     C.  Brine Treatment System

         Aeration Unit (high-speed surface aerator)
         Sedimentation Unit
         Chemical Feeders and Controls          $ 58, 000

     D.  RQ Product  Water Treatment

         Iron  and  Manganese  Removal
         Final Filtration
         Chlorination                            $31, OOP

               Total Capital Cost                 $503, 000

               Amortized @ 6% - 20 years, = 15^/1,000 gallons of
                                            Product Water

II.   OPERATING  COSTS IN £/l, 000 GALLONS OF PRODUCT WATER

     A.  Chemical Additives	   4.8

     B.  RO Modules	  17.4

     C.  Power	   7.0

     D.  Maintenance-Materials	   2.0

     E.  Operating Manpower	  17.3

               Total                        48.5

After Rex Chainbelt,  Inc., 1972(72)

                          -293-

-------
       Gulf Environmental Systems Company performed studies(^) to evalu-
ate the reverse osmosis process for treating acid mine drainage with high
ferric iron content.   They found it possible to attain water recoveries of 80
to 90 percent.  Environmental Protection Agency personnel carried out neu-
tralization and decantation operations followed by recycling of the super-
natant through the reverse osmosis unit.  This resulted in effective 98 per-
cent water recovery based on feed volume, with maintenance of excellent
quality in the  recovered permeate water.  This process combining reverse
osmosis  and neutralization has  been termed "neutrolosis" by Hill,  et al.
                                 -294-

-------
SUBMERGED COAL REFUSE COMBUSTION PROCESS

        Black,  Sivalls and Bryson, Inc. ''  '  performed engineering, laboratory
and economic studies on a two-stage coal refuse combustion process  for the
treatment of acid mine water.  The process utilizes coal refuse as fuel to gen-
erate steam for the conversion of acid mine water to potable water.  Energy
for steam generation to operator evaporators  for distillation or to drive pumps
for reverse osmosis, is derived from a two-stage coal refuse combustion pro-
cess.  In the first stage  of combustion, high-sulfur coal refuse or similar
low-cost fuel is dissolved in a molten iron bath.  In the second stage  of com-
bustion the fuel carbon is burned with air at the surface of the iron bath,  gen-
erating hot carbon monoxide which can be further burned to release additional
heat in a boiler.

        Two-stage combustion makes it possible to use high sulfur bearing fuels
without polluting the air.  Fuel sulfur is trapped in the iron from which it is re-
moved via a lime-bearing slag in the form of calcium sulfide,  without generating
sulfur oxides.  Sulfur is also recovered from  the reduction of  the sulfate  content
of the  acid mine water.   Sulfates contained in  the sludge generated  by distillation
or reverse osmosis units are dried and added to the combustor as part of the
slag.  Sulfur is extracted from the calcium  sulfide in the slag  by  treating the
hot slag with steam and air  to recover elemental sulfur.

        The recovery of sulfur from the acid mine water and the fuel, coupled
with the utilization of coal refuse as a fuel,  provides the economic  incentive for
treatment of acid mine water using this process.

        Figure 61 presents a flow chart of the  process.  The dotted lines on the
flow chart indicate the acid  mine water may or may  not be partially neutralized.
Partial neutralization will be required for concentrated acid mine  water to pre-
vent excessive corrosion of the  flash distillation equipment,  but for moderately
concentrated acid mine  water the process economics are more attractive without
neutralization.  Referring to Figure 61, if neutralization is required,  acid mine
water  is introduced into a neutralizer (1) where it is contacted with finely divided
limestone to partially neutralize the acid mine water to a pH of 3 or more.  The
limestone used for partial neutralization  reduces the amount of flux introduced
into the dryer  (4) for use  in combustor (5).  The neutralized water which  con-
tains  suspended solids is pumped to a flash distillation unit (7) to produce potable
water and a concentrated brine slurry which is subsequently fed to the rotary
kiln dryer (4).  If acid mine water is not  neutralized,  it is fed  directly into the
distillation unit.

        The rotary kiln dryer serves  three functions:  1) to dry the concentrated
brine slurry from the distillation unit, 2)  to calcine dolomitic limestone to pro-
duce lime and magnesia for  use  as flux in the  combustor, and 3) to preheat the
portion of the desulfurized spent slag from the desulfurization  unit.  The con-
tents of the dryer are fed to the  combustor (5) to minimize the quantity of dolo-
mitic limestone required in the process.
                                  -295-

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       The combustor is a refractory-lined steel vessel that contains  molten
iron.  Coal or coal refuse is pneumatically injected beneath the surface of the
iron bath where the carbon is dissolved to free its sulfur for ultimate reaction
with the flux floating  on  the molten iron surface.  Air is then injected slightly
below the surface of the bath and reacts with carbon to produce a carbon mon-
oxide rich  offgas. Heat generated during the combustion of the coal provides
the necessary heat of reaction to reduce  calcium sulfate contained in the dryer
solids  to calcium sulfide.  In addition, the combustor provides the energy re-
quired to produce iron from iron compounds  contained in the dryer  solids and
pyrite  contained  in the coal.  Molten elemental iron is continuously removed
from the combustor.  Slag containing calcium oxide, magnesium oxide, ash
and calcium sulfide is continuously removed from the combustor  and sent to
the slag desulfurization unit (8) where it is contacted with steam and air to
produce a  sulfur-rich gas.  Elemental sulfur is condensed out of this gas and
sent to storage.

       Desulfurized  spent slag exiting the desulfurization unit is  divided into
two streams which proceed to the dryer,  and to a spent slag storage pile.
Spent slag  consists of a  dry mixture of silica,  alumina, magnesium hydroxide
and calcium hydroxide.

       Carbon monoxide rich offgas generated in the combustor  is used to
supply energy for operation of auxiliary equipment.   A large fraction of the
combustor offgas is  sent to the waste heat boiler (10) which provides high
pressure steam for the  steam turbine-air  compressors (15) and  the exiting
low pressure steam for  the flash distillation unit. Steam generated in the
waste heat boiler undergoes a pressure reduction through the steam-turbine
air compressors before entering the distillation unit.  In the study, steam
from the waste heat boiler was assumed to enter the distillation unit directly.
Steam turbine air compressors are used to generate pressurized air for com-
bustion and coal  pneumatic conveying. Combustor offgas  is also  used  to pro-
vide the energy requirements for air preheating (13),  for  drying and calcining
the dryer contents, and  drying the incoming coal (14).

       Laboratory experimentation was conducted on those areas which could
profoundly affect the  process.  Engineering studies  show that the process has
potential for supplying inexpensive energy for distillation and permits  the re-
covery of sulfur  so that  distilled water is economically produced.  Depending
upon the  acid mine water composition and  a sulfur selling price ($20 to $30/
ton) the break-even price of water for a 5  MGD plant varies between $0.42 and
$0. 16/1, 000 gallons when a  14 percent capital  interest charge is  used.

       Table 57  shows the acid mine water compositions used in  the studies
and Table 58 gives an analysis of the coal  refuse selected as representative of
a high  sulfur coal. Table 59 shows the capital investment needed for various
sizes of treatment plants using the two-stage coal refuse combustion process.
The break-even price or the cost per 1, 000 gallons of product water for  a 5
MGD plant is shown in Table 60.  Figure  62 indicates that the capital invest-
ment is not a linear function of plant capacity and economies can  be realized
                                 -297-

-------
by using higher plant capacities.  This infers that the plant should be located
at a large source of acid mine drainage provided coal refuse  is located in the
vicinity.  All costs are based on mid-1970 prices.
                                  -298-

-------
                              TABLE 57

         ACID MINE DRAINAGE COMPOSITIONS  USED IN STUDY
        OF TWO -STAGE COAL REFUSE COMBUSTION PROCESS

                                                   Moderately
                             Dilute (ppm)       Concentrated (ppm)

Acidity  (as ppm CaCOj)            400                 1,200

Sulfate                          1,061                 3,183

Total Iron                         200                   600

Calcium (as Ca)                    80                   240

Aluminum (as Al)                    5                    15

Magnesium (as Mg)                 24                    72



                              TABLE 58

               ULTIMATE ANALYSIS OF COAL REFUSE
                            (% By Weight)

                   Carbon                    40.6

                   Hydrogen                   2.9

                   Oxygen                     3. 7

                   Nitrogen                    0.7

                   Sulfur                     10.0

                   Moisture                    3. 0

                   Ash                       39.3
From: Black, Sivalls, & Bryson,  Inc.,
                                 -299-

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                                                -300-

-------
                                TABLE 60

         DETERMINATION OF BREAK-EVEN PRICE OF WATER**
           5 MGD ACID MINE DRAINAGE TREATMENT PLANT
        USING TWO-STAGE COAL REFUSE COMBUSTION PROCESS
 Investment Cost                                       $8,100,000
 Potable Water Production                              4, 975, 000 GPD
     Daily Production Cost
           Capital Interest Charge*, (14%)                   3, 150
           Flux, 1105 Tons @ $2/ton                         2,210
           Coal Refuse, 1427  Tons  @ $0. 25/ton                 357
           Labor                                               300
           Maintenance, 3% of Investment                	675
                                                       $    6,692

     Daily Production Credits (not including potable water credit)
           Sulfur, 126 tons @  $25/ton                   $    3, 150
           Iron,  60  tons @ $20/ton                           1,200
           Slag,  1082 tons @ $. 5/ton                     	541
                                                       $    4,891

 Operating Revenue  (not including potable water credit)       (1,801)

 Break-even Price of Water         $1, 801 x 1, OOP = $0. 36/1000
                                       4,975,000       of water

 Potable Water Credit                                  $    1,801

 Operating Revenue                                             0
 ^Capital Interest Charge = $8, 100, 000 x . 14/360 days

##Assume:  1) Moderately concentrated acid mine drainage, 2) eight (8)
            percent sulfur refuse,  and 3) a heat rate of 3.25 million BTU
            per  1, 000 gallons of acid mine drainage.
                                  -301-

-------
                           FIGURE  62
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O
    I2r
    10
*    8
Q
c
o
     0
     0
 2         4          6          8          10
AMW Plant Capacity,  Million Gallons per Day
      EFFECT OF PLANT CAPACITY  ON CAPITAL INVESTMENT
         TWO STAGE COAL  REFUSE  COMBUSTION  PROCESS
From:  Black, Sivalls, & Bryson, Inc., 1971
                                    (76)
                              -302-

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FREEZING (CRYSTALLIZATION) PROCESS

       Hill, 1968*  ' discusses the principles of crystallization treatment and
says crystallization processes have a distinct energy advantage over many
other methods  of demineralization because the freezing  (heat of fusion) of
water only requires 144 btu per pound of water, or less  than one-sixth of the
heat of vaporization.  In his opinion, two methods of crystallization appeared
applicable to the treatment of mine drainage,  i.e. the freezing method and the
gas hydration method, although, these techniques  had not been tested on actual
mine drainage. He points out that the immediate research need in the area of
crystallization is a study to determine if the more troublesome ions found in
mine drainage, such as ferrous iron, ferric iron, sulfate,  calcium,  aluminum,
magnesium and manganese can be removed efficiently and economically.

       Applied Science Laboratories, Inc.'' ') under contract to the Environ-
mental Protection Agency performed a series of over 50 batch experiments in
a study of the freezing process  in 1970.  In these experiments four-liter quan-
tities of acid mine  water  were subjected to partial freezing to the extent of up
to 50 percent conversion to ice.   After partial freezing,  the ice and unfrozen
water (mother  liquor)  were separated.  The ice was melted and these melts
(product water) were found to have a reduction of metal  and acid components
of 85 to 90 percent. In experiments  in which both ferrous iron and total iron
were determined, the  product water had about the same  ratio of ferrous iron
to total iron as the original acid mine water, so it appears  there is little oxi-
dation of ferrous iron  during the partial freezing.  Difficulties  with analytical
results  prevented a firm conclusion as to  the reduction of sulfate.

       Similar percent reductions of metal ions occurred in freezing  experi-
ments using acid mine water that had been treated with lime.  Reduction in
hardness  of the lime-treated water was nearly 100 percent, but the pH remained
substantially unchanged.

       As a result of  these experiments, Applied  Science Laboratories, Inc.,
proposed  a partial  freezing process described in Figure 63 consisting  of the
following  three steps:

1.   The mineralized water is refrigerated to  convert a  considerable fraction
     of it into ice.

2.  As  much as possible of the mother liquor is drained off the ice,  almost all
     the salts remain in the mother liquor.

3.   The ice is melted to  produce product water.

       Partial freezing as a crystallization process appears to be technically
feasible for treatment of  mine drainage,  but studies have not advanced beyond
laboratory batch tests. It is yet to be proven that this method would be appli-
cable to mine drainage treatment in large scale studies, i.e. ,  technically or
economically feasible.
                                 -303-

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                       FIGURE 63
   MOTHER LIQUOR
                        ACID MINE WATER
                       (600 p.p.m.total iron)
                                PARTIAL FREEZING
                  I
                  ICE
          (wet with mother liquor)
                                  RINSE OR WASH WITH
                                  LIMITED VOLUME OF
                                  PURE WATER
    FIRST MELT
  PRODUCT WATER
                    WASHED OR RINSED
                            ICE
                              FIRST
                              PARTIAL MELTING
UNMELTED ICE
                     WASH WATER
                         OR
                     RINSE WATER
                                          SECOND
                                          PARTIAL MELTING
                   SECOND MELT
                  PRODUCT WATER
                  UNMELTED ICE
                                                     THIRD MELT
                                                   PRODUCT WATER
              COMBINED PRODUCT WATER
                (60 p.p.m. total iron)

             FLOW DIAGRAM FOR PARTIAL FREEZING
                      OF ACID MINE WATER
From:  Applied Science Laboratories, Inc.,  1971
                                           (77)
                              -304-

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       The Office of Saline Water has been studying the separation of salts
from water by crystallization for a number of years, but these studies are
concerned with treatment of brackish water and not mine drainage.  Several
pilot plants are in operation. Schroeder, et al.V'"),  in 1966 wrote a report
for the Office of Saline Water in which they analyzed the application of saline
water conversion processes to acid mine waters.  They estimated the cost
of treating mine drainage from Kittanning Run, Pennsylvania by vacuum
freezing,  secondary refrigerants (N-Butane) and the hydrate process.  These
costs for  plant investment and operation are calculations only, based  on the
assumption that the desalinization data are applicable to acid mine drainage.
The capital and operating costs are presented in Table  61 and they have not
been updated since it is felt that updating these costs would serve no purpose.
                                 -305-

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                         TABLE 61

         SUMMARY OF CRYSTALLIZATION COSTS
        USING KIT TANNING RUN,  PENNSYLVANIA,
                     WATER  AS FEED
                        Capital Costs
Plant Capacity
(millions of
gal. /day)
0.1
1.0
10
100
Production
(millions of
gal. /day)
0. 1
1.0
10
100
Direct
Freezing
$ 434,900
2,219,000
12,945, 000
81,608,000
Operating
(dollars per 1,

Direct
Freezing
3.10
1.32
0.85
0.68
Secondary
Refrigerant
$ 456,800
2, 198,000
11, 970, 000
70, 362, 000
Costs
000 gallons)

Secondary
Refrigerant
3.18
1.34
0.85
0.67
Hydrate
Process
$ 465,900
2,273, 000
12, 572, 000
74, 940, 000

Hydrate
Process
3.23
1.38
0.89
0.71
Note:  (1) Plants operate at a load factor of unity
       (2) Product water is  about 400-500 mg/1 total dissolved solids
After Schroeder, et al. ,  1966(70)
                            -306-

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ELECTRODIALYSIS PROCESS

        Considerable work has been accomplished by the Office of Saline Water
in using electrodialysis for production of fresh water from brackish water.
The electrodialysis process, like the reverse  osmosis process, utilizes mem-
branes,  however,  electricity is  the driving force in electrodialysis.

       An electrodialysis unit would consist of a number of narrow compart-
ments separated by closely spaced membranes.  Each  compartment is  bound
by a cation and  an  anion membrane which are permeable to positive  and nega-
tive ions respectively.  A positive electrode is located at one end of this "stack"
and a negative electrode  is located at the other end.  The intermediate  channels
between each pair  of membranes is filled with the solution to be processed.
When the electrodes are  energized, thereby causing an electric current to pass
through the solution and the  stack of membranes, the ions contained in  solution
migrate through the various channels.  Cations migrate through the  cation mem-
branes  and anions  through the anion membranes.  Considering  a group  of three
channels separated by two membranes (one anion permeable and one cation per-
meable),  it can be  seen that the  cations and anions migrate from the center
channel through the respective membranes  enclosing the channel reducing  the
concentration of salts in this center compartment. Since the entire  stack of
membranes consists of alternate anion and  cation elements, a succession of
fresh water and brine channels is found to exist'   '.

        The principle energy requirement of the electrodialysis process is elec-
trical energy to the electrodes in the  stack.  Energy is also used for pumping
the feedwater through the system.   The total electric energy required is a func-
tion of the salt reduction which must be accomplished in producing fresh water.
An electrodialysis  plant for  treatment of acid mine drainage would consist of
1) a coagulation-filtration pretreatment processing unit to reduce iron,  mangan-
ese, and suspended solids concentrations and to adjust pH,  2) a circulating pump,
3) electrodialysis unit, 4) product water recovery and storage system,  and 5)
provisions for brine
       Bench scale  studies of electrodialysis for mine drainage treatment were
performed by the Environmental Protection Agency at Norton, West Virginia, in
cooperation with the Office of Saline Water^   '.   When used on water receiving
no pretreatment, the cathode cell quickly became fouled with iron.  In those
cases where the mine  drainage was pretreated by lime neutralization for iron
removal,  the unit operated satisfactorily.
       Schroeder,  et al. '    calculated capital and operating costs  for various
size treatment plants in their 1966 analysis of the application of saline water
conversion processes to acid mine drainage treatment.  It should be pointed out
that these costs are assumptions based on the application of a process effective
in saline water conversion, but not tested for  acid mine drainage treatment.
Table 62 presents these capital and operating  costs which are not updated for
this study.
                                 -307-

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                          TABLE 62

           ELECTRODIALYSIS TREATMENT PLANT
          USING KIT TANNING RUN,  PENNSYLVANIA
                       WATER AS FEED
Plant Capacity
(Millions of
Gal. /Day)
0. 1
1.0
10.
100.
Capital
Cost
$ 249, 000
1, 309, 000
8, 760,000
65,709,000
Operating Costs
($/l, 000 Gallons)
2.52
1.01
0.68
0.58
Note:  1) Plants operate at a load factor of unity.
       2) Product water is about 400-500 mg/1 total dissolved solids.


After Schroeder, et al. ,  1966(70)
                             -308-

-------
FOAM SEPARATION (FRACTIONATION) PROCESS

        Foam separation (fractionation) is based on the phenomenon of surface
activity which results from the ability of certain solutes (surfactants) to re-
duce the surface free  energy of their solutions, and therefore the total free
energy  of the system, by accumulating at an interface.  Surface  activity as it
relates  to foam separation process is  described using the concept of Gibbs
surface excess^'''.

       In practice,  foam separation consists of passing bubbles  through a solu-
tion of surface active  solute(s) with the aim to adsorb the solute(s) onto the gas -
liquid interfaces and to  remove these surfaces  intact as foam,  thus  effecting a
separation.  Further, by coadsorption of non-surface active with surface active
solutes,  the  former can be separated from solution with the  latter.   This is the
case in the treatment  of acid mine drainage''"I

       Horizons Incorporated^"^),  conducted laboratory studies  of continuous
flow foam separation to determine the optimum operating conditions  of maxi-
mum extraction of dissolved  metal cations (Fe, Ca, Mg, Mn and Al) from acid
mine drainage.  Continuous flow foaming experiments were conducted in a 6 inch
diameter glass column capable of  liquid flow rates of  3 to 12 gallons per hour.
The approach to foam separation taken was the  production of persistent foams
which allowed protracted foam drainage to reduce liquid carry-over  in the foam.
The effects  of pH, chelate addition,  surfactant type and concentration,  air sparg-
ing rate, metal concentration and  foam drainage were investigated in relation to
metal extraction.

       The  low  extraction capacity of foam separation (fractionation) makes the
process unattractive for the treatment of acid mine drainage.
                                 -309-

-------
NEUTRADESULFATING PROCESS

       This process essentially involves 1) neutralization of mine drainage
feed and precipitation  of iron and aluminum using soda ash or sodium bicar-
bonate as the neutralizing agent and 2) treatment of the  effluent which is now
free from iron and aluminum by an ion exchange system to remove sulfate.
The  resin is loaded in the barium form, and the barium sulfate precipitate is
removed.  Catalytic, Incorporated^*) conducted laboratory studies on acid
mine drainage  and developed the conceptual neutradesulfating process shown
in Figure 64.

       The advantages claimed for the process are:

1.   A  substantial reduction in the concentration of major pollutants in the
     acid mine  water.  Virtually a complete removal of  iron and aluminum
     and a large reduction in sulfate content.

2.   Sludge disposal is at a minimum.

3.   Operating  costs for labor  are low.

4.   Almost all of the chemicals produced are reused in the process.

5.   Production of a high-purity water.

       However,  as reported by Catalytic, Inc. , based on the projected or
scaled up technology,  the treatment cost for a 1 MGD plant would be $2.69/
1, 000 gallons  of treated water based on a  30 year payback period at 4, 6%.
The  total capital investment was estimated at 4.96 million dollars and rep-
resents about 35% of the unit cost or $0.94/1, 000 gallons.

       Because of the high projected cost of acid mine drainage treatment by
this  method,  the project was terminated.
                                 -310-

-------
                                         1
                                         f^
                                         5
                                         1
                                    ^   r\ ^
                                    O   ^> ifi
                                    05  —
                                    c   ^  ^
-311-

-------
                             REFERENCES

 1.   Hill, Ronald D. ,  1968,  Mine Drainage Treatment - State of the Art and
     Research Needs:  Fed.  Water Pollut. Coiitr. Adm. , Mine Drainage
     Contr. Activities, Cincinnati, 101 p. (BCR 68-150)

 2.   Corbitt,  R.  G. and Growitz, D. J. ,  1967, Composition of Water Dis-
     charged from Bituminous Coal Mines in Northern West Virginia:  Econ.
     Geol. , 62., p.  848-51 (BCR  67-178)

 3.   Holland,  C. T. , Corsaro, J.  L. ,  and Ladish,  D. J. ,  1968,  Factors in
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     Mine Drainage Res. Preprints, Pittsburgh, p. 274-90 (BCR  68-19)

 4.   Bituminous  Coal Research,  Inc.,  1970, Studies onJLimestone Treatment
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     01/70, 96 p. (BCR  70-51)

 5.   Bituminous  Coal Research,  Inc.,  1971, Studies of Limestone Treatment
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     Quality Office, Res. Ser. 14010 EIZ 12/71,    p. (BCR 71-

 6.   Deul, Maurice and  Mihok, E. A., 1967, Mine  Water Research - Neutrali-
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 7.   Mihok, E. A., et.  al. ,   1968, Mine Water Research - The Limestone
     Ne utr aliz a tign_ Pr o c e s s :  U.S. Bur.  Mines Rept.  Inv. 7191,  23 p. ^BCR
     68-166)

 8.   Mihok, Edward A. ,  1970, Mine Water Research - Plant Desj.gji . and__C_o3_t
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 9.   Mihok,  E.  A. and Moebs, N.  N. ,  1972,  U. S.  Bureau of Mines
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10.   Mihok,  Edward A. ,  1969, Mine Drainage Research - Catalytic Oxidation
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     Mines Rept.  Inv. 7337, 7 p. (BCR 69-44)

U.   Wilmoth, R.  C. , Scott, R. B.  and  Hill,  R. D. , 1972, Combination
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     Mine Drainage Res.  Preprints, Pittsburgh, p. 244-65 (BCR 72-

12.   Johns -Manville Products Corp.,  1971, Rotary Precoat Filtration of Sludge
     from Acid  Mine Drainage^Neutralization:  Environmental Protection Agency,
     Water Quality Office, Res. Ser. 14010 DH 05/71,  121 p.  (BCR 71-35)
                                  -312-

-------
13.   Davis,  D. W. ,  Brown, T. S. and Long,  B.  W. , 1972, De water ing
      Sludge  by Using Rotary Vacuum Precoating Filtration:  Fourth Sym.
      Coal Mine Drainage Res. Preprints, Pittsburgh, p. 201-33 (BCR  72-
14.   Gaines, L., Jasinski,  R. and Gruber, A.,  1972, Electr_p_ch_emical
      Oxidation of Acid Mine Waters:  Fourth Sym. Coal Mine Drainage
      Res. Preprints, Pittsburgh,  p.  105-13 (BCR 72-

15.   Tyco Laboratories, Inc., 1972,  Electrochemical Treatment of Acid
      Mine Waters:  Environmental Protection Agency, Water Quality Office,
      Res. Ser.  14010 FNQ 02/72,  81  p.  (BCR 72-

16.   Draper, JohnC.,  1970,  Remarks for the Panel on Sludge Handling and
      Dis_p_os_al:  Third Sym.  Coal Mine Drainage Res., Pittsburgh, 8 p.
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17.   Wakeman, S. A. and Joffe, J. S. ,  1922, Microorganisms Concerned
      in the Oxidation of Sulfur in the Soil II - Thiobacillus Thiooxidansf a
      New Sulfur-Oxidizing Organism  Isolated from the Soil:  Jour. Bact.,
      7, p.  239-56 (BCR 20-12)

18.   Continental Oil Company, 1971,  Microbiological Treatment of Acid
      Mine Drainage Waters:  Environmental Protection Agency,  Water
      Quality Office,  Res. Ser. 14010  ENW 09/71, 78 p. (BCR 71-

19.   Glover, H. Gordon, 1967,  The Control of Acid  Mine Drainage Pollution
      by Biochemical^Qxklation and  Limestone Neutralization Treatments:
      Presented at 22nd  Ann.  Purdue Ind. Waste Conf. ,  36 p.  (BCR 67-15)

20.   Lovell, Harold L. , 1972, Experience with Biochemical jron^Oxidation
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      burgh, Separate, p. 292-1  to 292-9, 10 fig. (BCR 72-

21.   Lovell, Harold,  L. ,  1970,  The Control and Properties  of Sludge Pro-
      duced from jhe^Treatment of  Coal Mine Drainage Water by Neutraliza-
      tion Processes:  Third Sym.  Coal Mine Drainage Res. Preprints,
      Pittsburgh, p.  1-11 (BCR 70-4)

22.   Baker, R. A.  and  Wilshire, A.  G. , 1970,  Microbial Factor in Acid
      Mine Drainage Formation:  Fed. Water Quality Adm. ,  Res.  Ser.
      14010 DKN 11/70,  68 p.  (BCR 70-76)

23.   Brookhaven National Laboratory, 1970, Treatment of Acid Mine Drain-
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      Quality Office,  Res. Ser. 14010  FMH 12/70, 87 p. (BCR 70-97)

24.   Wilmoth, R. C.  and Hill, R.  D., 1970, Neutralization of High Ferric
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      ETV  08/70,  38 p.  (BCR 70-85)


                                -313-

-------
25.   Calhoun, F. P., 1968, Treatment of Mine Drainage with Limestone:
      Second Sym. Coal Mine Drainage Res. Preprints, Pittsburgh,  p.  386-
      91 (BCR 68-25)

26.   Heine,  W. N. ,  and Giovannitti, E.  F.,  1970,  Treatment of Mine Drain-
      age by  Industry in Pennsylvania:  Jour.  Sanitary Eng. _96_ (SA3), p. 743-
      55 (BCR 70-84)

27.   Dorr-Oliver, Inc.,  1966,  Operation Yellowboy -  Mine Drainage Treat-
      ment Plans and Cost Evaluation:  Rept.  to Pa. Dept. Mines Mineral
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28.   Dorr-Oliver, Inc. ,  1966,  Operation Yellowboy -  Mine Drainage Plan,
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      Pennsylvania:  Rept. to Pa. Dept. Mines  Mineral Ind. , Coal Res. Board,
      unpublished  (BCR 66-124)

29.   Charmbury, H. B.,  Maneval, D. R. , and Girard, Lucien, III,  1967,
      Operation Yellowboy -  Design and Economics of a Lime  Neutralization
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30.   Kostenbader, P. D.  andHaines,  G. F. ,  1970,  High-Density Sludge
      Treats Acid Mine Drainage:  Coal Age 75  (9),  p.  90-7  (BCR 70-61)

31.   Haines, G.  F. and Kostenbader,  P. D. ,  1970,  High Density Sludge
      Process for Treating Acid Mine Drainage: Third Sym. Coal Mine
      Drainage Res. Preprints, Pittsburgh, p.  12-26 (BCR 70-5)

32.   Bituminous Coal Research,  Inc., 1971,  Studies on Densification of Coal
      Mine Drainage Sludge:  Environmental Protection Agency,  Water Quality
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33.   West Virginia University, Coal Research Bureau, 1971, Dewatering of
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34.   Rinne,  W. W. ,  1970, Panel on Sludge Handling and Disposal:   Third Sym.
      Coal Mine Drainage Res.,  Pittsburgh, 4 p.  (BCR 70-31)

35.   Steinman, H. E. , 1970, Acid Mine  Drainage Treatment, Sludge Handling
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      Pittsburgh,  3 p. (BCR  70-31)

36.   Dean, Robert B. , 1970, Disposal of Chemical Sludges and Brines:  Third
      Sym. Coal Mine Drainage Res. Preprints, Pittsburgh,  p.  367-75  (BCR
      70-27)
                                -314-

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37.   Osman, M. D. , Skelly, J. F. ,  and Wood,  C.  D. ,  1970, Coal Mine
      Drainage Sludge Utilization:  Third Sym. Coal Mine Drainage Res.
      Preprints,  Pittsburgh, p. 376-401, (BCR 70-28)

38.   Maneval, David R.,  1966, Technical Development of Systems for Con-
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39.   Tybout, Richard A. , 1968, A Cost-Benefit Analysis of Mine Drainage:
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40.   Selmeczi, Joseph G. ,  1972, Design of  Oxidation Systems for Mine Water
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      p. 307-30 (BCR 72

41.   Cyrus  Wm. Rice and Co., 1969, Engineering Economic Study of Mine
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42.   Draper, John C.,  1972,  Mine Drainage Treatment Experience:  Fourth
      Sym. Coal Mine Drainage Res.  Preprints,  Pittsburgh,  p. 415-22
      (BCR 72-

43.   Pennsylvania Department of Health,  1965,  Report  on Pollution of Slippery
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44.   Lisanti, A. F. , Zabban,  Walter, and Maneval,  D. R. ,  1972,  Technical
      and Economic Experience in the Operation  of the Slippery Rock Creek
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45.   Kosowski, Z. V.  and Henderson, R. M.,  1968,  Design of Mine Drainage
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46.   Charmbury, H. B.,  Buscavage, J. J.  and  Maneval,  D. R., 1968,
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47.   Maneval, David R. ,  1968, The  Little Scrubgrass Creek AMD Plant:  Coal
      Mining Process. _5 (9), p. 28-32 (BCR  68-169)

48.   Coal Mining & Processing, 1969, Little Scrubgrass Creek Goes Full
      Cycle:  6 (3), p. 47 (BCR 69-5)
                                -315-

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49.   Anthracite Research and Development Co. , Inc. ,  not dated (1970 ? ),
      Report of Mine Drainage Project SL-112, Schuylkill County, Rausch
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50.   Pennsylvania Department of Environmental Resources,  1972,  Bond
      Issue Report for Period Ending,  February, 1972:   Prepared by Office
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51.   Gwin Engineers, Inc., 1968, Acid Mine Drainage  Treatment Facilities,
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52.   Shirley Machine Co., 1972, Information Manual and personnel communi-
      cation with Mr. H. D. Letts,  Manager.   (No BCR No.)

53.   Westinghouse  Electric Corp. ,  1969, Acid Mine Drainage Blow-Down
      Disposal and Utilization:  Rept. to Pa. Dept.  Mines Mineral Ind. ,
      December,  1969 (No BCR No. )

54.   Maneval, D.  R. and  Lemezis,  Sylvester, 1970, Multi-Stage Flash Evap-
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55.   Westinghouse  Electric Corp.,  1971, Wilkes-Barre Demineralization
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56.   Maneval, D.  R. and  Lemezis,  Sylvester, 1972, Multistage Flash  Evap-
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57.   Burns and Roe, Inc., 1971, Evaluation of Ion Exchange  Processes for
      Treatment of Mine Drainage Waters:  A proposal presented  to Pa. Dept.
      Environmental Resources, March 26,  1971, 49 p.  (No BCR No. )

58.   Pollio, F. X.  and Kunin,  Robert, 1967,  Ion Exchange Processes for the
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59.   Rose, John L. ,  1970, Treatment of Acid  Mine Drainage by Ion Exchange
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      p. 267-78 (BCR 70-22)

60.   Burns and Roe, Inc. , 1969, Preliminary  Design Report - Acid Mine Drain-
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      Mines Mineral Ind. (No BCR No.)
                                 -316-

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61.   Chester Engineers,  1966, Report on Treatment of Brackish Water;
      Prepared for Smith Township Municipal Authority, November,  1966
      (No BCR No. )

62.   ZabbanW., Fithian T.  and  Maneval, D. R.,  1972, The Coal Mine
      Drainage Problem - Conversion to Potable Water by Ion Exchange:
      Am. Water Works Ass. Ann. Conf. , Chicago, 31 p. , 3 fig. (BCR 72-

63.   Bowen,  D.H.M. (Managing  Ed. ),  1971,  Ion Exchangers Sweeten Acid
      Water:  Environ. Sci. Technol. _5 (1), p. 24-5 (BCR  71-1)

64.   Holmes,  Jim and Schmidt, Ken,  1972, Ion Exchange Treatment of Acid
      Mine Drainage:  Fourth Sym. Coal Mine Drainage  Res.  Preprints,
      Pittsburgh,  p.  179-200  (BCR 72-

65.   Rex Chainbelt,  Inc.,  1970,  Treatment of Acid Mine Drainage by Reverse
      Osmosis: Fed.  Water Quality Adm. , Res. Ser.  14010 DYK 03/70,  35 p.
      (BCR 70-53)

66.   Golomb,  A. and Besik,  F. ,  1970,  Reverse Osmosis for Wastewater
      Treatment:  Ind.  Water Eng. 	 (  ), p.  16-19, (No BCR NoT)

67.   Reidinger,  A. B., and Schultz J. ,  1966, Acid Mine Water  Reverse
      Osmosis Tests  at Kittanning, Pennsylvania,  Final Report:  Office Saline
      Water, Rept. GA-7019 (No BCR No.)

68.   Kreman, S. S. ,  Nusbaum, Isadore, Riedinger, A. B. ,  1970,  The Rec-
      lamation of Acid Mine Water by Reverse Osmosis:  Third Sym. Coal
      Mine Drainage Res.  Preprints, Pittsburgh, p. 241-66 (BCR 70-21)

69.   Keilin, B.,  1966,  The Fundamentals of  Reverse Osmosis:  Proc. Sym.
      Membrane  Processes for Ind.  (No  BCR  No.)

70.   Schroeder, W.  C., et al. , 1966,  Study and Analysis of the  Application
      of Saline Water Conversion  Processes to Acid Mine Waters:  Office
      Saline Water, Progr. Rept.  No.  199, 65 p. (BCR 66-101)

71.   Mason,  D.  G. ,  1970, Treatment of Acid Mine Drainage by  Reverse Os-
      mosis :  Third Sym. Coal  Mine Drainage Res.  Preprints, Pittsburgh,
      p.  227-40 (BCR  70-20)

72.   Rex Chainbelt,  Inc. ,  1972, Reverse Osmosis Demineralization of Acid
      Mine Drainage:  Environmental Protection Agency,  Water Quality Office,
      Res. Ser. 14010 FQR 03/72, 109 p. (BCR 72-
                                 -317-

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73.   Wilmoth, R.  C. ,  Mason,  D. G. ,  and Gupta, M. ,  1972,  Treatment of
      Ferrous Iron Acid Mine Drainage by Reverse Osmosis:  Fourth Sym.
      Coal Mine Drainage Res.  Preprints,  Pittsburgh, p. 115-56 (BCR 72-

74.   Gulf Environmental Systems Co.,  1971,  Acid Mine Waste  Treatment
      Using Reverse Osmosis:  Environmental Protection Agency, Water
      Quality Office, Res. Ser. 14010 DYG 08/71, 84 p.  (BCR 71-34)

75.   Hill, R. D.,  Wilmoth, R. C.  and Scott,  R. B., 1971, Neutrolosis Treat-
      ment of Acid  Mine Drainage:  26th Ann.  Purdue Ind. Waste Conf. ,
      Lafayette, Ind.,  13 p. (BCR 71-17)

76.   Black, Sivalls & Bryson,  Inc., 1971, Evaluation of a New Acid Mine
      Drainage Treatment Process:  Environmental Protection Agency, Water
      Quality Office, Res. Ser. 14010 DYI 02/71,  155 p. (BCR 71-25)

77.   Applied Science Laboratories,  Inc.,  1971, Purification  of Mine Water
      by Freezing:  Environmental Protection  Agency,  Water  Quality Office,
      Res. Ser. 14010 DRZ 02/71, 61 p.  (BCR 71-4)

78.   Powell, J. H. and Vicklund, H. I.,  1968,  Preliminary Evaluation of the
      Electrodialysis Process for Treatment of Acid Mine Drainage Waters:
      Final Report  to Office of Saline Water,  Contract 14-01-0001-1187,  un-
      published, April, 1968 (No BCR No.)

79.   Hanson, Peter J. , 1972,  Foam Separation of Metals from Acid Mine
      Drainage: Fourth Sym. Coal Mine Drainage Res. Preprints, Pittsburgh,
      p.  157-78 (BCR 72-

80.   Horizons, Inc.,  1971, Foam Separation  of Acid Mine Drainage:  Environ-
      mental Protection Agency, Water Quality Office, Res. Ser.  14010 FUI
      10/71, 55 p.  (BCR 71-

81.   Catalytic, Inc.,  1971, Neutradesulfating Treatment Process for Acid
      Mine Drainage:  Environmental Protection Agency, Water Quality Office,
      Res. Ser. 14010 DYH 12/71.  102 p. (BCR 71-

82.   O'Melia, C.  R. and Stumm, W. , 1967,  Aggregation of Silicon Dispersion
      by Iron (III):  Jour. Colloid and Interface Sci. , 23 ( ),  p.
      No BCR No. )

83.   Singer,  P. C. and Stumm,  W. , 1968, Kinetics of the Oxidation of Ferrous
      Iron:  Second Symposium Coal Mine Drainage Res. Preprints, Pittsburgh,
      p.  12-34 (BCR 68-2)
                                 -318-

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         OTHER MINE DRAINAGE ABATEMENT PROCEDURES

                          Table  of Contents

                                                                 Page No.

Limestone Barriers Across  Streams                                 321

Insitu Precipitation of Ferric Hydroxide                             323

Spoil Pile Neutralization                                            323

Deep Mine Water Diversion                                          324

Insitu Neutralization of Acid Mine Water by Injecting Fly Ash
   into Deep Mines                                                  325

References                                                          327
                                 -319-

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         OTHER MINE DRAINAGE ABATEMENT PROCEDURES
Limestone Barriers Across Streams
       It has long been known that acid mine waters flowing through a lime-
stone terrain become neutralized.   The construction of limestone barriers
across streams is an attempt to create similar environmental conditions in
alkaline  poor stream basins.

       This method of stream neutralization was tried on Sandy  Run in Vin-
ton County, Ohio in  the early 1950's^).  Sandy Run is  an acid stream feeding
Lake Hops, a center for extensive water-oriented recreation.  A low dam was
constructed across Sandy Run and  the upstream side of the structure filled with
granular limestone. The path of natural stream flow was directed through the
limestone bed.  The limestone was initially effective in raising the pH of the
water, but in less than one month, a heavy rain and resulting high stream flow
largely covered the  limestone  bed  with sand and reduced its effectiveness.
The sedimentation problem grew progressively worse  so that within six months,
it was  necessary to  move the limestone from behind the dam to the stream bed
below the structure.  Again, an initial improvement in water quality was noted
at normal stream flow rates.  As before, this improvement gradually dimin-
ished as sediment accumulated in the voids of the limestone bed.  The project
was abandoned.

       Recently, under Operation  Scarlift Project SL  121, a series of six
limestone barriers were constructed across Trough Creek in Huntingdon County,
Pennsylvania.  The project was designed by Africa Engineering Associates, Inc.
for the Pennsylvania Department of Environmental Resources and the cost of
construction was funded  by a grant from  the U. S. Environmental Protection
Agency(2).

       The barriers were constructed of coarse limestone aggregate having a
high calcium-low magnesium carbonate composition.   The aggregate is held in
place by a  blanket of heavy stone riprap on the upstream and downstream sides
of the limestone barrier.  Riprap was also placed along the stream banks for
erosion control.  The total cost of construction was $191,270.00 and engineering
design costs were $22, 198.00,  Contract items and costs are  as  follows:
                                  -321-

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                                                    Unit
           Item               Quantity    Unit     Price        Cost

Site Clearing                     Job      L.S.      ---     $ 15,000.00

Excavation and Disposal         9,306     C.Y.    $ 2.40    $ 22,334.40

Rolled Embankment             1,109     C.Y.    $ 1.80    $   1,996.20

Furnishing and Placing
Riprap Creek Bank Linings        552     S.Y.    $12.00    $   6,624.00

Furnishing and Placing
Grouted Stone Riprap              798     S.Y.    $18.00    $ 14,364.00

Furnishing and Placing
Concrete  Masonry                153     C.Y.    $80.00    $ 12,280.00

Furnishing and Placing
Rock  Fills                      1,552     C.Y.    $12.00    $ 18,624.00

Furnishing and Placing
Limestone Media                3,336     C.Y.    $24.00    $ 80,064.00

Other Misc.  Items               ---       ---       ---     $ 19,983.40

    Total  Cost                                              $191,270.00

       The average cost for a limestone barrier on this project was $31, 878. 33.
The limestone barriers are still undergoing evaluation  for their effectiveness in
neutralizing the acid flow.  It appears  remedial construction will  be necessary
because of erosion and siltation of the  barriers and it is possible  this problem
may occur annually.

       Major factors affecting costs on projects of this nature are:

1.  Accessibility of project area.
2.  Time  of construction.
3.  Complexity of design.
4.  Availability  of riprap materials.
5.  Haulage distance of suitable crushed limestone.
6.  Nature of stream bottom.
7.  Frequency and magnitude of stream flooding.
8.  Stream water quality.
9.  Degree of neutralization desired.
                                  -322-

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Insitu Precipitation of Ferric Hydroxide

       Laboratory studies performed by the Parsons-Jurden Corporation^)
indicated insitu neutralization of mine water with the resulting precipitation
of sludge would be effective in mine sealing.  Water slurries of alkaline re-
actants such as limestone or fly ash if injected directly into the water in a
mine would form a sludge.  The sludge formed should eventually fill the mine
and effectively seal it.  The advantage of filling with sludge,  is that sludge  is
a balking type precipitate, taking up more volume than that occupied by the
unreacted material used to treat the mine water.

       In 1968 the Parsons-Jurden Corporation received a contract from the
Pennsylvania Department of Mines  and Mineral Industries, now the Department
of Environmental Resources,  for mine sealing by insitu  precipitation of ferric
hydroxide.  The  actual work performed  consisted of the  construction  of rubble
barriers within three mine headings of the inactive Driscoll No.  4 mine near
Vintondale, Pennsylvania.  The barriers were constructed of available mat-
erials from within the mine and injection pipes extended through the barriers
to the interior of the mine.  A lime slurry was injected into the mine  to neu-
tralize the mine  water and precipitate iron hydroxide.  Clogging of the rubble
barriers with iron hydroxide did not occur and the project was abandoned.

       The mine drainage effluent was alkaline during pumping operations,
but whenever the injection of lime slurry was stopped the effluent became
acidic.   The reasons  for the failure of sludge to form have not been docu-
mented,  but it appears the alkaline effluent did not precipitate iron hydrox-
ide until after it  left  the mine.  Cost figures are not available, but it  is esti-
mated the total project cost exceeded $Z50, 000.

Spoil Pile Neutralization

       Spoil pile neutralization by drilling and grouting a pulverized limestone -
lime  slurry has  recently been completed near Toms Run in Clarion County,
Pennsylvania.   This  work was performed for the Pennsylvania Department  of
Environmental Resources under Operation Scarlift Project SL 165(4).

       If mine refuse is  grouted with powdered limestone  and lime, an alkaline
reserve  should be available for neutralization of the acid salts produced by
pyrite oxidation.  In  addition to this effect, pyrite may become sealed from the
air when surrounded  by the grout slurry.  A third mechanism may also operate
to reduce the amount  of pyrite undergoing chemical reaction; the sudden change
in pH of  the spoil material may decrease the activity of iron oxidizing bacteria.
                                  -323-

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       The costs for this project are as follows:

                                 Unit
         Description             Price       Quantity        Cost

1.  Slurry Injection Holes    $ 1.00/Each      453.       $   453.00
2.  Driving Grout Sleeves      0.50/L. F.    9,778.         4,889.00
3.  Pulverized Limestone     11.45/L.F.    5,234.4       59,933.88
4.  Hydrated Lime             35.00/L.F.      504.13      17,644.55
5.  Flume Drains              3.25/L.F.    1,400.         4, 550. 00

    Total Cost                                            $87,407.43

       Pollution abatement using this method would have the advantage of pro-
ducing immediate and significant results.  There  is some doubt,  however, as
to the lasting  effect of this type treatment.

       The main factors affecting costs of spoil  pile neutralization are:

1.  Accessibility of the project area.
2.  Unit  Costs of materials.
3.  Haulage distance for materials.
4.  Number of drill holes required.
5.  Degree of abatement desired.

Deep Mine Water Diversion

       Mine water diversion work is in progress  at the  Ernest Mine Complex,
Operation Scarlift Project No. SL 107-4, in Indiana County, Pennsylvania^).
The purpose of the  project is to divert mine drainage flows from various lo-
cations in the mine  to a central point where a water treatment plant will be
constructed in the future.

       In order to  achieve this goal,  it is necessary in  several areas  of the  ex-
tensive mine workings  to impound water to  a design elevation so  that mine waters
can flow  over drainage divides or humps within the mine to the central treatment
location.   The necessary work includes sealing of numerous shafts, drifts and
boreholes, the placement of an 18 inch mine water transfer pipe  within the mine,
removal of a mine  barrier,  installation of permanent valves and  concrete struc-
tures as  well  as  other items.

       The original contract estimate for this diversion work was $266, 815,
however, a total of five change orders to date have increased the total estimated
cost to $333,790 and additional change orders may be necessary.  Some reasons
for the additional cost are as follows and they provide an insight into the types of
problems that can be expected in deep mine water diversion:
                                  -324-

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1.  Additional boreholes were discovered during exploratory shaft excavation
    and they required  sealing.

2.  Dewatering of some areas was not practical and the 18 inch transfer pipe
    had to be installed under water in these areas.

3.  Two mine dams  were found to  be unsatisfactory and additional work was
    required.

4.  A subsidence cave-in developed during construction which required re-
    moval of material and support to prevent a total collapse which would
    have damaged the  18 inch transfer pipe.

5.  The sealing  of some parts of the mine created hydraulic heads which
    caused boreholes and nearby water wells to develop artesian flow.  These
    boreholes and water wells will have to be sealed.

6.  Some contract items,  such as  calipering and reaming  of boreholes, appear
    to be unnecessary and may have added to the project cost.

Insitu Neutralization of Acid Mine Water by Injecting Fly Ash into Deep Mines

        The Duquesne  Light Company  is sluicing  alkaline fly ash from the Col-
fax power station into an abandoned section of the Harwick Mine.   The mine
and power  station,  both owned by Duquesne Light Company, are about 14 miles
northeast of Pittsburgh.  The  idea of  this unique system was conceived,  in part
at least, because of space limitations  for fly ash disposal at the adjacent site
for the  new Cheswick  plant under construction.   The Harwick Mine will be com-
pletely  worked out about the time the  new power  station goes into service.

        The engineering study  for Cheswick plant indicated there were distinct
economic advantages in disposing  of fly ash into  the Harwick Mine.  Cost of
removal of  fly ash to a landfill area is 80 - 90^/ton.  Capital investment pro-
posals for  conventional ash disposal varied from $500, 000 to over $1, 000, 000
and annual operation and maintenance  cost was estimated  at $Z50, 000.

        Cost estimates for the proposed fly ash disposal system,  including mine
modifications,  pumps, an electrical substation and the necessary controls, were
less than the amounts  for  conventional fly ash disposal methods.  Savings for the
new  Cheswick plant  are estimated at $700/day,  after allowances for mine de-
watering costs.

        In addition to treatment of acid mine water, deep mine disposal of fly
ash has the distinct  added advantage of eliminating completely the air pollution
problems associated with  landfill disposal.
                                  -325

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       The disposal system using both fly ash and bottom ash from the  Colfax
plant has operated for 18 months,  with only minor problems (as of December,
1968).   The ash is pumped as a slurry through a borehole into the mine.  Dams
have been constructed in the mine to form a large sedimentation basin to  settle
the fly ash out of the mine water.

       The water quality characteristics  of the  effluent have  been well within
the quality limits prescribed by the Pennsylvania Sanitary Water Board.  The
amount of water pumped from the ash disposal basin has  averaged over 2
million gallons/day.  In the  18 months the ash disposal system has  been in
operation,  the suspended particulate content of the  effluent has never approached
the permissible maximum of 200  mg/1; the highest observed value was 97 mg/1.
Average values for water quality  characteristics are:  pH - 7.2, Fe -2.5 mg/1
and suspended solids - 9.4 mg/1.
                                  -326-

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                            REFERENCES

1.  Stanley Consultants,  1969,  Lake Hope Acid Mine Drainage Abatement
    Program:  Rept. to Ohio Dept.  Natural Resources,  38 p.   (BCR 69-31)

2.  Pennsylvania Department of Environmental Resources, 1972, Informa-
    tion in Files: Ebensburg District Office

3.  Jones,  J. B. and Ruggeri,  S. ,  1969, Abatement of Pollution from Aban-
    doned Coal Mines  by  Means of In-Situ Precipitation Techniques:  ACS
    Div. Fuel Chem. Preprints _13_ (2), p. 116-19  (BCR 69-14)

4.  Molinski, A. E. ,  1972,  Personal Communication:  Ebensburg District
    Office,  Pa.  Dept.  of  Environmental Resources

5.  Love,  L. R. and Whirl, S. F. , 1969, Fly Ash Disposal in a Deep Mine:
    Coal Mining  and Processing 6_ (3),  p. 50-53  (BCR 69-99)
                                  -327-

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                   REFUSE BANK AND MINE FIRES




                        TABLE OF CONTENTS




                                                               Page No.




Introduction                                                      331




National Surveys of Burning Refuse Banks                         331




Ignition of Refuse Banks                                          332




Methods of Controlling and Extinguishing Fires                    332




Prevention of Coal Refuse Bank Fires                              333




Prevention of Deep Mine Fires and Explosions                     334




Cost Figures for Refuse Bank and Mine Fire Projects              335




References                                                       342




                           LIST OF TABLES




1. Appalachian Mine Fire Control Projects                        336




2. Refuse Bank and Stripping Fires                               342
                                  -329-

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                   _REFUSE BANK AND MINE FIRES

Introduction

       Our present day environmentally oriented society is constantly on the
alert for new ways and means to combat all forms of pollution.   In the Appa-
lachian region,  a recurring  and everpresent source of pollution has been the
sulfur-emitting,  smoldering coal waste banks and deep mine fires.  The popu-
lation has been able,  only in recent years, to make  their voices  heard regard-
ing the detrimental effects of these fires and urge that measures be taken to
eliminate this source of pollution.

       The deep mine fires  are usually extinguished or brought under control
in a relatively short period of time,  only if they associated with  actively pro-
ducing coal properties,  fires in abandoned mines have been allowed to burn
unattended, but  not unnoticed for  decades.

       Coal refuse or waste banks have never seemed to warrant the  attention
of the deep  mine fires, even though they are a public nuisance and an  environ-
mental hazard.

       Over the  many years these fires have  existed, sporadic attempts have
been made by coal companies,  municipal and  other governmental bodies to
control them.  It was not until the establishment of the Appalachian Regional
Commission which was created by the Appalachian Regional Development Act
of 1965 that sufficient funds were made  available to  put forth a concentrated
effort to combat  refuse bank and mine fires.  This  effort is not only helping
to reduce pollution, but is protecting a valuable national resource.

National Surveys of Burning Refuse Banks

       In 1963,  the U.S. Bureau  of Mines,  through  a cooperative agreement
with the  Public Health Service, Department of Health, Education and Welfare,
conducted the first nationwide reconnaissance survey of burning  coal refuse
banks.  This survey noted 495 burning coal refuse banks in the United States^  '  '.

       Another  survey conducted in late 1968 and early 1969 noted 292 burning
coal refuse banks in 13 of the 26 coal-producing states.  This total includes only
refuse banks that were determined to be smoldering or buring through visual
indications  such  as flames or "fire glow, "  thermal waves above  the refuse bank,
smoke,  fumes,  or a combination  of these conditions. Seven states in the Appala-
chian region accounted for 264  burning banks,  or 90 percent of the total.  States
that had  reported burning  refuse banks in the past,  but in which none were known
to be burning in 1969,  include Alaska, Indiana,  Iowa, New Mexico,  Tennessee
and Wyoming(2).
                                  -331-

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       Coal refuse fires  have proven to be extremely hazardous to the environ-
ment and its  inhabitants.   At least 55 persons have lost their lives as a result
of burning  banks.  The health and safety of nearby residents, particularly child-
ren and elderly persons,  is  threatened as a result of the  impairment of air
quality caused by the airborne pollution generated by burning waste banks.  Veg-
etation and building  materials are also severely  damaged or destroyed when the
gases are  heavily concentrated in an area nearby these sulfur-emitting banks' '.

Ignition of  Refuse Banks

       Ignition of a  refuse bank can be initiated in several ways.  A recent
U.S. Bureau of Mines report outlines the following possible sources of com-
bustion (Maneval'l));

1.  Spontaneous ignition

    a.  Sufficient air must  enter the refuse dump to oxidize the coal and
        other combustible materials.

    b.  Air  must be insufficient in quantity to carry away the heat generated
        during the oxidation,  thus permitting the heat to accumulate.

2.   Careless burning of  trash on or near the bank.

3.  Forest fires

4.  Camp  fires left burning

5.  Intentional ignition to create residue which may be used for road base
    materials.

       Spontaneous  combustion is a common cause of coal refuse fires.   Sixty-
six (66) percent of the 292 refuse banks found burning in  1968 are believed to
have started  by heat generated within the pile. This  phenomenon results  from
the flow of air through combustible  refuse material and consequent oxidation.
When sufficient oxidation occurs, heat is generated,  and  the combustible  com-
ponents in  the  pile ignite'  '.

Methods of Controlling and Extinguishing Fires

       Federal and  State governments have undertaken research projects to
control and extinguish coal waste bank and deep mine  fires.   Various techniques
have been  tried,  some of which are listed as follows:
                                 -332-

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       Coal Refuse Bank FiresH)

       1.  Accelerated Combustion and Quenching
       2.  Isolation
       3.  Foam Covering
       4.  Vermiculite and Sodium Bicarbonate Injection and Coating
       5.  Injection of Fine  Mineral Matter
       6.  Mine Drainage Sludge Injection
       7.  The Use of Anti-Oxidants
       8.  Saturation  Through Serpentine Canals
       9.  Ponding Technique (Rice Paddy)
      10.  Cooling and Dilution
      11.  Blanketing with Clay  and Cement Waste
      12.  Blanketing - Quarry Wastes
      13.  Use of Explosives Followed by Quenching
      14.  Hydraulic Jets (Water Cannon Technique)
      15.  Water Sprays

       Deep Mine Fires

       1.  Dry Fly Ash Injection with Surface Seals
       2.  Isolation Plug Barrier and Surface Seal
       3.  Fly Ash Injection (Wet and Dry)
       4.  Sand Flushing (including sand barriers)
       5.  Trenching and Sand Barrier
       6.  Underground Dam with Water Flooding
       7.  Smothering with Isolation Seal

Prevention of Coal Refuse Bank  Fires
                 discusses the problems associated with coal refuse  disposal
and indicates refuse bank fires can be  prevented if more attention is directed
toward:  1) Site  selection and preparation,  2) Refuse  bank design,  and 3) Site
reclamation and abandonment.  The following factors and requirements are
important when  considering these items of refuse disposal planning:

1 .   Site Selection and Preparation

    a.  Terrain suitable for intended type  and quantity of refuse disposal
    b.  Geologic investigation of site
    c.  Evaluation of drainage  in area
    d.  Source of non-combustible material nearby
    e.  Clearing of all combustible material from the site
    f.   Adequately seal off all  coal outcroppings

2.   Refuse Bank Design

    a.  Slope of terrain and foundation materials
                                  -333-

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     b.  Site drainage
     c.  Compaction methods (soil mechanics principles employed)
     d.  Control of material segregation, sizing and grading
     e.  Outside slope  sealing

 3.   Site Reclamation and Abandonment

     a.  Bank properly graded,  compacted and sealed
     b.  Final  layer of non-combustible material placed over bank
     c.  Establish vegetative cover
     d.  Fencing and signing
     e.  Periodic inspection or regular patrols

 Prevention of  Deep Mine Fires  and  Explosions(3)
                                                «
        The down-time of a mine as  a result of a fire or explosion can be long
 and the  cost of recovery and reconditioning can be  extremely high.  Some com-
 panies have been forced into bankruptcy as a result of such disasters.  Every
 individual working in a coal mine should be educated as to the  cause and pre-
 ventative measures designed to prevent disasters.   They must see that  the
 measures are adequate, are maintained, and are enforced.

        With the advent of mine  mechanization,   changes in mining methods and
 transportation have been revolutionary and the  use  of electricity has multiplied
 many times.   Electric power sources must be effectively controlled at all times,
 because a mine environment is  not favorably suited to electrical installations -
 saturated atmospheres,  dust, in suspension, roof falls, poor lighting, restricted
 areas, constant jarring of unit-mounted sensitive control or detecting equip-
 ment, shock waves from blasting, abrasive use and makeshift repairs,  all of
 which complicate the electrical, operational and maintenance problems.

        Deep mine fires may be initiated in may ways,  the following is a list of
 possible causes of ignition:

 1.   Rock falls knocking down bare electrical conductors.
 2.   Faulty tracks and rolling stock triggering energized trolley wires into
     igniting dust or other  combustiles as the result of wrecks.
 3.   Arcs  and  sparks from trolley skids or wheels.
 4.   Overloaded power cables and conductors.
 5.   Failure to properly maintain permissible electrical equipment.
 6.   Conveyor belt fires,  often due to stuck rollers.
 7.   Sparks from continuous  mining machines cutting through pyrite inclusions.
 8.   Mishandling  of explosives used for production  blasting.
 9.   Smoking or open lights in gassy mines.
10.   Welding operations not properly conducted.
11.   Spontaneous  combustion due to  poor housekeeping and inadequate ventilation.
                                   -334-

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       The majority of the above causes can be eliminated through compliance
with the existing Federal and State mining laws,  in addition to a company or
mine owner following a regular strict inspection and maintenance  program per-
formed by reliable and capable personnel.

Cost Figures for Refuse Bank and Mine Fire Projects

       Since the majority of the efforts directed toward the extinguishment and
control of refuse bank and deep mine fires has taken place in the Pennsylvania
anthracite and bituminous coal regions,  the cost figures  for bank  and mine fire
abatement projects  presented  in this section are from Pennsylvania projects.

       Table 1  is a compilation of information on nine  (9) mine fire extinguish-
ment projects performed in the bituminous region  of Pennsylvania.  The un-
published data obtained from the U.S.  Bureau of MinesV'*) presents information
on project and unit costs,  and the method of extinguishing the fire is indicated.

       Data on nine (9) refuse bank and stripping fires was obtained from the
Pennsylvania Department of Environmental Resources'^' ") for the anthracite
region of Pennsylvania.  This information is presented in Table 2 and includes
project and unit costs,  method of extinguishment and other pertinent data.
                                  -335-

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                               TABLE 1

          APPALACHIAN MINE FIRE CONTROL PROJECTS*4)

          (U.S. Bureau of Mines - Pittsburgh, Pennsylvania)

                      Pennsylvania - Bituminous

PROJECT NO.  9                                              January, 1972

       Upper Whyel, Sewickley Township,  Westmoreland County, Pennsylvania

        Method:  Dry Fly Ash Injection - Surface Seal -  Emergency Drainage -
                 Erosion Prevention
        (Contractor - Dragan & Son)
Unit Cost
$ 21.00/hr.
   3. 15/ft.
   2.00/ton

  21.50/hr.
  23.90/ton
 100.00/ton
   1.00/lb.
   1.00/bale
                      Project Costs
Remove Vegetation
Angle Dozer                  2,082 hrs.
Vertical Boreholes           1, 142 ft.
Loading, Transporting and    29.09 tons
 Discharging Fly Ash
Dragline                     408-1/2 hrs,
Agricultural Limestone       20.45 tons
10-6-4 Fertilizer             5 tons
Grass Seed                   500 Ibs.
Hay or Straw                 700 bales
                16 Percent (Supervision-Administration-
                          Engineering)
$ 5, 000.00
 43,722.00
  3, 597. 30
     58. 18

  8,782.75
    409.00
    500.00
    500.00
    700.00

$63, 269.23

 10,123^08
$73,392.31
                                  -336-

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                       TABLE 1 (continued)

PROJECT NO. 10                                            September, 1970

       Carpentertown, Mt. Pleasant Township,  Westmoreland County,
       Pennsylvania

       Method:  Backfilling and Erosion Prevention

       (Contractor: Yelinek & Smail, Inc. )

Unit Cost                            Project Costs
$13.75/hr.
5.00/hr.
7. 00/ton
70. 00/ton
40.00/100#
unit
0.75/bale



Angle Dozer
Laborer
Limestone
Fertilizer

Grass Seed
Hay or Straw

16 Percent/Administration &

806 hrs.
16 hrs.
16 tons
4 tons

4 100# units
300 bjales

Engineering

$10,276.50
80,00
113.00
280. 00

160.00
225,00
$11, 133. 50
1, 781.36
$12,914.06
PROJECT NO. 11                                            August,  1968

       Lloydsville,  Unity Township, Westmoreland County, Pennsylvania

       Method - Dry Ash Injection Method

       (Contractor - Dragan & Son)

Unit Cost                            Project Costs

$ 1.25/ft.      Drilling Boreholes            6,449ft,        $ 8,061.25
 20.00/ft.      Casings                      123ft.            2,460,00
  2.80/ton     Fly  Ash                      6,237. 54 tons    17,465. 12

               Total Cost Including Labor, Fertilizer,
               Seed, Lime, etc.

               (Including  16 Percent for Administration)      $ 5, 234. 16

                                                             $38,600.13
                                 -337-

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                       TABLE 1  (continued)

PROJECT NO.  17                                            December, 1970

       Near Pennsylvania Turnpike - Plum and Monroeville Boroughs,
       Allegheny County, Pennsylvania

       Method:  Fly Ash Injection and Revegetation

       (Contractor:  Dragan & Son)
Unit Cost
$ 3.70/ft.
20.00/unit

25.00/unit
1.50/ton
5. 00/ton
10. 00/ton
50.00/100#
unit


Drilling
Casing with Caps
Holes)
Casing Adapters
Fly Ash
Top Soil
Limestone

Grass Seed
Laborers
Project Costs
3, 546 ft.
(Inject.
31 units
1 unit
78. 33 tons
70 tons
1/5 ton

1-100# unit
220 hrs.

$13, 120. 20

620.00
25. 00
117.50
350.00
2.00

50. 00
1, 100. 00
                                                             $15,384.70
                24 Percent Allowance for Administration
                and Engineering                                3, 692. 33
                                                             $19,077.03
PROJECT NO. 18                                            March,  1970

       Peters Creek,  Jefferson Borough,  Allegheny County,  Pennsylvania

       Method:  Surface Seal and Isolation Plug Barrier

       (Contractor: Dragan & Son)

Unit Cost                            Project Costs

$ 4.00/hr.      Laborer                      748 hrs.        $ 2,992.00
  9. 00/hr.      Dragline                     256 hrs.          2,304.00
 16. 00/hr.      Straight Blade Dozer          1,068 hrs.       17,088.00
 17.00/hr.      Angle Blade Dozer            2, 583 hrs.       43,911.00
  2.00/ft.       Drilling 6" Boreholes         819ft.            1, 638.00

                16 Percent Administration - Engineering -
                Planning and Direction                        $12, 133. 28

                Total Cost (Including Fertilizer,  Seed, Lime,
                Dynamite,  etc.)                              $87,966.28
                                 -338-

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                      TABLE 1 (continued)
PROJECT NO.  20
                                                             September,  1970
      City of Monongahela, Washington County,  Pennsylvania

      Method:  Removal of Vegetation - Installation of Surface Seal -
               Injection of Fly Ash - Prevention of Erosion
      (Contractor: Dragan &c Son)
Unit Cost

$16.80/hr.
 12.00/hr.
  5. 00/hr.
  4.00/hr.
  1.60/ft.
  1.60/ft.
  2. 00/ton
  4. 00/ton
  8. 00/hr.
                                    Project Costs
Dozer
Hi-Lift
Chain Saws
Laborers
6" Vertical Boreholes
6" Angle Boreholes
Fly Ash
Top Soil
Truck
                                             1,079-1/2 hrs.  $18, 351.50
404 hrs.
1,092 hrs.
1,720 hrs.
13,784 ft.
418 ft.
2,284.075 tons
304 tons
412 hrs.
 4
 5
 6
22

 4
 1
 3
848.
460.
880.
054.
668.
568.
216.
296.
                                                                     00
                                                                     00
                                                                     00
                                                                     40
                                                                     80
                                                                     15
                                                                     00
                                                                     00
               Misc. (Fertilizer,
               Casing,  etc. )
                                  Seed Limestone,
               24 Percent Allowance for Supervision
               and Administration
                                                                ,209. 10


                                                              16, 370. 18

                                                             $84,579.28
                               -339-

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                       TABLE 1  (continued)

PROJECT NO. 33                                            August,  1969

       Ken Ridge Drive, Kennedy Township, Allegheny County, Pennsylvania

       Method:  Dry Fly Ash Injection - Fly Ash Slurry - Revegetation

       (Contractor:  Construction Methods , Inc.)

Unit Cost                            Project Costs

$18.00/hr.      Hi-Lift                       Z36hrs.        $4,248.00
  5.60/hr.      Laborers                     202-1/2 hrs.      1,113.75
0.95/ft.
10. 00/unit

15. 00/unit
1.85/ton
0.50/lb.
3.00/ton
10.00/hr.
20.00/hr.




6" Boreholes
Basings w/caps
(injection holes)
Casing Adapters
Fly Ash
Grass Seed
Top Soil
High Pressure Slurry Pump
Challenge Truck Mixer
Misc.

24 Percent Administration and

6, 822 ft.

34
2
297.25 hrs.
250 Ibs.
325 tons
110 hrs.
170 hrs.


Engineering

6,480.90

340. 00
30.00
549.91
125. 00
975. 00
1, 100. 00
3, 400. 00

$18, 371. 56
4,409. 17
$22, 780. 73
PROJECT NO. 38                                            December, 1970

       Peferman's Corners, Penn Hills Township, Allegheny County,
       Pennsylvania

       Method:  Fly Ash Injection (Wet and Dry) - Revegetation

       (Contractor: Allied Asphalt Company,  Inc. )

Unit Cost                            Project Costs

$1.25/ft.       Vertical Boreholes            9,530ft.        $11,912.50
  1.25/ft.       Angle Boreholes               1,322ft.          1,652.50
  2.00/ton       Dry Fly Ash                   340. 81 tons         681.63
  6.50/C.Y.     Fly Ash - Water Slurry        5.968.85C.Y.   38,797.50

                Misc. Costs plus

                24 Percent Allowance - Supervision and
                Administration                               $34, 671. 77

                                                             $87, 715.90


                                  -340-

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                       TABLE 1 (continued)

PROJECT NO.  39                                           January,  1972

       Upper Tyrone Township, Fayette County, Pennsylvania

       Method:  Fly Ash Injection - Revegetation

       Contractor:  Allied Asphalt Company, Inc. )
Unit Cost

$24.00/hr.
 15.00/hr.
  7.00/hr.
  1.00/ft.
 20. 00/unit

 20.00/unit

  2.35/ton
  6. 00/ton
 18.00/ton
 80. 00/ton
  3.00/ft.
 50.00/100#
       unit
 12.00/C. Y.
                     Project Costs
Dozer (D8)
Dozer (Tractor)
Laborers
6" Boreholes
Casing w/caps
 (injection holes)
Casings w/caps
 (inspection holes)
Fly Ash
Top Soil
Limestone
Fertilizer
3" Boreholes

Grass Seed
Wet Fly Ash
8 hrs.
96-1/2 hrs.
2,040 hrs.
15,418 ft.

34
4,444.86 tons
204.75 tons
3-1/2 tons
3-1/4 tons
620 ft.
3-1/2 100#
units
1,961.45 C.Y.
               24 Percent Supervision and Administration
$    192.00
  1,447.50
 14,280.00
 15,418.00

     680.00

     60. 00
 10,445.42
  1, 228.50
     63. 00
     260.00
  1, 860. 00

     175.00
 23, 537.40

$69,646.82
 16,715.24

$86,362.06
                                -341-

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                            TABLE 2  (continued)

  *Mt. Carmel (Project SL 304)

        8, 000, 000 cu. yds. @ $1.28 per c.y.  This figure includes drilling,
        blasting, loading,  hauling,  spreading, quenching,  backfill, mobili-
        zation and demobilization.

        A coal credit of $4. 50 to $4. 75 per ton was allowed for approximately
        360, 000 tons  of coal,  (deduct)

 **Kehley Run (Shenandoah) Project SL 309

        1,100, 000 cu. yds. refuse and spoil material @ $1. 65/c. y.
        4,300,000cu. yds. consolidated & solid material @ $1. 65/c. y.
        2, 600, 000 cu. yds. backfill @ $0. 50/c. y.
        14" pipeline and deep well pump installation (including power costs) $70, 000
        85, 000 cu.  yds.  of clay seal @ $3. 20/c.y.
        40,000cu.  yds.  of deep mine  flushing @ $3. 60/c. y.
        2,400 linear ft. 6" diameter boreholes @ $9. 00/foot
        600, 000 tons  coal  credit @ $4. 35/ton (deduct)

***Baker Bank (Scranton)  U.S.  Bureau of Mines Demonstration Project

        Bank contained an  estimated 3. 5 million cubic yards of refuse, the section
        of the bank used for the demonstration project contained an estimated 1. 1
        million cubic yards.  Two techniques were employed:  1) Quenching and
        sluicing the hot material with available mine water,  then bulldozing the
        cooled refuse into  an adjacent strip pit; 2) Quenching the hot  refuse with
        water cannons and a sprinkler  system, a bulldozer was then  used to rip
        the quenched  material and a tractor-scraper transported, spread and com-
        pacted the extinguished material.

        For technique No.  1  the cost was $0.66/c.y.,  costs  for technique No. 2
        were $0. 44/c. y.
                                     -343-

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                            REFERENCES

1.  Maneval,  David R., 1969, Recent Advances in Extinguishment of Burning
    Coal Refuse Banks for Air Pollution Reduction:  Proc. Am.  Chem. Soc.
    _U (2) 27-41

2f  McNay, Lewis M. ,  1971, Coal Refuse Fires, An Environmental Hazard:
    U.S. Bur. Mines Inf. Circ. 8515,  50 p.

3.  Dougherty, John J. , 1969, Control of Mine Fires: West Virginia Univ. ,
    Mining Extension Serv. Publ. , 89 p.

4.  Magnuson, Malcolm O.,  1972, Personal Communication:  Project Coord-
    inator,  Mine Fire Control,  U.S.  Bur. Mines,  Pittsburgh

5.  Deyens,  Willis,   1972, Personal Communication:  Pa. Dept. Environ-
    mental Resources, Wilkes Barre District  Office

6.  Yaccino,  Michael, 1972. Personal Communication: Pa.  Dept. Environ-
    mental Resources, Pottsville District Office

7.  Dierks, H. A., et al. ,  1971,  Three Mine  Fire Control  Projects in North-
    eastern Pennsylvania:  U.S.  Bur. Mines Inf. Circ.  8524, 53 p.
                                 -344-

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                     MINE SUBSIDENCE CONTROL

                       TABLE OF CONTENTS

                                         ^                   Page No.

Introduction                                                      347

Pressure Grouting of Mine Voids                                  347

Construction of Concrete  Piers                                   348

Drilled Caissons                                                 348

Grouted Aggregate Piers                                          348

Fly Ash Injection Method                                          349

Flushing Coal Mine Refuse                                        351

Controlled Mine Subsidence                                       353

References                                                      355


                          LIST OF TABLES

1.  Mine Stabilization Projects Using Fly Ash,  Pennsylvania        350

2.   Mine Stabilization Projects Utilizing Coal Mine Refuse, Northern
     Anthracite Field,  Pennsylvania                              352
                                 -345-

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                      MINE SUBSIDENCE CONTROL

Introduction

        The prevention and limitation of subsidence caused by underground
mining is an art which is rapidly becoming an exact science  as  recent appli-
cation and observation technology for controlling the damaging effects of
surface subsidence are put into effect.  Most of the really significant tech-
nological developments have occurred in Pennsylvania as a result of the
funding available under the Operation Scarlift Program which permitted rapid
development of the needed technology.

       Surface subsidence as a result of coal mining has been a problem in
the United States for over one hundred years, and in  1864, hydraulic stowing
was "invented" in the anthracite region of Pennsylvania to control subsidence'•*•).
Numerous papers have been published on mine subsidence,  but  probably one
of the  most useful to the engineer is a recently reprinted publication (1972)
by the British  Institution of Civil Engineers titled "Report on Mining Subsi-
dence"^).  This report prepared by the Mining Subsidence Committee of the
Institution in 1959 discusses the types of subsidence movements and the
effects of mining subsidence on the  stability and durability of all types of civil
engineering works and structures on or near the  surface.  It recommends
precautionary  measures to be taken and methods of construction for structures,
bridges, roads and public utilities in areas where subsidence is or  can be a
problem. An extensive bibliography  of pertinent publications is  included.

         To satisfy the ever increasing demand for energy, more  and more
land is being undermined to obtain coal, a prime energy source.  As the
areal extent of undermined land increases along with a growing  population
which  is expanding into areas that were formerly mined  or now  being mined,
the necessity for effective control of mine subsidence becomes  a pressing
need.

         Several methods of subsidence control are discussed in this section
of the  report.  In recent years, the Commonwealth of Pennsylvania  and the
U. S.  Bureau of Mines have developed a great deal of experience in pneu-
matic  and hydraulic injection of fly  ash and prepared  coal mine  refuse into
mine voids for ground stabilization.  Other methods such as  drilled caissons
and grouted aggregate piers have been used in areas where heavy  or valuable
structures are constructed on undermined land.

Pressure Grouting of Mine Voids

       Pressure grouting  of mine voids and the  roof rock with cement grout
has been technically feasible for many years.  The drawbacks have  been sev-
eral, most notably,  the high unit  cost of the medium and the  almost impossible
task of accurately estimating the grout take and thereby the total project cost.
If cost is not a factor, pressure grouting is the most positive stabilization
procedure,  particularly with the addition of modern inspection tools such as
the borehole camera  and television.

                                 -347-

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Construction of Concrete Piers

       A relatively simple technique,  the construction of concrete piers
within the mine void is somewhat less  expensive than pressure grouting,
but,  has many important limitations on its applicability.   Among these are
the need for a  relatively competent roof strata and, most important,  access
to the  void to permit standard construction procedures to be  carried  out in
the dry.

Drilled Caissons
       Drilled piers (caissons) have been utilized to support structures over
mine voids by drilling from the surface into the mine floor at the location of
the building column, placing shells, and then,  filling the shells with concrete.
After the  concrete has  set,  the structure can be framed in normal fashion. It
is necessary, however, that the floor be  constructed as a structural floor,
supported on grade beams between the piers, since only the column points
are dependably supported.   The average cost for a 30-inch drilled pier, in
medium hard rock, is about $40.00 per lineal foot, including all supplemental
costs.  The unit cost of these units appears to be high, however, the  available
bearing capacity is subject to so many factors  controllable in design that almost
any conceivable load can be supported by varying the characteristics  of each
caisson within a relatively narrow  range.  The drilled caisson is becoming
a standard method of supporting high and valuable loads over mines within
a 50 foot depth.   It is believed that further development of the controlled
fly ash flushing  method will soon lead toward package projects wherein both
structural and ground loads can be supported by a combination of drilled
piers and fly ash backfill of voids.

Grouted Aggregate Piers

       The grouted aggregate pier method of mine void stablization is prob-
ably the most efficient technique  yet devised for construction of valuable
structures on undermined land.  The  process has been applied sufficiently
often that considerable expertise  has  been developed, along with the efficient
observation and application tools.   In this method six inch borings are made
to the  floor of the void.  Gravel or slag is placed in the mine void and spread
with the assistance of compressed  air into a truncated conical form until
the top surface of the truncated cone achieves  a minimum diameter of six
feet against the  roof of the mine.   The aggregate cone and the rock over the
void are then pressure grouted to  an approximate diameter of six feet.  The
grouted aggregate  piers are normally spaced on 25 foot centers throughout
the area of concern, although the spacing can sometimes be increased to as
much as 40 feet depending on mine void conditions  and the proposed use of
the property'  '.
                                 -348-

-------
       Estimated unit costs for the grouted aggregate pier method are:

       Drilling (6 inch diameter hole)                 $   2.75 L.F.
       Casing (6 inch O.D.)        '                      1.50 L.F.
       Photography (For job planning and control)      175.00/Day
       Grouted Aggregate Pier                        700. 00 to 1, 000. 00 Ea.

       When it is considered that approximately 75 piers per acre are required
under standard conditions, it can be seen that this process is not cheap.  It does,
however, provide a method  of almost guaranteed stability  that is well within the
cost structure of almost any significant development, particularly since location
may be an important factor  in the economic consideration  of a project site.  Granted
the importance of location,  then  the approximate cost of $75, 000 per acre for
grouted aggregate piers becomes an easily handled item in the overall cost-benefit
ratio of the project.

Fly Ash  Injection Method

       The stabilization of mine voids  by pneumatic injection of fly ash or hydraulic
injection of a fly ash slurry is  a  process  employed by the Pennsylvania Department
of Environmental Resources to the level  of a "Standard Specification" type of work.
Significant cost reductions have occurred in this method as contractors have gained
experience  in equipment usage and the  cost factors involved.  The present overall
cost of fly ash injection is estimated at $4. 20 per cubic yard.  This cost includes
all supplemental costs and offers,  potentially, a low  cost approach to stabilization,
particularly since the application cost is  not apparently a function of depth with the
exception of the cost of borings.

       There are several minor questionable features to the system,  principally,
the surface supporting capacity of pneumatically injected fly ash is somewhat con-
jectural.  The take at any particular site is difficult to predict and finally there
is some  question as to whether the supply of fly ash is adequate within the areas
of need.   This could result in  increased overall costs because of transportation
costs. It would be desirable to see experimental projects  carried out to deter-
mine the consolidation properties of the fly ash after  being placed in a mine.
This information could provide reassurance that fly ash is the ultimate mine void
stabilizer that so many believe.  If so, this method could be applied in place of other
methods  which are much more expensive, but have been shown to offer stability
under  heavy imposed loads.

       Table  1 is a tabulation of recent fly ash injection mine stabilization pro-
jects performed under Pennsylvania's Operation Scarlift Program.  The projects
cover  a period from 1968  to 1971 and are arranged in order  of decreasing cost
per acre of stabilization.  When  project location,  areal extent of stabilization,
depth and thickness  of void is  considered, it is apparent that no cost trend can
be developed from the  information presented in the table.  The best unit  cost esti-
mates for fly ash injection obtained from individuals familiar with this method
ranged from $4.00 to  $4.50  per cubic  yard.  Allowance must be made for extra
deep borings, difficult site conditions,  haulage distances and other factors which
could increase costs(4).

                                    -349-

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-350-

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Flushing Coal Mine Refuse

       A number of mine stabilization projects have been completed in the
Northern Anthracite Field of Pennsylvania using anthracite breaker refuse
crushed  to minus one-half inch as the fill material^).   The cost of the pro-
jects were borne jointly by Federal and State government and were part of
a program called "Operation Backfill. "  The work consisted  of the filling of
mine voids by the application of the "controlled flushing" and  "blind flushing"
techniques.  Table 2 presents cost data and volumes of coal refuse utilised
in 14 of these projects.

       Quantities of various "pay items"  used for Project ASP-1, the Pine
Brook Mine Project at Scranton, Pennsylvania were as follows:

       Cubic yards placed by controlled flushing           491,955
       Cubic yards placed by blind flushing                   7, 956
       Linear  feet six (6) inch diameter boreholes          12, 053
       Linear  feet six (6) inch O.D. casing pipe              4, 885
       Linear  feet 12 inch diameter boreholes                 396
       Linear  feet 12 inch O.D.  casing pipe                   173
       Linear  feet 28 inch diameter boreholes                 202
       Linear  feet 28 inch O.D.  casing pipe                   220

       This  project was  started in 1966 and completed in 1968.  "Pay items"
are those which the Contractor submitted unit prices in his bidding proposal
and they are the  only items for which payment was made.  The price con-
tracted for per cubic yard of flushing included all costs for the crushing plant,
preparation of  flush material, haulage, labor and materials incident to actual
placement underground.   The  price per foot of drilling the flushing boreholes
includes  all labor and materials incidental thereto,  likewise  the installation of
casing pipe.  Cost of installing hoisting equipment,  headframes,  fan,  etc.,
is included in the unit price  of the large diameter boreholes.  Therefore,  the
total amount paid for the entire project is the sum of the amounts  obtained by
multiplying each of the few quantities bid  on a unit price basis in the contract(5).

       This  was mostly a "controlled flushing" project and the cost on a per
cubic yard basis was $1.75.  Project ASP-2, completed on the other side  of
Scranton, the Morse School  Project, had  a  cost of $3. 65 on a cubic yard basis.
Approximately 70 percent of the flushing on this project was  "blind flushing"
which accounted  for a much  greater borehole footage,  over 200, 000 linear feet
of borehole.

       Another,  newer method of backfilling abandoned mine  workings is the
so-called Dowell System("), a slurry hydraulic injection process.  In  this sys-
tem locally available permeable materials,  usually mine wastes,  are  crushed
and then pumped through a central borehole under pressure until the void is
filled. The method has  several advantages, it results  in removal of unsightly
surface wastes and require-s only one injection point which makes  the process,
                                   -351-

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                 TABLE  2

       MINE STABILIZATION  PROJECTS
       UTILIZING COAL MINE REFUSE
NORTHERN ANTHRACITE FIELD, PENNSYLVANIA
Project No.
NRD-3
NR-32
NR-32A
NR-33
NR-34
NR-37
NR-39
NR-46
NR-55
NR-56
NR-10
PH&S-2
ASP-1
ASP-2
Location
Pitts ton
Scranton
Scranton
Scranton
Scranton
Scranton
Scranton
Scranton
Scranton
Scranton
Pitts ton
Scranton
Scranton
Scranton
Volume Filled
(Cubic Yards)
271,122
50,008
23,985
49,613
169,392
92,680
54,931
61,977
399,368
10,181
70,348
291,077
491,911
259,306
Total
Cost
$239,974
82,372
35,187
74,780
240,165
130,531
75,274
85,975
445,431
23,753
146,884
364,293
858,865
946,474
Cost Per
Cubic Yard
$0.89
1.65
1.47
1.51
1.42
1.41
1.37
1.39
1.12
2.33
2.09
1.25
1.75
3.65
                     -352-

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aesthetically, far more acceptable than other methods.  On the  other hand, the
process  requires  such extensive physical plant and pumping time that the appli-
cation cost appears high, even with the  advantage of cost free materials.  One
project,  at Rock Springs, Wyoming, was completed with injection of 20,000
cubic yards of sandy waste  at a cost of $8. 65 per cubic yard.  Another  project
is being  performed at Scranton,  Pennsylvania.   This project will involve about
300, 000  cubic yards of anthracite mine  waste and application costs are esti-
mated at $5.60 per cubic yard of, again, cost free  material.  The process  is
not inexpensive,  it does,  however,  seem to have a  very real place in urban
areas and in other areas where disruption from multiple injection points has
high economic importance.

Controlled Mine Subsidence

       For many years little was known about the nature of ground movement
and subsidence calculations were therefore very approximate.   But  in recent
years, affected areas have  been carefully measured and observed and the
principles of ground movement  cause by extraction of stratified deposits are
now  more fully understood.

       There is a new mining technique that was brought to this country from
Germany during the last decade and has only recently been put to use in bitum-
inous coal mines(7).  This technique uses a special machine, known as  a long-
wall miner, which removes all  of the coal as the machine advances  through
the seam; a set of automatic advancing jacks holds up the mine roof immediately
behind and parallel with the cutting  bits. As the operation moves farther along
the coal  deposit,  the jacks are also moved,  leaving behind a completely mined-
out area. The surface  over this area settles,  but because 100 percent  of the
coal has  been removed,  the settling or subsidence is uniform.

       Uniform subsidence seldom  causes damage to any surface structures
which lie directly and entirely above the mining operation.  The damage occurs
where  there are variations  in the degree of subsidence.  Where, for example,
one part  of a house stays at the  same level  and the rest of the house drops sev-
eral inches.   Traditional mining techniques, with their coal pillars  interspersed
throughout the post-mining  cavity, can and  do  cause this variable subsidence;
the long-wall  miner does not.  In virtually all  cases where the long-wall method
has been used, little or no damage to surface structures has  been reported,
although  there are frequently cases  where wells run dry because of  the  fractur-
ing of aquifers caused  by subsidence.

       Formulas have been worked out to determine how much subsidence will
occur as  the result of a given long-wall mining operation.  If a six foot  thick
coal seam lying  100 feet beneath the surface is  removed, for example,  the
overlying surface will  sink  six inches; if the seam is thinner or  lies deeper,
the subsidence will be  less.
                                  -353-

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       Since there will be a drop-off of the land surface at the perimeter of
each long-wall mining operation, care must be taken to plan the operation so
that there is no surface structure sitting athwart this perimeter.  For this
reason,  the new mining method is most suitable in areas which are rural and
where the coal deposits occur in large blocks.

       Only a brief mention has been made of pillar mining in previous para-
graphs.  In room  and pillar mining,  it is not possible to predict the develop-
ment  of subsidence, since there is such a great variety of pillar sizes and
depths.  Pillars may fail after years have  elapsed, the amount of  movement
depending on the room space available into which they can crush.  Or the
pillars may be forced into a soft floor such as fireclay.  This will result in
a lowering of the surface just as though the pillars had been crushed and spread.
Where the  floor is soft the  limiting  factors  are the thickness  of the soft floor
stratum  and the space available  in the rooms  into which the pillars can be forced.
In general  it has been found that the  smallest  safe dimension for pillars  is about
one-tenth the depth of the coal seam.
                                   - 354-

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                            REFERENCES

1.  Spicer, T. S. ,  1971, Pennsylvania Anthracite Refuse, A Summary of a
    Literature Survey on Utilization and Disposal;  Pa.  State Univ. Spec.
    Res.  Report SR-79, 43 p.

2.  Institution of Civil Engineers,  1959,  Report on Mining Subsidence:  Mining
    Subsidence Committee, Great Britain,  52 p.

3.  Sturges, F. C. and Clark, J. H. ,  1970,  Fly Ash -  The Answer to Mine
    Subsidence Protection;  Coal Mining and Processing,  	(  ),   p.

4.  Pennsylvania Department of Environmental Resources, 1972,  Information
    in Files of Office of Engineering and  Construction:  Harrisburg

5.  Charmbury,  H.  B. , Smith, G. E. and Maneval, D. R. ,  1968, Subsidence
    Control in the Anthracite Fields of Pennsylvania: ASCE Ann.  Meet, and
    Nat. Meet. Structural Eng. ,  Pittsburgh,  22 p.

6.  U. S. Bureau of Mines, 1972,  Final Environmental Impact Statement,
    Demonstration - Hydraulic Backfilling of Mine .Voids, Scranton, Penn-
    sylvania:  May  15,  1972, 93 p. including Appendix.

7.  Maneval,  David R. , 1972,  Coal Mining Vs. Environment, A Reconciliation
    in Pennsylvania:  Appalachia, ^(4), p. 10-40.
                                 -355-

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                 PART B

ABATEMENT OF POLLUTION FROM SOURCES
        OTHER THAN COAL MINING
                   -357-

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    COST ESTIMATES FOR AIR POLLUTION CONTROL EQUIPMENT

                          TABLE OF CONTENTS

                                                                 Page No.

 Introduction                                                       361

 Classes of Air Pollution Control Equipment                        361

 Cost Estimates for Pollution Control                               362

 Incinerator Emissions and Control of Odors                        364

 Stacks for  Air Pollution Control                                   364

 References                                                       384

                            LIST OF TABLES

 1. National Ambient Air Quality Standards                         365

 2. Typical Incinerator Emissions Compared to Open Burning       366

 3. Pollution Control Costs for  50,000 ACFM Units - 1972          367

 4.  Installation Costs as a Percentage of Purchase Costs for
    Four Generic Types  of Control Devices - 1968                  367

 5. Annual Maintenance Cost Factors for Four Generic  Types
    of Control Devices in 1967-68                                  372

 6. Approximate Characteristics of Dust and Mist Collection
    Equipment                                                     373

 7. Industrial Process and Control Summary                        374

 8. Advantages and Disadvantages of  Collection Devices             375

 9. Actual  Costs for Air Pollution Control Equipment in
    Pennsylvania,  1971-1972                                       377

10. Fuel Cost Comparison for Control of Odors                     383
                                   -359-

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                          LIST OF FIGURES

                                                               Page No.

1.  Gas Cleaning Systems Cost Flow Diagram                      366

2.  Estimated 1967-68 Purchase Costs for Fabric Filters           368

3.  Estimated 1967-68 Purchase Costs for Wet Scrubbers           369

4.  Estimated 1967-68 Purchase Costs for Electrostatic
   Precipitators                                                  370

5.  Estimated 1967-68 Purchase Costs for Mechanical
   Collectors                                                    371
                                  -360-

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    COST ESTIMATES FOR AIR POLLUTION CONTROL EQUIPMENT

       Cost estimates performed without the benefit of design or technical
specifications are nebulous at best.  Stricter emission standards and rapidly
changing technology in the field of air pollution control have brought into play
far too many variables to enable accurate predictions.   The year data was
compiled is very important, since equipment, material and labor costs have
risen each year.  The data used in this  section of the report ranges from
less than a year to four years in age.  However,  before a  cost comparison
was made for a fixed size  unit, costs were updated to a July, 1972 base using
"Marshall and Stevens Index" as published in Chemical Engineering Magazine.

       The volume of gas  to be cleaned is the single most important factor
in determining the  cost of  an  air pollution control device and the removal
efficiencies for contaminants  are paramount in deciding which type  of equip-
ment is to be  used.  The unit selected must be able  to produce an effluent
capable of meeting the National Ambient Air Quality Standards established
by the Environmental Protection Agency (Table 1).

       Two other factors affecting equipment costs  are  system design and
process  control.  Their  importance  cannot be overemphasized.  A poor de-
sign will increase emissions  or amounts of exhaust  gas  to be treated, thus
making  cleaning more difficult and more expensive.  Improper  operation of
the best design possible  will result in the same outcome.

       Figure 1 summarizes  the most important factors affecting the final
net cost of an air pollution control system.

Classes of Air Pollution Control Equipment

       Four  classes of pollution control equipment are analyzed as well as
odor control  devices which are considered separately.   They are as follows:

1.   Mechanical Collectors -  This  type of collector is used for removal of
     particUlate  emissions  only.  They rely on gravity,  particle inertia  or
     centrifugal force to  effect removals. The types of units included in
     this category are:  1)  settling  chambers,  2) inertial separators and 3)
     cyclones.  Efficiencies depend heavily upon the  particle characteristics,
     removal percentages decreasing rapidly with decreasing particle size.
     These units are most  effective in collecting particles  ten microns in
     size or larger. Efficiencies can vary from 20-90 percent.  Overall,
     mechanical collectors are the least  expensive equipment to purchase
     and operate.  However, low removal efficiency and large space re-
     quirements make this  equipment undesirable  as a single unit installr
     ation. Generally, they are used in series with  other kinds of units as
     a pretreatment stage.  Contaminants are collected in  a dust bin,  further
     disposal being to a landfill or  similar area.
                                  -361-

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2.  Wet Scrubbers - This class of devices uses a liquid, usually water, to aid
    in the  removal of contaminants.  They are effective in removing gas  and
    vapor  phase pollutants as well as particulates.  The units are effective at
    high temperature and are not significantly affected by particle size or load-
    ings.  Efficiencies for particles ranging in size from submicron to ten
    microns vary from 80-99.5 percent. According to Cross(^),  scrubbers
    are the  most widely used  control equipment and have  been recommended as
    the only economical and  effective control device for moderately sized in-
    cinerators (less  than  1, 000 Ib. /hr.  capacity).  Sulfur dioxide can also be
    controlled with scrubbers.  The disadvantage of wet collectors include
    corrosion problems,  wastewater disposal,  contamination of the exhaust
    gas by liquid entrainment,  freezing  in cold weather and visibility of water
    vapors from stacks during certain weather conditions.  Costs vary with
    respect  to the  amount of  pressure drop through the unit, the construction
    materials  and  the unit size.

3.  Electrostatic Precipitators - This type of device employs the principle of
    particle ionization by a discharge electrode and then entrapment by a col-
    lecting plate consisting of a grounded electrode.  They are  most effective
    with particles  ranging from one to ten microns.  Efficiencies start at 60
    percent  and  can  exceed 99.5 percent.  A mechanical collector generally
    precedes a precipitator because large particles can cause damage  to the
    discharge electrodes.  Agglomerates of particles are formed and these
    are  collected below the grounded electrodes.  Disposal to a landfill or a
    similar  site is easily accomplished. Unit capacities can be as high as
    three  million cubic feet per minute  (CFM), pressures  can approach 150
    pounds per square inch of gas (PSIG) and gas temperatures can be  as high
    as 1,200° F.  Electrical power  is consumed at the rate of 50 to 500 watts
    per  1, 000 CFM.  Electrical costs in Western Pennsylvania are  between
    $0.01  and $0.02 per kilowatt hour for units of 50,000 CFM capacity.

4.  Filters  - In this  type  of unit an exhaust gas is passed through a porous
    structure.  The  units operate effectively on all sizes of particles,  effici-
    ency being determined by the type of filtering material used.  Removal
    values can approach 99.99 percent in some instances.   This type of unit
    is particularly valuable when the contaminant can be recycled for use
    elsewhere.  Temperatures  usually must be kept below 550° F, however,
    this limitation is a function of filter material properties.  The filter mat-
    erial or fabric is subject to chemical attack and collection efficiency is
    affected by humidity.   Unit costs vary with the type of shaker (used to clean
    filter  material), the reuseability of filter material, unit size and the amount
    of pressure drop.

Cost Estimates for Pollution Control

       Table 3 is a tabulation of cost estimates for the four classes of pollution
control equipment based on a 50, 000 actual cubic feet per minute (ACFM) unit
with average to high  efficiency. The results are in dollar  cost for purchase and
                                   -362-

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installation of the unit per 1, 000 ACFM size.  An "average" unit is assumed.
Capital costs would be affected by special design factors, unusual installation
problems,  a requirement for very high efficiencies, construction with other
than steel and other variables.  The cost estimates in Table 3 are  for a fixed
size unit.  Variations in cost relative to size for each class of equipment are
shown in Figures 2 through 5.

       Table 4 from Ernst & Ernst(^) presents installation costs as a per-
centage of  capitalized purchase cost. When capitalized purchase costs are
added to the capitalized installation cost,  the sum is the annual capital cost.
Table 5, also from this publication,  is based on information from several
sources which suggests maintenance costs can be approximated by using the
cost factors in the table.   Local labor cost and price conditions can cause
wide departures from the factors shown and should be used when available.

       Table 6, reproduced from Stern(^) shows relative cost and  character-
istics of dust and mist collection  equipment.  A summary of important indus-
tries,  their pollutant sources, particulate pollutants,  and air cleaning techni-
ques is presented in Table 7.  Table 8  lists advantages and disadvantages for
each of the  general types of collection devices.  Tables 7 and 8 were repro-
duced from Kerbec(^).

       Actual 1971-72 capital and operating costs,  design data, and other
pertinent information for air  pollution control equipment is  presented in  Table
9.  This unpublished  information  covering various industries was  obtained
from Mr. Douglas Lesher, Pennsylvania Department of Environmental Re-
sources^).
               presents data on expenditures for air pollution control by 330
firms in various  industries for 1967.  The cost figures are five years old and
air quality standards and equipment design have changed considerably since
then.  On the average,  each firm spent:

              Capital Equipment Costs      $88,400
              Installation Costs             53,200
              Operating Costs              46,550

       The breakdown in operating costs and percent of total for each item
              Power, fuel and water       $19,840           43%
              Materials and spare parts      5,100       10-11%
              Maintenance and labor         7, 100       15-16%
              Collected waste disposal      14, 510           31%
                                           $46,550
                                  -363-

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Incinerator Emissions and Control of Odors

       Emissions from incinerators are not constant in character or amount.
The amounts and kinds of emissions  will vary with the character of  the mat-
erial  being  burned.  Incinerators are capable  of producing all six of the cate-
gories of pollutants  recognized by the Environmental Protection Agency.
Table 2 shows typical amounts of incinerator emissions,  and as a basis of
reference,  they are compared with open burning.  Odor can also be a prob-
lem in incineration, especially when the material incinerated has a  high
organic content,  a condition to be expected in  municipal waste incineration.

       The control of odors from organic sources is usually accomplished by
heating the  exhaust gas to  1400° F for a period of 0.5 second.  For  practical
purposes,  three types of equipment are available to  achieve odor control.

       1.  Afterburner
       2.  Afterburner with Energy Recovery
       3.  Thermal Regenerative System

       A fuel cost comparison was presented  by  Mueller'") to show the sig-
nificance of thermal energy and system exhaust temperature (Table 10).

Stacks for  Air Pollution Control
       Stacks are air pollution control equipment since their purpose is to
1) reduce temperatures  of exhaust gases, 2) increase the dispersion of con-
taminents to achieve lower ground concentrations, and 3) reduce sulfur di-
oxide concentrations. According to First'"),  current estimating practice for
construction costs of tall stacks is $1, 000 per foot for the first 600 feet and
$2, 500 for each additional foot.
                                   -364-

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                          TABLE 1

          NATIONAL AMBIENT AIR QUALITY STANDARDS
             ENVIRONMENTAL PROTECTION AGENCY

  PRIMARY STANDARDS - are to protect public health.
  SECONDARY STANDARDS - are to protect against effects  on  soil,
  water, vegetation, materials, animals, weather, visibility  and
  personal comfort and well-being.


  I.   SULFUR OXIDES - primarily from the combustion of sulfur
                       containing fossil fuels.

       PRIMARY -  80 micrograms/cubic meter (0.03 ppm)  annual
                  arithmetic mean.
               - 365 micrograms/cubic meter (0.14 ppm)  as  a maximum
                 24 hour concentration not to be exceeded  more than
                 once a. year.

       SECONDARY -   60 micrograms/cubic meter  (0.02 ppm)  annual
                     arithmetic mean.
                 -  260 micrograms/cubic meter  (0.1 ppm) maximum
                    24 hours concentration not to be exceeded more
                    than once a year.
                 - 1300 micrograms/cubic meter  (0.5 ppm) as a
                   maximum three hour concentration not to be
                   exceeded more than once a year.


 II.   PARTICULATE MATTER - Industrial processes or human  activity.

       PRIMARY -  75 micrograms/cubic meter annual geometric  mean.
               - 260 micrograms/cubic meter as a maximum 24 hour
                 concentration not to be exceeded more  than once
                 a year.

       SECONDARY -  60 micrograms/cubic meter annual geometric mean.
                 - 150 micrograms/cubic meter as a maximum 24 hour
                   concentration not to be exceeded more than once
                   a year.


III.   CARBON MONOXIDE - by product of incomplete burning  of  carbon
                         containing fuels.

       PRIMARY/SECONDARY - 10 milligrams/cubic meter (9  ppm)  maximum
                           eight hour concentration not  to be ex-
                           ceeded more than once a year.
                         - 40 milligrams/cubic meter (35 ppm)  maxi-
                           mum one hour concentration not  to be
                           exceeded more than once a year.

 IV.   PHOTOCHEMICAL OXIDANTS - chief source is when hydrocarbons
       and nitrogen oxides are exposed to sunlight.

       PRIMAKY/SECONDATjY - 160 micrograns/cubic meter (0.08 ppm)
       as aTriaximuirT'oneThour concentration not to be exceeded
       more than once a year.


  V.   HYDROCARBONS - Processing,  marketing and use of petroleum
       products.

       PRIMARY/SECONDARY - 160 microqrams/cubic meter (0.24 ppm)
       aca~iiiaxin"ulvrTFiree hour concentration ( 6 to 9 AM) not to
       be exceeded more than once  a year.


 VI.   NITROGEN OXIDFS - originate  from high temperature combustion
       processes.

       P_RIf-^RY/Sj;cOFD^!-!Y - 100 miciograms/cubic meter (0.05 ppm)
       annual aritnraetic inean.

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                                          FIGURE 1
Operation and operational
variables Influencing
control costs
Gas Cleaning System
factors influencing
control costs
                           Cost areas determining
                           the net cost of control
                    GAS CLEANING SYSTEMS COST FLOW DIAGRAM

        Source:  Ernst & Ernst,
                                          TABLE 2

          TYPICAL INCINERATOR EMISSIONS COMPARED TO OPEN BURNING

                              Incinerator  Emissions     Open Burning Emissions
        Type of Emission  Pounds/Ton Refuse Fired   Pounds/Ton Refuse Fired
Particulate
SO^
X
CO
HC
NOX
Photochemical
30
1.5

1
1.5
2
NA
16
1

85
30
6
NA
        Source:  Engdahl,  1968(2)
                                           -366-

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                               TABLE 3

       POLLUTION CONTROL COSTS FOR 50, 000 ACFM UNITS*
                       (DOLLARS/1, 000 ACFM)

Purchase Cost
Installation Cost
Total Capital Cost
Annual Operating Cost
EFFICIENCIES
Mechanical
Separators
194
97
291
17
50-90%
Electrostatic
Precipitators
814
570
1, 384
ZO
98-99+%
i Filters 5
544
440
984
60**
98-99+%
scrubbers
556
526
1, 082
46
95+%
 *From various sources,  Updated to July,  1972 using Marshall and Stevens
  Index

**Variable depending on type of filter media used.
                              TABLE 4
   INSTALLATION COSTS AS A PERCENTAGE OF PURCHASE COSTS
      FOR FOUR  GENERIC TYPES OF CONTROL DEVICES - 1968
Generic Low
Type Percent
Mechanical Collector
Wet Scrubber
Electrostatic Precipitator
Fabric Filter
40
50
35
75
Mean
Percent
50
100
70
80
High
Percent
100
200
100
100
Extreme High
Percent
400
400
400
400
Reproduced from:  Ernst & Ernst,
                                -367-

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                                 FIGURE 2


     ESTIMATED  1967-68 PURCHASE COSTS FOR FABRIC FILTERS


                               (LOG SCALES)


            600

            400
            300
            200
PURCHASE COST
  ( $ X I03 )
                                                       200      400   600 BOO 1000
                                  GAS VOLUME THROUGH COLLECTOR
                                          (ACFM X I03)

                          PURCHASE COST  (AMOUNT CHARGED BY MANUFACTURER)

                         • CAPITALIZED  PURCHASE  COST  (62/3 % DEPRECIATION + 6 2/3 %
                          ADDITIONAL CHARGES  TO CAPITAL),  EXCLUDING  INSTALLATION
             Reproduced From:  Ernst &  Ernst, 1968^)
                                    -368-

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                                             FIGURE 3


                ESTIMATED 1967-68 PURCHASE COSTS FOR WET SCRUBBERS


                                          (LOG SCALES)
PURCHASE COST
  ( $ X 103 )
                                     6   8  10
                                                   20
                                                           40   60  60 100
                                                                              £00
                                                                                      400  600 800 1000
                                            GAS VOLUME THROUGH COLLECTOR
                                                    (ACFM X 105)

                              PURCHASE COST (AMOUNT CHARGED BY MANUFACTURER)

                              CAPITALIZED PURCHASE COST (62/3% DEPRECIATION + 6 2/3 % ADDITIONAL
                              CHARGES TO CAPITAL),  EXCLUDING INSTALLATION
              Reproduced From:  Ernst & Ernst,  1968^)


                                               -369-

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                                FIGURE 4

                ESTIMATED 1967-68 PURCHASE COSTS
               FOR ELECTROSTATIC PRECIPITATORS

                             (LOG SCALES)
PURCHASE COST
  ( $X I03
                                 40    60  80  100
200
         400  600  800 1000
                                 GAS VOLUME THROUGH COLLECTOR
                                         (ACFM X 1C3)

                         PURCHASE  COST  (AMOUNT CHARGED BY MANUFACTURER)

                        ' CAPITALIZED  PURCHASE  COST (6 Z/3 % DEPRECIATION + 6 2/3 %
                         ADDITIONAL CHARGES  TO CAPITAL), EXCLUDING WSTALLATION
             Reproduced From:  Ernst & Ernst, 1968(1I

                                  -370-

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                                   FIGURE 5

  ESTIMATED  1967-68 PURCHASE COSTS FOR MECHANICAL COLLECTORS

                                (LOG SCALES)
PURCHASE COST
  ( $ X I03 )
               10
20
60  60 100
200
400   600 800 1000
                                  GAS  VOLUME THROUGH COLLECTOR
                                          (ACFM X I03)

                          PURCHASE  COST  (AMOUNT CHARGED BY MANUFACTURER)

                         ' CAPITALIZED PURCHASE  COST (6 2/3 % DEPRECIATION + 6 2/3 %
                          ADDITIONAL CHARGES  TO CAPITAL),  EXCLUDIN6 INSTALLATION
            Reproduced From:  Ernst & Ernst,  1968(1)

                                     -371-

-------
                          TABLE 5

  ANNUAL MAINTENANCE COST FACTORS FOR FOUR GENERIC
          TYPES OF CONTROL DEVICES IN 1967-1968
Generic Type
Mechanical Collectors
Wet Scrubbers
Electrostatic Precipitators
Fabric Filters

Low
0.005
0. 02
0.01
0.02
Cost ($/ACFM)
Mean
0.015
0.04
0.02
0.05

High
0.025
0.06
0.03
0.08
Reproduced From:  Ernst & Ernst, 1968(1)
                            -372-

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                             REFERENCES

1.  Ernst & Ernst, 1968, A Rapid Cost Estimating Method for Air Pollution
    Control Equipment:  Rept. to U.S. Public Health Service,  Contract No.
    PH 86-68-37, 41  p.

2.  Engdahl, Richard B.,  1968, Stationary Combustion Sources:  Chapter 32
    in Air Pollution,  Vol.  Ill,  ed. Stern,  Arthur C., New York, Academic
    Press,  866 p.

3.  Cross,  Frank L.  , Jr., 1972,  Planning Incineration Without Air Pollution;
    Pollution Engineering 4_ (4), p. 48-49

4.  Stern,  Arthur C., 1968, Efficiency, Application and Selection of Collectors:
    in Air Pollution.  Vol.  Ill,  Ed. Stern, Arthur C., New York,  Academic Press,
    866 p.

5.  Kerbec, Matthew J. , 1971, Your Government and the  Environment,  An
    Annual Reference:  Vol.  I, Arlington,  Va.,  Output Systems Corp.

6.  Lesher, Douglas, 1972,  Personal Communication;  Unpublished data com-
    piled by Pennsylvania Department of Environmental Resources, Harrisburg

7.  Lund, Herbert F.,  1971,  Industrial Pollution Control Handbook:  New York,
    McGraw-Hill

8.  Mueller, James H., 1971, Cost Comparison for Burning Fumes and Odors;
    Pollution Engineering _3 (6), p. 18-20

9.  First,  Melvin W., 1968,  Process and System Control: in Air Pollution,
    Vol. Ill, ed.  Stern,  Arthur C. ,  New York,  Academic  Press,  866 p.
                                  -384-

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           SOLID WASTES HANDLING AND DISPOSAL COSTS

                        TABLE OF CONTENTS

                                                                Page No.

Collection and Transportation                                       387

Disposal Methods                                                   388

Open and  Covered Dumping                                         389

Sanitary Landfills                                                  389

Incineration                                                        390

Composting                                                        394

Experimental Solid Waste Disposal and Recovery Techniques         396

Pyrolysis                                                          396

Biological Fractionation                                            396

Recycling                                                          396

References                                                         398

                           LIST OF TABLES

1.  Cost of Compacted Waste Transported in Containers -
    Vermont                                                        388

2.  Principal Components of a Municipal Incinerator and
    Costs  - New York City                                          392

                           LIST OF FIGURES

1.  Sanitary Landfill Operating Costs                                391

2.  Capital Costs of Municipal Incinerators                          393

3.  Capital Costs of Compost Systems                                395

4.  Operating Costs for Compost Systems                            395
                                  -385-

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            SOLID WASTES HANDLING AND DISPOSAL COSTS

        The primary purpose of this  section is  to analyze presently available
solid waste handling and disposal techniques and determine unit costs for each
such technique discussed.  The study is  intended to provide information neces-
sary to evaluate  the cost of solid waste management remedial programs in the
Monongahela River Basin.  Although many of the cost analyses given are de-
veloped for areas other than the Monongahela River Basin, the capital and
operating cost figures are  applicable to the region with the exception of land
acquisition requirements and labor costs which may be unique to the particular
area reported.

       Solid waste management involves the following elements:  collection and
transportation, processing and ultimate  disposal.

Collection and Transportation

       In urban and suburban areas, the most common methods of collection
include municipal collection, contract  with a private firm and private col-
lection service.  In any case,  refuse is normally collected in a compactor
truck which transports the  wastes to either the processing and disposal site
or to a central transfer station.  Toftner and Clark' ' recommend the use of
transfer stations and size reduction  techniques to reduce costs when long hauls
are necessary or when large areas are serviced.  Another study by Kramer^)
suggests the use  of transfer stations if the disposal facility is more than ten
miles  from the collection area.  Kramer lists  advantages of  transfer stations
as:  1) reduced cost of transportation;  2) more efficient use of collector  trucks;
3) modest  capital cost; and 4) reduced  vehicle requirement.  The capital costs
for such a station including one tractor and two trailers  is  given as $1, 620 per
ton per day capacity.  Estimated operating costs for a 15 mile haul using a
transfer station are given as $0. 17 to $0.27 per ton-mile while the cost  of
packer truck hauling over the same distance is estimated as  $0. 18 to $0.40
per ton-mile.

       In rural areas,  collection and disposal  are more difficult and more
costly than in urban and suburban areas.  Inadequate collection services in
rural areas lead  to unsightly dumping or open burning of  refuse.  In areas
of Pennsylvania infrequent  or nonexistant collection services have led to the
infestation of the State with over 2,600 roadside dumps and allowance of open
burning of domestic refuse in many municipalities  (Toftner and Clark^ ').
Andres and Cope'^) recommend a system of containerized storage and trans-
fer for rural areas.  The stated goal is to eliminate several  existing dumps
by promoting individual refuse disposal in 8 to 40 cubic yard containers placed
at central locations and  transfer of the containerized waste to a single cen-
trally  located sanitary landfill weekly.   The annual cost per ton including
amortization for  containers and transfer to landfills was  estimated to range
from $13. 63 to $17. 89 as compared to  a $17. 39 annual cost for operation and
maintenance of individual community modified  sanitary landfills.   A similar
                                   -387-

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study was conducted in Vermont (Cacioppi,  et al. ^  ').  Costs were estimated
on the basis of the number of cubic yards of compacted waste transported to
sites  various distances from the collection point in 35 cubic yard containers.
Compactor and container leasing costs were estimated at $235 per month,  and
the charge for disposal at $25 per  container.  An average of one hour travel
time for 30 miles and a time of one-half hour  for unloading was assumed.  On
the basis  of 500 pounds per cubic yard compacted,  a cost per container load
is given.  For this study  the costs  have been converted to a cost per ton of
compacted waste.  The data is reproduced in Table  1.

                                TABLE  1
Container Site
Distance from
Disposal Site
(Miles)
3
6
9
12
15
18
21
24
27
30
Cost/Ton
Times Per
1
10.23
10.43
10.64
10.85
11.05
11.26
11.47
11.67
11.87
12.08
@ 8.75 Ton per
Container
Week Containers Emptied
2 3
6.67
6.88
7.09
7.29
7.50
7.71
7.98
8. 11
8.32
8.53
5.64
5.88
6.05
6.26
6.48
6.67
6.88
7.08
7.29
7.49
       Source:  Solid Waste Section, Environmental Protection Division
                Agency of Environmental Conservation, State  of Vermont
                in Cacioppi et al.,  1970(4)

       The data may be extrapolated to greater distances  at a rate of $0. 07
per ton-mile.  The report states that the  containerization system is highly
suitable for rural areas and small communities and is  sanitary, flexible and
economic.

Disposal Methods

       The conventional solid waste disposal methods include  open dumping,
sanitary landfill, incineration and composting.  Some advanced disposal and
recovery  or recycling techniques are also known, such as pyrolysis, biologi-
cal fractionation,  and various separation processes; however, most of these
techniques are still in the experimental stage.
                                   -388-

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Open and Covered Dumping

        Open dumping is the most common method of solid waste disposal in
some areas of the United States, although it is  by far the least desirable
method.  No direct cost figures are available for open dumping;  however, the
intangible costs  of unsanitary conditions, ground and surface water pollution,
air pollution, insect and rodent problems, and  aesthetic degradation may be
associated with this method.

        Covered  dumping is similar to open dumping except that the refuse is
periodically covered with soil.  The disadvantages of covered dumping are
the same as  those mentioned for open dumping.  Vermont has estimated costs
for closing and sealing dumping sites to be $8, 000 per acre (Cacioppi, et al.' ').

Sanitary Landfills

        Sanitary  landfill techniques are the most practical and economical
methods of solid waste disposal in many areas.  Two basic methods of sani-
tary landfill exist, trench fill and area fill.  The area landfill involves the
filling of large low-lying areas with cells of refuse compacted and covered
with soil at regular intervals.  The trench method involves excavation of
trenches,  filling with refuse and recovering the trenches with soil.  The soil
cover should be  two feet deep over the refuse cells (Golueke(^)).  The refuse
layers  should not exceed five to six feet in depth and should be compacted be-
fore being covered.

        In several areas of the anthracite and bituminous coal regions  of Appa-
lachia,  abandoned strip mines are  used for sanitary landfills.  The use of
strip mines not only solves local solid waste disposal problems,  but may also
lead to  restoration of the strip mine areas.  Emrich and Landon(") investigated
five strip mine landfill sites in Western Pennsylvania.  They found little or no
ground  or  surface water pollution where care is taken to avoid permeable or
fractured rock.

        For either the area fill or trench fill method equipment requirements
range from a single crawler tractor with dozer blade  or bullclaw attachment
for smaller operations to one bulldozer, compacting equipment,  water trucks
and earth movers for  larger sanitary landfills.   One bulldozer of the 4, 700
pound gross weight size will handle 250 tons of  solid waste per day (Golueke^)).

        Sanitary landfill costs will depend on the population served, size of the
landfill, and  the  equipment required.  Initial investments are variable depend-
ing on the price of the property acquired.  The  initial land costs  may be par-
tially or completely offset by restoration of the  completed landfill for develop-
ment purposes.  Operating costs are more definable,  and several costs of
operation are given in the literature.  Kramer(^) gives  operating costs of $1.65
to $2. 10 per  ton  for a 300 acre site handling 96, 000 to 150, 000 tons per year.
In Vermont,  sanitary landfill operation costs are estimated to range from
                                   -389-

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$0.60 to $3.00 per ton depending on the amount of waste to be disposed (Cacioppi,
et al. v'*) Ralph Stone and Company^'' gives costs of $1.50 per ton for sanitary
landfill disposal.  Sorg and Hickman(°) have stated that wages  account for 40 to
50 percent of costs; equipment, 30 percent; and cover material,  administration
and overhead,  20 percent.  Operating costs developed by Sorg  and Hickman are
presented in Figure 1.

Incineration
       Modern incineration involves controlled burning of solid wastes in a
closed vessel at high temperatures.  The solid waste may be batch fed or con-
tinuously fed onto agitating grates where primary combustion occurs.  Ashes
and noncombustables are fed into hoppers  for disposal.  The smoke,  exhaust
gases and fly ash are directed into a secondary combustion chamber  where they
are burned at temperatures of 1,500 to  1, 800 degrees F (Flower(9)).  The gases
then flow through settling chambers for  removal of heavy particulates and then
through various gas cleaning devices to  the exhaust stack.

       Incineration reduces the volume  of waste to be disposed of to  10 to 30
percent of its original volume  (Engdahl(lO)).  ^he  residues may be landfilled
directly  or separated by mechanical and/or magnetic devices for recovery of
ferrous metals and glass. Gilbertson and Black'*M have found landfill or ash
residues to  cost approximately $1.00 per ton.

       Gouleke(S) has listed equipment  needed for incineration of municipal
solid waste.  A storage pit or  hopper holding an amount equal to 24 hours of
burning capacity  is needed for receiving and storing refuse. A bridge  crane,
a charging hopper, a feeding and drying stoker and a burning stoker are needed
for charging the incinerator.   The  incinerator should have primary and second-
ary combustion chambers lined with refractory materials and various gas clean-
ing chambers,  flues and dampers.   Ash hoppers and conveyors must be provided
for removal of residues.   Various  instrumentation for temperature measure-
ment, draft gaging and stack gas monitoring should also be provided.   Finally,
a landfill site is necessary for disposal  of the incinerator residues.

       Michaels^   ' in 1956 reported the capital costs of municipal incinerators
to range  from $3, 000 to $4, 000 per ton  of 24  hour  capacity with buildings account-
ing for 40 to 76 percent,  furnaces and auxilary equipment accounting for  18 to
24 percent and stacks  accounting for 4.5 to 11 percent of the total capital cost.
More recently, Cacioppi,  et al., 1970(4) reported capital costs to range  from
$8, 000 to $11, 000 per ton of 24 hour capacity.

       Greeley(13) listed the  capital costs  of municipal incinerators  for New
York City by component.   These unit capital costs are reproduced in Table 2.
                                   -390-

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                           FIGURE I

            SANITARY  LANDFILL  OPERATING  COSTS
   4.00
   3.00
o

g  2.00
CL
O
o
    1.00
      0
               100,000    200,000   300,000   400,000   500,000

                           TONS  PER YEAR
        Reproduced From "Sanitary Landfill Facts"
        Thomas J. Sorg and H. Lanier Hickman, Jr 1970
        PHS Publication No. 1792
                            -391-

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                                TABLE 2

              PRINCIPAL COMPONENTS OF A MUNICIPAL
                      INCINERATOR AND COSTS
                                                     Unit Cost Per Ton
                      Item                           Of Rated Capacity

Scales, roadways,  dumping rail and enclosing wall          $   100

Storage bin                                                   200

Cranes                                                       225

Flues and fly ash removal facilities                            400

Chimneys                                                     300

Furnaces                                                   1,200

Inside  Flues                                                   85

Building and enclosure                                      1,415

Miscellaneous                                              	75_

       Total                                               $4, 000
Source:  Greeley, S. A., "Background of Design Criteria for Municipal
         Incinerators - The Designer's View," JAPCA 6(3)133-9, 1956.

       Further,  Drobny, et al.(14) give  total capital costs of various sizes of
municipal incinerators  based on conventional engineering estimating factors.
A portion of their data  is reproduced in Figure 2 for construction of inciner-
ators with conventional refractory and no waste heat recovery.

       Operating costs for municipal incinerators are highly variable and
primarily related to the size capacity of the units and the percent of capacity
use per day.  Several authors have reported  operating costs for  municipal
incinerators.   Rogusv-'1-') reporting on large incinerators of approximately
1, 000 ton per day capacity in New York found costs to vary from $4.78 per
ton for older plants to $2. 39 per ton for newer design plants. Gilbertson and
Black(H) found operating costs to average $3.00 per ton in the Washington,
D.  C.  area.  The Committe on Refuse Disposal, APWA(16) reported unit costs
for municipal incineration in six major U.S.  cities to range  from $2.28 to
$6.49 per ton on a 1959 base.  A unit cost of $8.53 per ton including the cost
of disposal of ash and inerts was  estimated for incineration by the City of
                                   -392-

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            CAPITAL COSTS  OF MUNICIPAL INCINERATORS
200
400
600
800
1000
1200
                        CAPACITY-TONS PER DAY
      From Drobny, N. L et a I. Recovery and Utilization of Municipal Waste  US. EPA 1971
                               -393-

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Santa Clara, California (Ralph Stone and Company^'').  Golueke^  ' found incin-
eration costs to vary from $4.00 to $12.00 excluding pollution control devices
in the Oakland,  California area.  Unit costs estimated by Kramer(^) ranged
from $6.50 to $8.40 per ton for  two 300 ton per day capacity incinerators for
Clark County, Ohio.  Costs  for incineration in the  state of Vermont were esti-
mated  to range from $7. 00 to  $11. 00  per ton (Cacioppi,  et al. (4)).

Composting

       Composting, presently more common to Europe than to the United States,
is a biological digestion process whereby the organic components of refuse are
degraded  into a humus-like product.  The process  involves the screening of
refuse to  remove nonorganic materials and biological oxidation of the  remaining
organics for a period of two to five weeks.  The cured compost may be used  as
a soil conditioner,  but  because its nutrient content is low, it does not  make a
good fertilizer.

       In the United States composting has not been too attractive because it is
not economically competitive with other disposal methods and because no major
United States markets have yet developed for compost.  Additionally,  since the
bulk of solid waste is produced in large urban areas and compost would be util-
ized in rural areas, the transportation costs to move large volumes  long dis-
tances would often  be prohibitive.

       Estimated costs for composting operations  in Vermont were estimated
to average as high  as $8. 00  per  ton.  A composting demonstration plant in
Gainesville, Florida had operating costs of $6.25 per ton.  Goleuke^  ' gives
estimated operating costs for  composting of $7.00  to $8.50 per ton to  serve a
population equivalent of 100,000. Kramer'  ' estimates compost costs to range
from $7. 00 to $8. 00 per ton of solid waste. Engdahl^10) reported on pilot
studies on composting municipal garbage at San Diego, California.  Costs  of
operation excluding administration, overhead and capital amortization ranged
from $1.56 per ton where no grinding  or other preparation occurred to $20.48
per  ton where the garbage was course ground and straw was added.  The report
further states that  grinding accounted  for 30 to 60 percent of the total  cost per
ton.

       Drobny,  etal. (14) reported on the operation of six privately owned
compost operations.  Estimates of the capital and operating costs of the sys-
tems have been summarized based on operation of a 25 ton per day pilot plant
in Altoona,  Pennsylvania and  Houston, Texas.   These costs are illustrated
graphically in Figures  3 and 4 for various  capacity plants.   Operating costs
include payroll, utilities and supplies  and administration.  The reasons for
the large  range of  operating costs are not clear.

       Composting in Europe  was reported by  Hart(l?).  He found European
refuse more amenable  to composting  by virtue of its composition.  Compost-
ing costs  were reported as $2.00 per metric ton or $1.80 per short ton.
                                   -394-

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Experimental Solid Waste Disposal and Recovery Techniques

       There are a number of experimental techniques for solid waste process-
ing now in the research and pilot study stages.  Most of these processes now
under development are oriented toward the recovery of some economically use-
ful component of solid waste for reprocessing or reuse.

       A  few of the existing solid waste processes may be modified for recovery
of salvageable materials; however, the economics have not been thoroughly de-
fined at this  time.  The U.S.  Bureau of Mines has been the most active organi-
zation  in developing these recovery methods.  A Bureau of Mines pilot plant
erected in 1967  has successfully separated metallic iron, non-ferrous metal,
glass and ash tailings from incinerator residues (Davis(18)).  The plant has an
operating cost of $2.  00 per ton of residue processed and produces $10 to $12 in
recoverable  products per ton of residue, KenahanU9)  reports.  Drobny, et al.
discusses similar recovery systems applicable  to compost operations.

Pyrolysis

       Pyrolysis, or destructive  distillation, is a process of heating a material
to about 1, 500 degrees F without air to break down the organics into component
parts.  The process  was originally developed by the U.S. Bureau of Mines for
coal and coke research;  however,  the process is now finding limited applications
in the  solid waste field for the production and recovery of tars, fuel gases and
liquids, alcohols, acetic acid, charcoal ash and other organic chemicals (Sanner,
et al. '^)).   Drobny,  et al. (*-^i has estimated the net operating  costs to be about
$5.70  per ton of refuse;  however,  because of the retort residence time require-
ment of 23 hours, the process appears unprofitable on a large scale.

Biological Fractionation

       Biofractionation involves the processing of organic components of  solid
wastes in a manner similar to aerobic digestion to produce a solid residue with
nutrient value for animal feed. The system is highly experimental and costs
now average  over $40 per ton of refuse processed (Golueke'-3').

Recycling

       The ultimate  solution to solid waste disposal problems will be utilization.
Several community groups and some commercial organizations are salvaging
metals, glass,  and paper by  voluntary sorting the components of solid waste.
To date,  the majority of operations recycling municipal refuse have been  on a
very limited scale.   However, the role  of the organizations in acting as a cata-
lyst to bring about changes  in attitudes toward waste  in general has been of
great  value.
                                  -396-

-------
       Since the majority of organizations involved in recycling use volunteer
labor,  no cost estimates  are  available.  Methods of economically separating
and concentrating urban refuse must be developed before large scale applica-
tions of this method are possible.  Central storage areas must be developed
and minimum daily supplies to recovery industries must be insured (Clark'^•"•').
Conversion of solid wastes into only a few marketable products critically limits
the number of markets which can be reached and increases the possibilities of
oversupply.  Gentile(^2)  stated, "It is important to combine the element of
'separation' and 'salvage' into a complete  conversion system in order to develop
a greater variety of by-products and distribute the resultant items  and raw mat-
erial to the most diversified markets possible."

       Even though the recycling of urban refuse may be uneconomical in  itself
at the present time, it may be economically attractive when considering the total
cost to the consumer for  producing and discarding  a particular product. Not
only are the natural resources  used in the production and disposal of a product
utilized,  but  new natural resources must be developed  and utilized to replace
the discarded product. When considering  reclamation costs, possible devaluation
of affected lands and decrease in aesthetic value,  a net savings may be incurred
from recycling  of a majority  of urban refuse.  A national effort will have to be
exerted, however, before the true economic advantages of  recycling  can be fully
realized.
                                  -397-

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                             REFERENCES

 1.   Toftner, R. O.  and Clark, R.  M. , 1971, Intergovernmental Approaches
     to Solid Waste Management:  U.S.  Environ.  Prot.  Ag. , Solid Waste Mgt.
     Office,  Rept. No SW-47ts, 18 p.

 2.   Kramer, R. J. ,  1969, Solid Waste Survey Prepared for Clark  County -
     Springfield Regional Planning:   U.S.  Dept. Housing Urban Developm.
     Report No. P-239, 78 p.

 3.   Andres,  D.  R.  and Cope, F. W. , 1970, Solid Waste Transfer and Dis-
     posal for Rural  Areas:  California Vector Views, IT_ (7), 67-76.

 4.   Cacioppi, J.  T. , et al. , 1970,  Report of the Governor's Task Force -
     Solid Waste Management in Vermont:  State  of Vermont, 75 p.

 5.   Golueke, C. G. , 1971,  Comprehensive Studies of Solid  Waste Manage-
     ment:  3rd Ann. Rept. U. S.  Environ.  Prot.  Ag.,  Solid Waste  Mgt. Office,
     201 p.  also 1st and 2nd Ann.  Repts.,  U.S. Public Health Serv. Publ. No.
     2039 (1970), 245 p.

 6.   Emrich, G. H.  and Landon,  R. A.,  1971, Investigation of the Effects of
     Sanitary Landfills in Coal Strip Mines on Ground Water Quality:  Pa. Dept.
     Environ. Resources, Bur. Water Quality Mgt. Publ.  No.  30,  39 p.

 7.   Ralph Stone and Co. , 1968, Solid Wastes Landfill Stabilization,  An Interim
     Report:  U.S.  Dept. Health,  Educ., Welf. ,  Grant No. DO  l-UI-00018,  120 p.

 8.   Sorg, T. J. and Hickman,  H. L. ,  1970, Sanitary Landfill Facts:  U.S.
     Public Health Serv.  Publ.  No.   1792,  30 p.

 9.   Flower,  F.  B.,  1969, Combustion and Heat: Dept. Environ. Sci. , State
     of New Jersey,  15 p.

10.   Engdahl, R. B., 1969,  Solid Waste Processing, A State-of-the-Art Report
     on Unit Operations and Processes: U.S. Public Health Serv. Publ.  No.
     1856, 72 p.

11.   Gilbertson,  W.  E.  and Black,  R. J. , 1966,  A National Solid Waste Program
     is Created:  Compost Sci.  _6_  (3), 4-7.

12.   Michaels, A.,  1956,  Design Criteria for Municipal Incinerators:  Jour.  Air
     Poll. Control Assoc. _6 (3), 139-43.

13.   Greeley, S. A.,  1956, Background of Design Criteria for Municipal Incin-
     erators - The Designers View:  Jour. Air Poll. Control Assoc. 6_ (3),
     133-39.
                                   -398-

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14.  Drobny,  N. L. , Hull, H. E. and Testin, R. F. ,  1971,  Recovery and
     Utilization of Municipal Solid Waste:  U.S. Environ. Prot. Ag. , Solid
     Waste Mgt. Office  Publ.  No. SW-lOc, 118 p.

15.  Rogus, C. A., 1965, Sanitary Fills and Incinerators:  American City
     £0(3), 114-15.

16.  Committee on Refuse Disposal, APWA, 1966, Municipal Refuse Disposal:
     Public Administration Service, Chicago.

17.  Hart, S. A.,  1967, Solid Waste Management in Germany,  Report of the
     U.S.  Solid Waste Team Visit,  June 25 - July 8.  1967:   U.S.  Public Health
     Serv.  Publ. No.  1812,  18 p.

18.  Davis, F.  F., 1972,  A New Resource Opportunity - Urban Ore:  California
     Geology  2_5_ (5), 99-112.

19.  Kenahan, C.  B., 1971, Solid Waste,  Resources Out of  Place:  Environ.
     Sci. Tech. _5_  (7), 594-600.

20.  Sanner,  W. S. , et  al., 1970, Conversion  of Municipal and Industrial Refuse
     into Useful Materials by Pyrolysis:  U.S.  Bur. Mines Rept.  Inv. 7428, 14 p.

21.  Clark, T. D. , 1971,  Economic Realities of Reclaiming Natural Resources
     in Solid Waste:  in  Inst. Environ. Sci. Ann. Tech. Meet.  Proc., Los Angeles,
     p. 39-43.

22.  Gentile,  P.,  1964,  Resources  for the Future and Industrial Conversion:  in
     Proc., Nat.  Conf.  Solid Waste Res., Chicago, Dec. 2-4,  1963, Am. Public
     Works Assoc., p.  187-90.
                                  -399-

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            ABANDONED AUTOMOBILE REMOVAL COSTS




                       TABLE OF CONTENTS




                                                              Page No.




Introduction                                                     403




Proposed Federal Legislation                                     403




Other Abandoned Automobile Recycling Recommendations           404




The Need for a Comprehensive Field Survey                       405




Costs of Retrieving Abandoned Automobiles                         405




References                                                      407
                                -401-

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             ABANDONED AUTOMOBILE REMOVAL COSTS

Introduction

        According to the National Industrial Pollution Control Council^ ',
approximately 21% of the automobiles produced in the United States since
1959  are either abandoned or in automobile graveyards.  The wide use of
the basic oxygen furnace in the steel industry is the major factor respon-
sible for this accumulation of unused  automobile scrap (Dean,  et al.* ').
The oxygen furnace is limited to an initial charge of 26 percent scrap com-
pared to 48 percent in the open hearth process.  As a result, the market
value of ferrous scrap has decreased proportionately.  Although the chief
component by weight of the average automobile is steel and iron (95%),
other metals present in recoverable amounts  are lead (1%),  copper (1%),
aluminum (1%) and zinc (2%) as  reported by the Bureau of Solid Waste Man-
agement'-^  and  Dean and Sterner'**),

        Besides being a serious  waste of natural resources  (Shapiro(^)),
unused automobile scrap is responsible for health and safety problems and
environmental degradation (Dean("').  Environmental damage not only occurs
as a result  of the physical presence of an unused automobile, but also be-
cause of the increased amount of ore, coal, limestone, and  other raw mat-
erials necessary to replace the  metals discarded.  Even  though automobile pro-
duction requires 20 percent of the steel produced and imported by this country
(Javits'''),  reprocessed automobile scrap accounts for only nine  percent
of total scrap utilized (Ralph Stone and Company(°)).

        The  recycling of rubber  used in  automobile production, approxi-
mately 60 percent of the total U.S. production, has presented similar prob-
lems.  The  primary deterrent to rubber product reuse in the form of auto-
mobile tires has been storage and shipping costs (Hassell(9), Pettigrew and,
Roniger(10)).

Proposed Federal Legislation

        Proposed federal legislation that could alleviate future  problems
associated with abandoned automobiles and automobile graveyards was
recommended in 1970 by Javits^11) and Gurney(12) in Senate Bills S4204
and S4197 respectively.

       Senate Bill 4204 proposes the use of a  "disposal deposit" on all new
automobiles.  This deposit would be transferrable and refunded at the time
the automobile is  deposited at an authorized scrap center.  If the  car was
illegally abandoned, a public  agency or authorized scrap  dealer would re-
move the vehicle and collect the disposal fee.   This bill is also designed
to decrease  the  number and size of junk car lots since a dealer would not
receive the  disposal deposit until the automobile is actually sent to a re-
processing center.  Except for  initial organizational expenses, the program
                                 -403-

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 should be  self-financing.  This abatement method possibly could be applied to
 other  items such as  tractors, industrial equipment, refrigerators and other
 househould appliances.

        Senate Bill 4197 proposes  financial aid to states and would allot funds
 based on motor vehicle registration in the state. The additional revenues
 provided to salvage operators in the form of a "bounty payment" would be an
 incentive to scrap any unusable automobile.

        A similar system is already in operation in Maryland where licensed
 scrap processors receives $10 for each car certified as actually  reused  as
 scrap (Leib^-*)).  Another method involves  collection and accumulation of
 abandoned  automobiles by municipal agencies with aid of state funds (Karr(14))«

 Other Abandoned Automobile Recycling Recommendations

        Other recommendations designed to  make automobile  scrap recycling
 economically attractive are:

 1.   A uniform title clearance procedure which will make abandoned automobile
     reprocessing easier.

 2.   Restrictions on the importation of iron ore  and steel to encourage the use
     of scrap.

 3.   Financial incentives  to automobile reprocessors  in the form  of guaranteed
     loans and tax write-offs.

 4.   Manipulation of freight rates  to favor scrap reuse.

 5.   Federally controlled stockpiling of scrap to limit fluctuations in market
     demand and scrap availability.

 6.   Development of recycling districts with reprocessing centers.

 7.   Elimination of "built in" obsolescence in the automobile industry.

 8.   Development of more efficient methods of nonmetallic waste  separation in
     abandoned automobile reprocessing.

 9.   Acceleration and expansion of research devoted to the increased  use of
     automobile  scrap.

10.   Initiation of legislation prohibiting abandonment  of vehicles and restrictions
     on ownership of wrecked,  nonoperating or discarded vehicles as  outlined
     in the "Model Ordinance" prepared by the National Institute of Municipal
     Law Officers(15).
                                   -404-

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 The Need for a Comprehensive Field Survey

        A comprehensive field survey is necessary to insure the success of an
 abandoned vehicle  collection program.  Information from such a survey should
 include type of automobile,  general condition,  amount of surrounding rubble,
 and if possible, the owner of the land on which the vehicle is  located.  Location
 is probably best facilitated by assigning the vehicle a number  and marking it
 on an appropriate map.

        Many surveys have  been performed utilizing community service organi-
 zations such as the Boy Scouts of America, YMCA and other  groups.  Some-
 times  local and state agencies can be utilized in the compilation of abandoned
 automobile  data.  West Virginia used the state police to locate and obtain re-
 lease of discarded vehicles.  In some communities,  it may be possible to have
 "phone-in"  campaigns  such  as in Michigan where  citizens were informed of the
 program through the local news media as reported by General Motors  Corpor-
 ation!16).
        ChaseV !7) mentioned a bounty system where students were given a $1
reward for each automobile reported and accompanied  by a  certificate of re-
lease.  Some commonly accepted title clearance procedures must be developed
before a program such as this could be applied on a large  scale.  Another pos-
sible method that may be economically feasible  in locating abandoned automo-
biles is aerial reconnaissance.  Two people  is all that  is necessary to complete
such a survey and large areas can be viewed in  a relatively  short period of time.

Cost of Retrieving Abandoned Automobiles

       After an adequate survey has been prepared  and certificate of release or
title clearance is accomplished, actual removal  of discarded vehicles will be
possible.  In the West Virginia program, the National Guard were used to re-
trieve vehicles.  Reported costs were $40 per automobile, but it was  estimated
this  cost would be 50 percent less  if the  program was conducted when weather
conditions  were more favorable (Gandee'  ').

       In a cleanup  campaign in Columbia County, New York, the  County Health
Department  collected 12, 000 automobiles at  a unit cost of $1.67.   In programs
conducted  by the Vermont Motor Vehicle Department 13, 151 vehicles  were col-
lected at an  average  cost of $10 per  car.  Both projects used trucks to pick up
vehicles.  Automobiles were deposited in a central collection area where sal-
vage operators disposed of the accumulated scrap.

       Steen' ') reported that the  Tennessee Valley Authority has developed a
feasible method of collecting derelict vehicles in rural areas. The focal point
of this method according  to Steen'^0) is the use of a  modified truck which re-
quire only  one man to pick up, deliver, and deposit a vehicle with or without
wheels.  A summary of the results of this program based on available infor-
mation is as follows:
                                   -405-

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      Location

Anderson Co., N.C.
LoudonCo., Tenn.
Towns Co. , Georgia
Murphy, N. C.

TOTALS
 Number of
Automobiles
Total Expenditures   Unit Cost
   1,577
    $4,183.59
       450.00
     1,450.00
       736.36

    $6,819.95
$4.32
       The average reported unit cost of $4.32 per vehicle compares favor-
able with the estimate of $4. 50 made by the TVA during initial stages of the
program.

       Little data exists concerning the cost of vehicle retrieval labor, im-
poundment, and subcontractor cost breakdown. Rothman(^) estimates the
total cost of disposing of abandoned automobiles in New York City is $40 to
$60 per vehicle.  In areas  where impoundment is not necessary,  automobiles
may be removed by licensed processors free of charge.

       Better cost estimates will be possible when a standard format is de-
veloped for reporting results of an abandoned automobile removal program.
The  information form should include descriptions  of:

1.   Field Survey Methods
2.  Advertisement Methods
3.  Removal Techniques (including equipment, average haul distance,  con-
    dition of abandoned automobiles,  source of labor and other pertinent
    factors)
4.  Storage Facilities
5.   Final Disposition of Scrap
                                 -406-

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                             REFERENCES

 1.  National Industrial Pollution Control Council,  1970,  Junk Car Disposal:
     U.S.  Dept.  Comm. ,  54 p.

 2.  Dean,  K. C. , Chindgren,  C.  J.  and Valdez, E. G. ,  1972, Innovations
     in Recycling Automobile Scrap:  U.S. Bur. Mines,  1Z  p.

 3.  Bureau of Solid Waste Management,  1970,  The Automobile Cycle:  An
     Environmental and Resource Reclamation Problem:  Publ. No. SW-80,
     46 p.

 4.  Dean,  K. C. and Sterner,  J.  W. ,  1969! Dismantling a Typical Junk
     Automobile to Produce Quality Scrap:  U.S. Bur. Mines  Rept.  Inv. 7350,
     17 p.

 5.  Shapiro, I.  D., 1964, The Scrap Processor's  Role in Auto Salvage: Proc.
     Nat. Conf. Auto Salvage Inst. of Scrap Iron and Steel,  p. Dl-6

 6.  Dean,  K. C., 1967, Bureau of Mines Research for Utilizing Automobile
     Scrap:  Hearings before the Committe on Public Works,  U.S. Senate,
     416 p.

 7.  Javits, J. K. ,  1970,  Disposal of Junked and Abandoned Motor Vehicles:
     Hearings of the Subcommittee on Air and Water Pollution before  the
     Committee on Public Works,  U.S. Senate, 416 p.

 8.  Ralph Stone and Company, 1969, Copper Content in Vehicular Scrap:
     U.S.  Bur.  Mines, 43 p.

 9.  Hassell, E. W. , 1970, The Automobile Wrecking/Dismantling Industry:
     U.S.  Dept.  Comm.,  Office Business Programs, 93  p.

10.  Pettigrew, R. J. and Roninger, R.  H. ,  1971,  Rubber Reuse and Solid
     Waste Management, Part I:  U.S.  Environ. Prot,  Ag.  , Solid Waste Mgt.
     Office Publ.  No. SW-ZZC, 1ZO p.

11.  Javits, J. K. ,  1970,  The Motor  Vehicle Disposal Act: U.S. Senate Bill
     S4204

12.  Gurney, E. J. , 1970, The Motor Vehicle  Disposal Assistance Act: U.S.
     Senate Bill S4197

13.  Leib, P.,  1971, Junk Cars -  Mines of Valuable Metal:  Appalachia _5 (2),
     1-13
                                  -407-

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14.   Karr, R. K. ,  1972,  Vermont Shows the Way with Junk Vehicle Program.;
     Public Works  103 (5),  104-5

15.   National Institute of  Municipal Law Officers, 1967,  Model Ordinance on
     Abandoned, Wrecked,  Dismantled or Discarded Vehicles; Wash., B.C.,
     4 p.

16.   General Motors  Corporation, 1971,  How to Harvest Abandoned Cars;
     Detroit, 19 p.

17.   Chase,  P.,  1972,  Personal Communication;  Michigan Dept. of Corrections

18.   Gandee, J. , 1972, Personal Communication:  West Virginia Dept. of High-
     ways

19.   Steen, R. J.,  1972,  Try a Tilt-Bed Truck to Solve the Junk Car Problem;
     American City 87_ (3),  123-27

20.   Steen, R. J, ,  1972,  Personal Communication: Tennessee  Valley Authority,
     Knoxville,  Tennessee-

21.   Rothman, N. , 1972, Personal Communication: New York Dept. of Sani-
     tation

22.   Management Technology,  Inc., 1970. Automobile Scrapping Processes
     and Needs for Maryland;  U.S.  Public Health Serv.  Publ. No. 2027,  64 p.
                                  -408-

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           EROSION AND SEDIMENTATION CONTROL COSTS




                        TABLE OF CONTENTS




                                                               Page No.




Introduction                                                      411




Prevention and Control of Erosion and Sedimentation               412




Cost of Erosion and Sediment Control Structures                   414




References                                                       417




                           LIST OF TABLES




1.   Variables Affecting Erosion and Sediment Control Costs         415




2.   Summary of Sediment Collection Facility Construction Costs     416
                                 -409-

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           EROSION AND SEDIMENTATION CONTROL COSTS

Introduction

       Sediment is the greatest single pollutant of streams, lakes, ponds and
reservoirs.  Sediment lowers the quality of water for municipal and industrial
uses and for boating,  fishing, swimming, and other water based recreation; it
increases the wear on equipment,  such as turbines, pumps and sprinkler irri-
gation systems.  Sediment carries with it pesticides,  phosphates and other
chemical pollutants(1).

       Each year more than  a million acres of land in the United States are con-
verted from  agricultural use  to urban use.  Studies show that erosion on land
going into use for highways,  houses,  shopping centers and other commercial
or residential uses is about 10 times  greater than on land in cultivated row crops,
200 times greater than on land in pasture and 2, 000 times greater than on land
in timber.  The nationwide damage caused annually by sediment has been esti-
mated at more than $500 million.  Much sediment comes from agricultural land,
but the amount contributed by land undergoing urban development is high in pro-
portion to the acreage(l).

       Severe  sediment problems  occur when covering vegetation is removed
in construction areas,  when the flow regime in channels is altered by realign-
ment or  by increased  or decreased flow,  or when fill, buildings,  or bridges
obstruct the  natural flowway(^). Sediment movement  and deposition are  part
of the natural environment, but the average sediment  yield from the landscape
and the condition of stream channels tend to change with the advancing forms
of man's land-use activity. A major problem is  that the  scientist or engineer,
because  of his  relatively narrow field of investigation, cannot always completely
envision the  less desirable effects of his work and  communicate alternative sol-
utions to the  public(2).  Recent publications, Powell,  et  al. (3),  West Virginia
Department of Natural Resources^),  Pennsylvania Department of Environmental
Resources(5), and Soil Conservation Service^/ indicate  that governmental ag-
encies are becoming  very much concerned with damages  caused to the environ-
ment by  erosion and sedimentation.

       Urbanization tends to  increase  both the flood volume and the flood peak
as pointed out by Leopold(^) in his study summarizing existing knowledge of the
effects of urbanization on hydrologic factors.  Much of the erosion occurs during
the construction period,  but areas below a construction site may erode more
after construction is  completed because of the rapid runoff from impervious
pavement, parking lots,  or compacted soil.  Increased runoff erodes  stream
banks and channels and causes flooding below the construction site.

       Surface mining activities are responsible for serious erosion and sedi-
mentation problems in some areas because  of the highly erodable nature  of
spoil banks(^) and the  usual sparseness of vegetation as  compared to "undis-
turbed" areas(8).  In other areas,  timbering operations,  with attendant logging
and haul roads  and removal of a forest canopy which causes  increased runoff,
                                  -411-

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can be the most damaging environmental problem,  particularly downstream of
the operation.  The  major source of sedimentation pollution in some areas is
the "right-of-way" for a powerline, pipeline or other utility.

Prevention and Control of Erosion and Sedimentation

       As with most stream pollutants, sediment can best be prevented at the
source, i.e. , control erosion and runoff at or  near the area undergoing urbani-
zation, deforestation or surface mining.  Temporary or emergency "back-up"
precautions can be employed  using sedimentation and storage collection struc-
tures. The structures must be designed to insure there is  no danger of failure
which could cause downstream damage.  On large projects,  a comprehensive
survey must be performed to evaluate  geologic, hydrologic and engineering
design considerations. This  survey is necessary to insure that the structure
will provide adequate  sediment and storage capacity and be of safe design.

       Since urbanization and other land uses tend to increase flood volume
and the flood peak, provision for flood storage  upstream will decrease flood
peaks and sedimentation yield and compensate  for the increased flow caused
by land use.  Reservoir storage installed on a  river reduces the magnitude of
peak discharge by spreading the flow over a longer time period.  Channels
themselves provide  temporary storage and act as  if they were small reser-
voirs. Overbank flooding on  the flat flood plain is a way that natural rivers
provide temporary storage and thus decrease flood peaks downstream.

       Flood storage  for urban areas can take  many forms including the fol-
lowing(°):

1.  Drop inlet boxes at street gutter inlets.
2.  Street-side swales instead of paved gutters and curbs.
3.  Check dams, ungated, built in headwater swales.
4.  Storage volumes in basements of large buildings receiving  water from
    roofs or gutters and  emptying into natural streams  or swales.
5.  Off channel storage volumes such  as  artificial ponds,  fountains or tanks.
6.  Small reservoirs in stream channels such as  those  built for farm ponds.

       The following factors  determine the amount of erosion that occurs in
an area:

1.  Soil types
2.  Slope of the  terrain
3.  Rainfall intensity
4.  Infiltration capacity of the soils
5.  Amount and  kind of vegetation
6.  Construction methods
                                   -412-

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       Erosion and sedimentation can be controlled effectively, and at reason-
able cost,  if certain principles are followed in the use and treatment of land.

1.  Know the soil characteristics, geology, hydrology and topography of the
    area.  Information on soils can be found in the Soil Conservation Service
    (SCS) soil survey report of the area.  If there is no report, information
    may be available  in the  "open files" of the SCS District Office or the Agri-
    cultural Extension Service.  Soil surveys describe the characteristics and
    properties  of each kind  of  soil in the area - its  texture, slope, depth,
    erodibility, permeability,  degree of wetness, presence of impervious or
    porous layers  and other information useful in construction.  The soils
    information found in these  reports,  though very useful for an understanding
    of soils problems, is general in nature.  It does not replace the need for
    professional assistance in  the design of structures where failure would
    cause  loss  of life and property damage.

2.  Have a site development plan that includes provisions for control of run-
    off,  erosion and sedimentation and reclamation of areas disturbed  by the
    land use.

3.  Do not grade or strip more land than needed for immediate use.  In this
    way,  soil is left bare for the shortest period of time.  This calls for de-
    veloping large tracts in small workable units.   In the case of strip mining
    and timbering  operations,  reclamation of disturbed areas should be per-
    formed concurrently with development.

4.  In construction projects, keep grading at  a minimum and  remove only un-
    desirable trees wherever possible.  Protect critical areas with mulch or
    temporary  cover crops  and with mechanical methods such as diversions
    and prepared outlets.

5.  Reduce velocity and control the flow of runoff by detaining runoff on the
    site  to trap sediment by constructing sediment basins.  Consideration
    should be given to offsite measures  that may be needed  to prevent dam-
    age to downstream land and property by either erosion or sediment.

6.  During  construction use soils that are suitable to  the development.

7.  Establish permanent vegetation and  install erosion control structures as
    soon as possible.
                                  -413-

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Cost of Erosion and Sediment Control Structures

       Normally no two erosion or sediment control structures are alike.
Each facility has to be  individually designed to suit site conditions and to
satisfy hydrological requirements.  Therefore, no standard cost  estimate
per unit of watershed or other commonly accepted method of basing cost on
unit area  is practical without first considering site conditions and hydrologi-
cal requirements.  Some of the variables that affect construction costs for
these structures are presented in  Table  1.

       Most of the reported costs  for erosion and sediment control in Penn-
sylvania and West Virginia were for structures constructed in conjunction
with highway projects.  These structures are usually designed for a limited
life and require frequent dredging  or cleaning out to maintain operating
efficiency.  The unit cost estimates  reported by the highway departments are
presented in Table 2.   The design  of these structures conforms to design re-
quirements  given in publications by West Virginia Department of  Natural
Resources^), Soil Conservation Serviced) and Pennsylvania Department of
Forests and Waters(l°).

       On small projects,  the largest  cost may be mobilization of equipment.
It may, therefore,  be advantageous to  perform reclamation on a watershed
basis so as  to reduce individual mobilization costs and possibly the number
of structures required.
                                    -414-

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                               TABLE 1

  VARIABLES AFFECTING EROSION AND SEDIMENT CONTROL COSTS

I.   Type of Installation
     A.  Dams  - Embankment, rpckfill, concrete, log and pole/brush or
        other type of dam structure
     B.  Ponds -  Excavated, natural or embankment
     C,  Diversions  - Channel, ditch or other methods
     D.  Riprap for slope, shore or channel protection
     E.  Other  types of installations

2.   Size of Installation Required

3.   Hydrological Requirements - Design Flood

4.   Design Life of Installation

5.   Site Preparation
     A.  Access roads
     B.  Clearing and grubbing
     C.  Water diversion and dewatering
     D.  Other  site preparation requirements

6.   Availability and Haul Distances for Construction Materials

7.   Building Code Specifications, Inspection Fees, Performance Bond
     Requirements and Legal Requirements

8.   Post Construction Reclamation
                                  -415-

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                              TABLE 2

SUMMARY OF SEDIMENT COLLECTION FACILITY CONSTRUCTION COSTS

Structure  Type                                 Unit    Cost

       Excavated Dams or Ponds                C.Y.    $7 - $8
       Embankment Dams                      C.Y.    $4 - $6
       Stone Check Dams                       Ft.2    $10 - $30
       Log and Pole/Brush Dams               Dam    $150
       Riprap
           Dumped                            C.Y.    $5.50 -$6.75
           Placed                             C.Y.    $12 - $16
       Diversion Ditches (2' Deep x 6' Wide)     L.F.    $l-$2.75
       Sand Bags                              Bag     $2.50

Maintenance

       Sediment Dredging                      C.Y.    $5 - $7
       Hauling  ....  First Mile              C.Y.    $.55 -$.70
               ....  Each Additional  Mile     C.Y.    $.20-$. 25
                                 -416-

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                             REFERENCES

 1.  Soil Conservation Service, 1970, Controlling Erosion on Construction
     Sites:  Agriculture Information Bull.  347, 32 p.

 2.  Guy, Harold P. ,  1970, Sediment Problems in Urban Areas:  U.S. Geol.
     Survey Circ. 601-E,  8 p.

 3.  Powell, M.  D.,  Winter,  W. C.  and Bodwitch,  W. P., 1970, Community
     Action Guidebook for  Soil Erosion and Sediment Control:  Nat. Assoc.
     Counties Res. Foundation, Wash., D. C. ,  64 p.

 4.  West Virginia Department of Natural  Resources, 1972,  Drainage Handbook
     for Surface  Mining; Div.  Reclamation,  prepared by Div.  Planning and
     Development in cooperation with Soil  Conservation Service, 65 p.

 5.  Pennsylvania Department of Environmental Resources,  1972,  Implemen-
     tation Plan and Regulations Dealing With Erosion and Sedimentation Con-
     trol: Adopted by the Environmental Quality Board,  September 21, 1972,
     7 p.

 6.  Leopold, Luna B. ,  1968,  Hydrology for Urban Land Planning  - A Guidebook
     on the Hydrologic Effects of Urban Land Use:  U.S. Geol. Surv. Circ. 554,
     18 p.

 7.  Adams, L.  M. ,  Capp, J. P. and Eisentrout, E. , 1971, Reclamation of
     Acidic Coal -  Mine Spoil with Fly Ash:  U.  S.  Bur.  Mines Rept. Inv.  7504,
     29 p.

 8.  Bramble,  W.  C. and  Ashley, R.  H. ,  1955, Natural Revegetation of Spoil
     Banks in Central Pennsylvania:  Ecology _36.(3), p. 417-23.

 9.  Soil Conservation Service, 1969,  Engineering Standard - Debris Basin:
     Technical Guide No. 350, 11 p.

10.  Pennsylvania Department of Forest and Waters, 1968, Bridges. Walls,
     Fills, Channel Changes.  Etc.:  Water and Power Resources Board,
     Form FWWR-23, 23 p.
                                   -417-

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             INDUSTRIAL WASTES "ORPHAN" AND OTHER
        ENVIRONMENTAL PROBLEMS IN THE PUBLIC SECTOR

                        TABLE OF CONTENTS

                                                                Page No.

Introduction                                                       421

Types  of Solid Wastes                                             421

Cost Analysis and Methods of Disposal                             422

References                                                        425

                           LIST OF TABLES

1.  Ash Collection and Utilization in the United States -  1971         423
                                -419-

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             INDUSTRIAL WASTES "ORPHAN" AND  OTHER
        ENVIRONMENTAL PROBLEMS IN THE PUBLIC SECTOR

Introduction

       This section is concerned with accumulations  of solid wastes other than
municipal,  abandoned automobiles, and earth materials from the  coal mining
industry.  Further, the solid wastes  are abandoned and are now a public re-
sponsibility; they may be more a public nuisance than a source of air or water
pollution; and one can reasonably expect to find these wastes in the  Monongahela
River Basin. The solid waste accumulations are from manufacturing,  mining,
timbering,  transportation and other abandoned activities of man in the Monon-
gahela River Basin.

       Many of the wastes have littered the landscape and stream beds  for
a long  period of time, a hundred years or more, although, the volume of  solid
waste has increased  rapidly in the last 50 years.   The solid  wastes  fall  into
three main  categories of materials:

1.   Materials of metal manufacture which can be classified  as scrap metal.

2.   Wood product materials including timbering and manufacture.

3.   Soil and rock type materials including brick, coke breeze, fly ash,  slag
     and  other materials  resulting from production and manufacture.

Types  of Solid Wastes

       Other than coal mine refuse,  abandoned automobiles  and municipal
wastes,  there is very little information on the types,  characteristics and
quantities of abandoned industrial and other  solid wastes that can  be found in
the Monongahela River Basin.  The following list is based  on a knowledge of
the history  of industrial development within  the area and, for each industry or
activity the type or solid wastes that  can be  expected  are given.

1.   Coke Making Industry  - Coke breeze, beehive ovens,  abandoned buildings,
     track and other metal  equipment associated with  coke  manufacture.

2.   Coal Fired Power Plants  - Fly ash,  bottom ash,  boiler  slag,  abandoned
     buildings and metal plant  equipment.

3.   Coal Processing Plants and Other  Mining Equipment - Tipples,  hoists,
     engines,  pumps,  track, mine cars, scales, abandoned buildings and other
     wood and metal equipment.

4.   Railroad Industry - Abandoned track, ties, signalling  equipment, water
     towers, bridges  and other wood and metal equipment.

5.   Glass Industry - Slag,  cullet,  buildings  and equipment.
                                  -421-

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 6.   Pottery and Stoneware Manufacture - Broken crockery, refractories,
     platermolds,  abandoned buildings and equipment.

 7.   Brick Manufacture - Broken brick, molds,  ovens, plant and equipment.

 8.   Foundries - Stone furnaces,  refractories, waste products and metal
     working  equipment.

 9.   Chemical Industry - Plant wastes, abandoned buildings and equipment.

10.   Forest Products Industry - Slashings and bark from timbering operations,
     and sawdust,  sawmill slabs and scrap wood from  sawmill operations.

11.   Petroleum Industry -  Abandoned pumps, feeder lines,  pipe, derricks
     and other equipment from oil and gas production.  Wastes, trash, spent
     catalysts,  scrap lumber  and dense sludges from refinery operations.

12.   River Navigation  - Abandoned piers, wharfs, buildings, barges,  boats
   •  and other wood  and metal equipment.

13.   Metal Smelting  and Refining -  Slag, obsolete or abandoned plant and equip-
     ment,  residues  from  refining  iron, lead, zinc,  aluminum and other metals.

14.   Demolition Contractors - Refuse,  concrete, brick,  lumber and scrap
     metal usually in piles.

 Cost Analysis and Methods of Disposal

        An in depth survey has not been made on location and quantities of solid
 wastes discussed  in this section,  but it appears, that  for many of these wastes,
 the methods  of disposal and costs discussed in the section "Solid Wastes Hand-
 ling and Disposal  Costs" could be used for estimating  purposes.

        Most of the scrap metal would be iron and steel  and could have salvage
 value, the value depending on tonnage and size of pieces at a  specific location.
 Scrap metal  dealers may be willing to  salvage  this material if permission is
 granted by property owners.

          There is no information  on abandoned chemical wastes in the Monon-
 gahela River Basin.  It may be hazardous to disturb chemical wastes and each
 occurrance  of  this type material will have to be investigated prior to  disposal
 to prevent water pollution and handling problems.

        Fly ash, bottom ash and boiler slag does have limited  use and old dis-
 posal areas are being worked for construction materials and  other uses. Table
 1 based on a publication by Sikes  and Kolbeck^) tabulates ash collection and
 utilization in the United States in 1971.  The percent of  ash utilization has  risen
 from 12. 1 in 1966 to 20. 1 in  1971.
                                   -422-

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       Disposal of much of the solid waste can best be handled at the local
level.  A community action program designed to clean up the local  environ-
ment would remove many of these public nuisances.  If approached, scrap
dealers and property owners may be more than willing to cooperate in dis-
posing of solid wastes littering the landscape.  Clean up  programs  similar
to those initiated for removal of abandoned automobiles may be effective.
Most of the solid wastes are not sources of air and water pollution,  there-
fore, the part played by the Appalachian Regional Commission should be to
encourage  community  action programs.
                                  -424-

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                            REFERENCES

1.  Sikes, P. G. and Kilbeck,  H. J. ,  1972,  Disposal and Utilization of Power
    Plant Ash in a Metropolitan Environment:  Am.  Soc. Civil Eng. Ann. and
    Nat. Environ. Eng.  Meet., Oct.  16-22,  Meeting Preprint 1849,  30 p.

2.  Gibbs & Hill, 1972,  Preliminary Tabulation of Collected Data: prepared
    for Appalachian Regional Commission as part of study "Development of
    an Overall Economic /Environmental Plan for the Monongahela River
    Basin"
                                 -425-

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ADDENDUM
   -427-

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                              ADDENDUM





                         TABLE OF CONTENTS





                                                                 Page No.





Air Pollution Control and Wastewater Treatment                    431





Erosion and Sedimentation Control                                  433





Strip Mine and Refuse Bank Reclamation                            434





References                                                        436
                                  -429-

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                              ADDENDUM

Air Pollution Control and Wastewater Treatment

       Because of increasingly stringent SO2 emission regulations and a limited
reserve  of low cost,  low sulfur fuels,  a SOX removal process operated in an
efficient and economic  manner is urgently needed.  A new process designed to
control atmospheric  pollution in industries with the recovery of useful products
has been developed by Lin(l) in the laboratory.

       The new SO  removal system is described briefly as follows:
       The combustion gases from the  furnace  containing SC>2i SO^ and suspend-
ed solid particles are passed through a dust collector for removal of fly ash.
The flue gas containing SO  is then passed.through a catalytic oxidation converter
                          X
to oxidize SO2 into 803.  The flue gas then goes to a lime reactor where lime  is
purposely fed in excess  of the amount required  for complete  conversion of 803 to
CaSO4.  Since the flue gas  from the catalytic oxidation converter contains mois-
ture,  the following reactions take place:

       S03 (g) + H20 (g) 	^H2S04 (g)

       H2S04 (g) + CaO (s) 	^CaS04 (s) + H2O (g)

       803 is a very  reactive gas and may also combine directly with CaO to
form CaSO4:

       SO3 (g) + CaO (s)	5==CaSO4 (s)

       Dust particles in the gas discharged from  the lime reactor are  further
separated by a dust collector and the effluent will be substantially free  from dust
and SOX.  Nearly 100 percent SO3removal has been achieved in the laboratory.
The reacted lime particles are discharged from the lime reactor into a powder
processing  unit. After treatment,  a new product  is released from the  unit which
has been named "Linfans. "

       The important feature of this process is that the reactions in the lime
reactor are between gaseous and solid reactants, accompanied by a molecular
diffusion in the  solid reactant.  Since the reactant (CaO) added to the system is
in a solid form,  the rate  of application  needed may not be high and can  easily
be controlled.

       Laboratory investigation has shown the solid product,  Linfans,  contain-
ing anhydrous CaSO4 and unspent lime has the following uses:

1.  It can  be  combined with fly ash for production of construction materials.

2.  Used for  flooring plaster and hard  finish plaster.
                                  -431-

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3.  Used in wastewater treatment for acid neutralization and for phosphate
    and turbidity removal.

       A  series  of laboratory experiments were performed to compare Lin-
fans produced from different SOX removal systems with high calcium lime in
regard to sludge volume produced in neutralization of acid solutions.   The
tests were conducted on one percent (1%)  by volume sulfuric acid solutions.
In all cases,  Linfans produced the least sludge volume.  The  percentage of
sludge volume produced from neutralization was dependent on the percent of
unspent lime in  Linfans.  The percent of unspent lime should  be neither ex-
tremely high or low.

       The sludges from neutralization of acid solutions by high calcium lime
have poor compaction characteristics which are attributed to  the typical acic-
ular shape of the crystals that are formed.  By contrast, the  CaSC>4 crystals
from neutralization by unspent lime in Linfans are in rhombic form.  It is
believed the insoluble anhydrous CaSC^ in Linfans serves as nuclei for accel-
erated growth of CaSO^ particles.  This  results in higher  settling  velocities,
a considerable reduction in sludge volume and a shorter retention  time in a
sedimentation tank.  Therefore, it is indicated that sludge handling and dis-
posal problems  can be greatly minimized if Linfans is used.

       It  must be emphasized the information given in the publication by Lin(l)
indicates  a limited amount of laboratory  testing has been performed.  It appears
a great deal more laboratory testing will  have to be accomplished  before pilot
studies can be considered.

       Linfans possibly can be used in treatment  of wastewater from pickling
processes used  in basic steel making, metal working and plating.  It is not
known whether Linfans would be suitable for treatment of acid mine drainage.
The laboratory experiments were performed using strong  sulfuric acid solu-
tions (over 18, 000 mg/1 of H^SO,^) and there were no interfering metallic  ions.
This sulfate concentration exceeds that of most mine drainage discharges.
Calcium sulfate (CaSO4) is not normally  a precipitate in sludge from mine
drainage treatment because  sulfate ions are removed only when the solubility
product of calcium sulfate is reached (about ZOOO  mg/1 CaSO^).  It appears
Linfans would add additional hardness to the mine drainage effluent and cause
gypsum scale  on plant equipment and  possibly in the  effluent.   The possibility
of seeding high sulfate mine drainage to promote larger crystal growth and
therefore dense sludge should be investigated.

       Quicklime (CaO) does not react rapidly and efficiently with acids to
neutralize them.  It must first hydrate (convert to Ca(OH)2) before it reacts
readily and efficiently.  There are hazards connected with the use of quick-
lime.  It is a very caustic irritant to  human skin, eyes and mucuous mem-
branes.  A quantity of quicklime suddenly dumped into an influent can cause
a steam explosion.
                                  -432-

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Erosion and Sedimentation Control

        Two recent publications, one by Thronson(2) and the other by Becker
and Mills(3) contain a wealth of information on erosion and sedimentation con-
trol.

        Thronson comes to the conclusion the cost of effective erosion and sedi-
ment control is probably minimal and that the principal problem lies in achiev-
ing effective administrative control and enforcement by concerned agencies
involved in erosion and sediment control programs.  It is  extremely difficult
to obtain reliable information regarding the cost of temporary erosion and
sediment control used only during construction.  Normally the costs are hidden
in unit costs for excavation and compaction, pipe and other equipment.  It is
difficult to define the temporary and permanent portion of  a facility.  Tempor-
ary erosion and sediment control for highways  with average construction costs
of $1, 000,  000 per mile were estimated at $10,  000 to $15, 000 per mile.  The
cost for control in housing developments was given as $40  per lot by engineer-
ing and geologic consultants and $100 per lot by developers.

       A basin-wide task force, which includes representatives  from all con-
cerned  organizations within the basin,  probably has the best chance of develop-
ing and carrying out a successful control program.  Trained manpower can  be
made available by utilizing specific qualified personnel such as geologists,
hydrologists,  agronomists,  engineers, planners, lawyers  and managers from
the various participating groups within the task force.  The crucial  element of
a sedimentation control program is  the enforcement of adopted standards.

       The publication by Becker and Mills presents  a comprehensive  approach
to the problem of erosion and sediment control from beginning of project plan-
ning to completion of construction.  The  "Guidelines"  is designed and intended
for use by  both technical and lay personnel.  It provides:

1.  A description of how a preliminary site evaluation determines what poten-
    tial sediment and erosion control problems exist at a  site being considered
    for development.

2.  Guidance for the planning of an effective sediment and erosion control
    plan.

3.  Procedures for the  implementation of that  plan during operations.

       Technical information on 42  sediment and erosion control products,
practices,  and techniques is contained in four appendices.
                                  -433-

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Strip Mine and Refuse Bank Reclamation

       Heine and Nickeson(4) recommend the use of substantially increased
quantities of limestone in reclaiming old strip mines in alkalinity-poor water-
sheds.  The cost of limestone is essentially defrayed by limiting backfilling
to the degree necessary to improve surface runoff and  reduce erosion.

       Studies have shown there is less probability of success  in backfilling
and planting old strip mines than in reclamation of current active operations.
This is  principally due to the mixture of acid materials and tops oil in the spoil.
The  problem is further complicated  by the stony nature of old spoils.  Spoil
segregation and burial of acid materials are no longer  possible and there are
no concentrations of "soil type" material.   The stony material forming the  top
layer after reclamation  of an old strip mine will be of the same general chemi-
cal composition as the old surface and be as permeable (to both air and water)
as it was prior to grading.  Since there is  little soil type material in the top
layer, it is difficult to establish a dense ground cover.  Trees  are the only
vegetation that can be readily established and they do not rapidly form a soil
profile.  The surface of many reforested strip mines planted with trees  as
long as  30 years ago are almost as stony as the surface of a new unreclaimed
strip mine.

       Many old strip mines have developed excellent tree growths on some
portions of the disturbed areas while other  portions remain "hot" and devoid
of vegetation.  An important practical advantage to "limestone  reclamation"
is that areas with well established tree  growth can be left undisturbed except
for application of lime,  fertilizer and seed  to accelerate vegetation growth.

       In the Alder Run and Muddy Run watersheds, Clearfield County,  Penn-
sylvania,  Heine and Nickeson recommended the use of  quarry limestone (Class
2RC).  It is an aggregate of particle sizes  ranging from dust to 3/4 inch.  They
recommend an average layer of one  inch thickness be spread over the entire
strip mine (approximately 200 tons per acre).  In practice the limestone will
not be evenly distributed, but will be spread thicker in areas of thick spoil and
maximum recharge. The limestone is spread at the completion of grading  and
disked into the top layer of the  spoil.

       The presence of  this relatively fine  grained material will decrease  the
stoniness of the top layer, making it more acceptable for grass growth.  The
top layer will be alkaline for many years,  allowing grasses to become well
established and a soil profile to develop.

       The cost of quarry limestone (Class 2RC) was given as  $1. 15 per ton
by bulk,  $2.80 delivered, for the Alder Run and Muddy Run projects.

       The U. S. Bureau of Mines(^» °) has demonstrated the use of fly ash in
strip mine and refuse bank reclamation.  The addition  of large quantities of fly
ash  (150 to 800 tons per acre) will not only  dilute the surface materials and
                                   -434-

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neutralize acids,  but produce physical changes in the material that will en-
hance plant survival and growth.  The bulk density of the mixture is decreased,
thereby increasing pore volume,  moisture availability,  and air capacity, hence
improving conditions for root penetration and growth.

       Fly ash resembles soil  in certain physical and chemical properties and
it is mostly in the silt size range.  Beside often being alkaline, it contains plant
nutrients  and possesses moisture-retaining and soil conditioning  capabilities.
Analyses  indicate fly ash contains many trace elements  essential to plant growth.

       The use of fly ash in reclamation of strip mine and refuse banks  helps
solve the  fly ash disposal problem.  According to Sikes  and Kolbeckl') more
than 27, 000, 000 tons of fly ash were produced in 1971 by power plants and less
than 12 percent was utilized. Fly ash can be  obtained from power plants at no
cost in many areas.  The only costs attributed to using fly ash would be  hauling
the  fly ash from the power plant site to the reclamation  area and  those associ-
ated with  spreading and disking.
                                  -435-

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                            REFERENCES

1.  Lin, Ping-Wha,  1972, Air Pollution Control and Wastewater Treatment
    in One Unique Process:  ASCE Ann.  and Nat. Environ.  Eng. Meet. ,
    Oct. 16-22, Preprint 1786, 23 p.

2.  Thronson, R. E. ,  1972,  Control of Erosion and Sediment Deposition from
    Construction of Highways and Land Development:  U.S. Environmental
    Protection Agency,  Office of Water Programs, 50 p.

3.  Becker,  B. C.  and Mills, T. R. ,  1972, Guidelines for Erosion and Sedi-
    ment Control Planning and Implementation:  U.S. Environmental Protec-
    tion Agency, Office of Research and Monitoring, EPA-R2-72-015,  prepared
    by Hittman Assoc. , Inc.  for Maryland Department of Water Resources, 228 p.

4.  Heine, W. N. and Nickeson, T.  L. , 1971, Concept Paper  on the Proposed
    Use of Limestone in Strip Mine Reclamation:  p. 227-36 in Skelly and Loy,
    Muddy Run Mine Drainage Pollution Abatement Project, Operation Scarlift
    SL 155:  Rept.  to Pa. Dept. Environ. Resources,  239 p.

5.  Adams,  L. M. ,  Capp,  J. P.  and Gillmore, D. W. ,  1972,  Coal Mine Spoil
    and Refuse Bank Reclamation with Powerplant Fly Ash:  Third Mineral
    Waste  Utilization Symposium,  March 14-16,  Chicago, 7 p.

6.  Adams,  L. M. ,  Capp,  J. P.  and Eisentrout, E. ,  1971, Reclamation of
    Acidic Coal-Mine Spoil with Fly Ash: U.S. Bur. Mines Rept. Inv. 7504,
    29 p.

7.  Sikes,  P. G. and Kolbeck, H.  J. ,  1972,  Disposal and Utilization of Power
    Plant Ash in a  Metropolitan Environment:  ASCE Ann. and Nat.  Environ.
    Eng. Meet., Oct. 16-22, Preprint 1849,  30 p.
                                  -436-

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                                ACKNOWLEDGMENTS

  The purpose of this publication is to provide data •which will enable the
  Appalachian Regional Commission to estimate costs of pollution abatement
  in the Monongahela River Basin.  In order to perform this function, the
  Appalachian Regional Commission needed an effective, workable handbook on
  pollution control costs and factors effecting these costs.

  This study was performed by Michael Baker, Jr.,  Inc., for the Appalachian
  Regional Commission under ARC Contract No. 72-87/RPC-713 titled "Analysis
  of Pollution Control Costs."  Support came from the U.S. Environmental
  Protection Agency under Grant 1^010 HQC.

  The cooperation of many individuals in government and in private industry
  in supplying information used in the study is gratefully acknowledged.
  Special credit must be given to James F.  Boyer and Virginia E. Gleason of
  Bituminous Coal Research,  Inc.; Ronald D. Hill and Elmore C.  Grim of the
  U.S.  Environmental Protection Agency; Clifford H.  McConnell,  Fred S.  Oldham,
  Alexander E.  Molinski, Michael D.  Yaccino, Willis R. Devens,  Robert Buhrman
  and Donald Fowler of the Pennsylvania Department of Environmental Resources;
  Dr.  H.  B.  Charmbury and Dr.  Harold L. Lovell of Pennsylvania State University;
  Benjamin C.  Green of the West Virginia Department of Natural Resources;
  Malcolm 0.  Magnuson, Edward A.  Mihok and  Robert  J.  Evans of the U.S.  Bureau
  of Mines:  Dr.  Gerald L.  Barthauer and Jerry L. Lombardo of Consolidation
  Coal Co.,  Herbert E. Steinman of Jones £  Laughlin Steel Corp.; John C.  Draper
  of Duquesne Light Co.; John W.  Foreman of Gwin,  Dobson and Foreman, Inc.;
  Franklin H.  Mohney of Pennsylvania Coal Mining Association;  and Stephen
  McCann of Western Pennsylvania Coal Operators Association.

  The study was  performed by the Geotechnical Engineering Department and
  Bionomics Studies Group of Michael Baker, Jr., Inc.
4U.S. GOVERNMENT PRINTING OFFICE: 1974 546-317/32Z  1-3    14-37

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SELECTED WATER
RESOURCES ABSTRACTS
INPUT TRANSACTION FORM
                                            1, Report No.
                                                               w
                                                                S. Report Daw Feb. ,  197^
                                                                6.
                                                                8, Performing Organization

                                                              BAKER-ARK- 73-04
          Analysis of Pollution Control Costs
          Frank J.  Doyle, Harasiddhiprasad G. Bhatt,
  and John R.  Rapp
  Michael Baker, Jr. ,  Inc.
  4301 Dutch Ridge Road
  Beaver, Pennsylvania  15009

12. sp-y -w<,g organisation  Appalachian Regional Conwaitsion and U.S.
      -.._,' -i •<-   Environmental Protection Agency Report
                 Number EPA-6?0/2-7^-009, February
                                                                 1^010 HQC
                                                                72-87/RPC-713
                                                                   , ;.•„ df Report su
                                                                            Proteebion
                                                                                Agency
        In August,  1971,  the Environmental Protection Agency convened the Mononga-
hela Enforcement Conference in Pittsburgh, Pennsylvania.  At this meeting the
Appalachian Regional Commission was assigned the task of developing a comprehen-
sive environmental improvement program for the Monongahela River Basin.  The
study is one of several performed for the Commission as part of this assignment and
provides data which will enable it to estimate  costs  of pollution abatement in the
Monongahela River Basin.
        The report fulfills requirements for an effective, workable handbook on pol-
lution control costs and factors effecting these costs.  The information in the report
is based on the latest technological developments and cost analyses of recent reclama-
tion projects.
        Although the report  was developed for  the Monongahela River Basin study,
the cost estimates and supporting data should  prove useful for all of Appalachia and
other areas  with similar topography, mine drainage pollution problems and mining
history.
        *Coal mine drainage abatement and treatment, *Refuse bank and mine fires,
 *Mine subsidence control, *Abatement of pollution from sources other than coal
 mining, surface mines,  coal refuse banks, mine sealing,  mine drainage treatment,
 air pollution,  solid waste, erosion and sedimentation control, abandoned automobiles

        # Pollution control costs, *Monongahela River Basin (Pennsylvania,
 West Virginia and Maryland)
                        19, Security Class.
                          (Report)
                        .'0, Secunty Ct .>,
                                        21. No, of
                                       vii,p«6
                                        22. Price
Send To:

WATER RESOURCES SCIENTIFIC INFORMATION CENTER
U.S. DEPARTMENT OF THE INTERIOR
WASHINQTON, O.C. 20240
        Frank J. Doyle
                                             Michael Baker,  Jr. ,  Inc.

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