EPA/904-9-78-007
DRAFT
ENVIRONMENTAL IMPACT STATEMENT
United States Steel Corporation
Number 8 Blast Furnace
Fairfield, Alabama
UNITED STATES
ENVIRONMENTAL PROTECTION AGENCY
REGION IV
345 Courtland Street
Atlanta, Georgia 30308
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EPA 904/9-78-007
NPDES Application Number
AL0003646
DRAFT
ENVIRONMENTAL IMPACT STATEMENT
for
Proposed Issuance of a New Source National
Pollutant Discharge Elimination System Permit
to
United States Steel Corporation
Number 8 Blast Furnace
Fairfield, Alabama
prepared by
U.S. Environmental Protection Agency
Region IV
Atlanta, Georgia 30308
Approved:
cu.
May 12. 1978
egional Administrator Date
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Summary Sheet For Environmental
Impact Statement
Number Eight Blast Furnace
United States Steel Corporation
(X) Draft
( ) Final
U. S. Environmental Protection Agency, Region IV
345 Courtland Street N.E.
Atlanta, Georgia 30308
1. Type of Action: Administrative (X) Legislative ( )
2. Description of Action: The U. S. Steel Corporation is proposing to
modernize their facilities at the Fairfield, Alabama plant by addition
of the new (No. 8) blast furnace and auxiliaries. Accompanying this
action is the installation of a third Q-BOP (variant of the Basic Oxygen
Process) furnace, a 57-oven coke battery, 4 additional soaking pits, and
the idling of 4 old coke batteries.
These changes at the Fairfield plant will continue existing coking
capability and replace existing blast furnace operations at the U. S.
Steel Ensley plant. This will also restore the steel making capability
of the Ensley plant which was lost by shutting down its uncontrolled
open hearth furnaces. Moreover, successful operation of the new Fair-
field blast furnace will permit the phase-out of three Ensley blast
furnaces.
Blast Furnace No. 8 will be located immediately north of existing blast
furnace No. 7 at Fairfield operations. Fairfield Works is an integrated
steelmaking facility located within Opossum Valley and southwest of the
City of Fairfield, Alabama. Fairfield operations cover approximately
5,000 acres. The blast furnace complex area plan will occupy 13.15 acres.
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Blast furnace No. 8 will be characteristic of the larger capacity, higher
top pressure facilities being constructed by the industry during this
decade. The use of beneficiated fuels has increased output as well as
assisted control of the process from environmental considerations.
The three products of operation—molten iron, slag, and blast furnace
gas--are all of value and will be utilized.
Once in operation, the new blast furnace will require a different charge
than the older operating units. The new furnace will receive coke, iron
ore pellets, sinter and flux. The iron produced by this unit is estimated
to be approximately 1,825,000 tons per year, following break-in.
The existing capacity of the Fairfield-Ensley steel-producing complex is
3.5 million ingot tons per year. Implementation of the proposed action
would maintain this production capacity.
3. Summary of Environmental Impacts and Adverse Environmental Effects.
(A) Construction
The proposed new No. 8 blast furnace will be constructed on the Fairfield
complex immediately north of facilities for blast furnaces No. 5, 6 and 7
which run south to north. Construction impacts are limited to excavating
for foundations and earthmoving over approximately 13.15 acres prior to
fabrication of the blast furnace. Sedimentation and siltation, due to
construction runoff, have been controlled during heavy rains. These
impacts have been mitigated by using proper construction practices and
by directing all surface runoff through the U. S. Steel Corporation
final retention pond for removal of suspended particulates. With
construction limited to the existing facility, no impacts to wildlife
or vegetation will occur. No archeological or historical sites recorded
for the state of Alabama are located on the site of the proposed project.
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The new blast furnace will take a minimum of 29 months to construct with
a possible manpower peaking period around the twentieth month. Estimated
peaking daily manpower requirement will be approximately 1,200 men during
construction. The Birmingham SMSA will provide the major percentage of
this work force except for certain specialty subcontractors.
(B) Operation
Operation of the proposed No. 8 blast furnace at the Fairfield Works will
increase discharges approximately 1 MGD to Valley Creek through Opossum
Creek. The proposed action will result in increases of 1.3 Ib per day of
cyanide, 2.77 Ib per day of phenols, 52 Ib per day of ammonia and 52 Ib
per day of total suspended solids loadings to Valley Creek.
Following the break-in period for the new blast furnace, the three remaining
blast furnaces at the Ens ley Works will be shut down. The proposed action
will significantly reduce U. S. Steel Corporation discharges of 13.0 Ib per
day of cyanides, 1.8 Ib per day of phenols, 103 Ib per day of NH--N and
1668 Ib per day of total suspended solids to Village Creek. A reduction
of pollutants from improved municipal treatment facilities, together with
reduced loadings from the U. S. Steel facilities, may result in some
improvement to the backwaters of Bayview Lake.
Overall impacts on water quality will be a net reduction of 8.9 MGD of
waste water, 1616 Ib per day of total suspended solids, 51 Ib per day of
NHL-N, 11.7 Ib per day of cyanides and a net increase of 0.97 Ib per day
O
of phenols, discharged to the tributaries of Bankhead Reservoir.
Air emissions from the U. S. Steel Complex will improve over pre 1977
operations. The modernization program which includes the new No. 8
blast furnace is the result of a plan to phase out antiquated equipment
having high emission rates. The modern replacement facilities will utilize
the latest production technology and improved abatement technology which
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is expected to result in a decrease of emission rates when considering
the entire U. S. Steel Complex in the Birmingham area. Even though
there will be a reduction in emissions, modeling indicates the air
quality standards for particulates will be violated. However, there
are inadequacies in the computer model employed as a predictive tool in
the air quality investigation. These inadequacies preclude complete
acceptance of the modeling results as far as the magnitudes of the
predicted concentrations are concerned. An improvement in air quality
from the standpoint of total suspended particulates, will result due to
the substantially reduced emissions accompanying the modernization
program.
Impacts to the biology of the receiving stream are difficult to ascertain
since only pollution tolerant organisms have been observed in Opossum
Creek and the upper reaches of Valley Creek near the confluence of
Opossum Creek. The increased discharges from No. 8 blast furnace to
Valley Creek, via Opossum Creek, may extend the area of impact further
downstream toward Bankhead Reservoir.
The termination of wastewater discharge from the three remaining blast
furnaces at Ensley will contribute to long term biological recovery of
Village Creek.
The extractive industry and its attendant activities comprise the major
foundation of the economy of Birmingham and Jefferson County, Alabama.
Projections of future growth for the Birmingham area by local planners
rely heavily on assuming continuing growth of the iron and steel industry.
A reduction of 22 employees will occur when the three Ensley blast furnaces
are shut down. Additional employment may be generated by other U. S.
Steel facilities at the Fairfield Works because of the increased availability
of iron at higher production rates from the No. 8 blast furnace and the
additional employment required to process this iron into final products
for shipment.
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4. Alternatives to the Proposed Action:
A. Build or no build
B. Capacity alternatives
i
C. Site location alternatives
D. Wastewater treatment alternatives
E. Air emission abatement alternatives
5. Federal, State and Local Agencies and Interested Groups Requested
to Comment
Federal Agencies
Bureau of Outdoor Recreation
U. S. Coast Guard
Corps of Engineers
Department of Commerce
Department of Energy
Department of Health, Education and Welfare
Department of Interior
Department of Transportation
Department of Housing and Urban Development
Economic Development Administration
Federal Highway Administration
Fisheries and Wildlife Service
Food and Drug Administration
Forest Service
Geological Survey
National Park Service
Office of Federal Activities
Soil Conservation Service
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Members of Congress
Honorable John J. Sparkman, United States Senate
Honorable James B. Allen, United States Senate
Honorable John H. Buchanan, United States House of Representatives
Honorable Walter W. Flowers, United States House of Representatives
State
Alabama Air Pollution Control Commission
Alabama Department of Conservation
Alabama Forestry Commission
Alabama Water Improvement Commission
Bureau of Environmental Health
Honorable George Wallace, Governor of Alabama
Robert L. Ellis, Jr., Alabama State Senate
Hugh Boles, Alabama State Representative
Alabama Development Office, State Clearing House, Office of
State Planning
Local
Honorable Johnny T. Nichols, Mayor of Fairfield
Neal P. Ellis, Fairfield City Council President
Hoyt Trammel 1
Interested Groups
Alabama Wildlife Federation
National Audubon Society
Alabama Bass Chapter Federation
Sierra Club
Alabama Environmental Council
Alabama Ornithological Society
Alabama Federation of Women's Clubs
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6. This draft EIS was made available to the Office of Federal
Activities (OFA) and the public on May 12. 1978
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TABLE OF CONTENTS
Section No.
CHAPTER 1
1.1
1.2
CHAPTER 2
2.1
2.2
2.3
CHAPTER 3
3.1
3.1.1
3.1
3.1
3.1
3.1
3.1
3.1
3.1
3.1
3.1
3.1
3.1
3.1
3.1
3.2
.2
.3
.4
.5
.6
.7
.8
.9
.10
.11
,12
,13
,14
3.2.1
3.2.2
3.2.3
3.2.4
Title Page No.
REPORT ORGANIZATION
Table of Contents i
List of Figures iv
List of Tables viii
BACKGROUND
Project Development 1-1
NEPA Overview 1-2
INTRODUCTION
Historical and Geographical Back-
ground of Existing Facilities 2-1
Chronology of the Proposed Action 2-3
Existing Facilities and Summary
of the New Source Features 2-3
ENVIRONMENT WITHOUT THE PROPOSED ACTION
Existing Environment 3-1
Existing Facilities at Fairfield
Works 3-1
Proposed Replacement Facilities 3-22
Operation Changes 3-42
Meteorology and Climatology 3-45
Topography and Geography 3-48
Geology 3-56
Soils 3-66
Hydrology 3-66
Water Quality 3-77
Biology 3-105
Land Use 3-119
Socio-Economic Conditions 3-133
Cultural 3-140
Environmentally Sensitive Areas 3-141
Future Environment Without the Proposed
Action 3-143
Ambient Air Quality 3-143
Water Quality 3-158
Biology 3-159
Socio-Economic Conditions 3-164
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Section No.
Title
Page No.
CHAPTER 4
4.1
4.1.1
4.2
4.2.1
4.2.2
4.2.3
4.2.4
4.3
4.3.1
4.3.2
4.3.3
4.3.4
4.3.5
4.3.6
4.3.7
4.3.8
4.3.9
4.3.10
4.3.11
CHAPTER 5
5.1
5.1.1
5.1.2
5.2
5.2.1
5.3
5.3.1
5.4
5.4.1
CHAPTER 6
6.1
6.2
6.3
6-4
DETAILED DESCRIPTION OF THE PROPOSED
PROJECT
Physical Facilities
Construction
Operation
Resultant Changes
Process Description
Design Summary
Operational Parameters
Waste Generation
Gas Cleaning
Casthouse Emissions
Cooling
Slippages of Service Requirements
Material Handling
Boilers
Blast Furnace Gas Emission Summary
Wastewater Treatment System Summary
Furnace Cooling System Summary
Water Discharges
Solid Waste Management and Disposal
IMPACTS OF THE PROPOSED ACTION
with the Proposed
Suspended Parti-
Air Quality
Future Conditions
Action -- Total
culates (TSP)
Future Conditions with the Proposed
Action -- Other Pollutants
Socio-Economic Considerations
Future Conditions with the Proposed
Action
Water Quality
Future Conditions with the Proposed
Action
Biology
Future Conditions with the Proposed
Action
DISCUSSION OF ALTERNATIVES
Build or No-Build
Capacity Alternatives
Process Alternatives
Site Location
4-1
4-1
4-6
4-6
4-11
4-15
4-17
4-17
4-17
4-21
4-21
4-23
4-23
4-27
4-27
4-29
4-30
4-31
4-31
5-1
5-1
5-5
5-5
5-5
5-9
5-9
5-10
5-10
6-1
6-2
6-5
6-5
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TABLE OF CONTENTS (Cont'd)
Section No. Title
CHAPTER 6 (Cont'd)
6.4.
6.4.
6.5
6.6
6.6.
1
6.6.2
6.6.3
CHAPTER 7
7.1
7.2
7.2.1
7.2.2
Criteria For the Site Selection
Determination
Wastewater Treatment
Air Emission Control Alternatives
Coke Battery
Emission Control Alternatives for the
New Blast Furnace
Alternative Emission Control for the
Q-BOP Furnace
MITIGATIVE MEASURES
Construction Impacts
Operational Impacts
Air Quality
Water Quality
Page No.
6-5
6-9
6-9
6-14
6-14
6-18
6-19
7-1
7-1
7-1
7-3
i i i
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Figure No.
CHAPTER 2
2-1
2-2
2-3
2-4
CHAPTER 3
3-1
3-2
3-3
3-4
3-5
3-6
3-7
3-8
3-9
3-10
3-11
3-12
3-13
3-14
3-15
3-16
3-17
3-18
3-19
3-20
3-21
3-22
3-23
3-24
3-25
LIST OF FIGURES
Title
INTRODUCTION
United States Steel Operation in the
Birmingham Area
Fairfield Works - Birmingham, Alabama
Primary Steelmaking Processes
Fairfield Works Steel Finishing Process
ENVIRONMENT WITHOUT THE PROPOSED ACTION
Page No.
2-4
2-5
2-7
2-10
Flow Diagrams Showing the Principal Process
Steps Involved in Converting Raw Materials
Into the Major Product Forms (Excluding
Coated Products) at Fairfield Works 3-4
Emission Levels, Pre-1972 Levels and
Subsequent to Completion of the Modernization
Program 3-15
Overall Effluent Treatment System for Fairfield
Operations 3-16
Flow Sheet Showing the Major Steps Involved
in the Preheating and Carbonization of Coal 3-27
Coal Pre-heating Schematic for Coke Battery
No. 2 3-30
Coke Battery Plus Pre-Heat Schematic 3-33
Photograph of an Existing Q-BOP 3-39
Final Three Q-BOP Gas Cleaning System at Fairfield 3-43
Map of Warrior River 3-50
USGS Topographic Map Small-Scale Coverage of
Jefferson County 3-52
Slope Map 3-53
Physiographic Provinces of Alabama 3-58
Major Structural Features in Northwestern
Alabama 3-60
Areal Geology 3-62
Boring Plan 3-63
Boring Profile 3-65
Generalized Geological Cross Section of
Fairfield Area 3-67
Monthly Mean Hydrograph for Gauging Station
on Turkey Creek 3-70
Flow Duration Curve for Turkey Creek 3-72
Map of Flood Prone Area for the 100-Year Flood 3-76
Groundwater Availability 3-78
Point Source Discharge Schematic 3-81
Public Sewer Service Areas 3-82
Existing Land Use 3-85
Ultimate Carbonaceous Oxygen Demand - Opossum
and Valley Creeks - Fall Survey 3-89
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Figure No.
CHAPTER 3 (Cont'd)
LIST OF FIGURES (Cont'd)
Title
Page No.
3-26
3-27
3-28
3-29
3-30
3-31
3-32
3-33
3-34
3-35
3-36
3-37
3-38
3-39
3-40
3-41
3-42
3-43
3-44
3-45
3-46
3-47
3-48
Nitrogeneous Oxygen Demand - Opossum and
Valley Creeks - Fall Survey 3-90
Dissolved Oxygen by Winkler Method and D.O.
Probe - Opossum and Valley Creeks - Fall Survey 3-91
Opossum Creek Watershead 3-95
Storm Events and Magnitudes - March, 1977
Preceeding March 28 Storm 3-96
Stormwater Hyetograph - Hydrograph Opossum
Creek Monitoring Station RM 2.77
March 28, 1977 3-97
Weight Rates - Heavy Metals - During March 28,
1977 Storm - Opossum Creek RM 2.77 3-100
Weght Rates of Production of Water Quality
Parameters March 28, 1977 Storm at Opossum
Creek RM 2.77 3-101
Concentrations and Weight Rates of CBOD and
NOD Measured during the March 28, 1977 Storm -
Opossum Creek RM 2.77 3-102
Location of Biological Sampling Stations in the
Study Area 3-108
Land Accessibility Map 3-121
Land Suitability Plan 3-123
Large Landholders 3-125
Residential Land Suitability 3-126
Agricultural Land Suitability 3-128
Extractive Land Suitability 3-129
Open Space Land Suitability 3-130
Industrial And/Or Commercial Land Suitability 3-132
Existing Types of Vegative Cover 3-142
Percent Reduction of USSC Contribution to
Ambient Particulate Concentrations for
Condition 2 3-148
Percent Reduction of USSC Contribution
to Ambient Particulate Concentrations
for Condition 3 3-149
Percent Reduction of USSC Contribution
to Ambient Particulate Concentrations
for Condition 4 3-150
Percent Reduction of USSC Contribution
to Ambient Particulate Concentrations
for Condition 5 3-151
USSC Contribution to Ambient Expected
Arithmetic Mean of Particulates for
Condition 1 3-152
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LIST OF FIGURES (Cont'd)
Figure No.
Chapter 3
3-49
3-50
3-51
3-52
CHAPTER 4
4-1
4-2
4-3
4-4
4-5
4-6
4-7
4-8
4-9
4-10
CHAPTER 5
5-1
5-2
5-3
5-4
5-5
Title P
(Cont'd)
USSC Contribution to Ambient Expected
Arithmetic Mean of Particulates for
Condition 2
USSC Contribution to Ambient Expected
Arithmetic Mean of Particulates for
Condition 3
USSC Contribution to Ambient Expected
Arithmetic Mean of Particulates for
Condition 4
USSC Contribution to Ambient Expected
Arithmetic Mean of Particulates for
Condition 5
DETAILED DESCRIPTION OF THE PROPOSED PROJECT
Blast Furnace No. 8 - Plan of Area South
of Match Line
Blast Furnace No. 8 - Plan of Area North
of Match Line
Energy Balance - Before No. 8 Blast Furnace
Energy Balance - After No. 8 Blast Furnace
Twin Hopper System of Charging for Blast
Furnace No. 8
Water Treatment Flow Diagram for No. 8 Blast
Furnace
Gas Cleaning System for Blast Furnace No. 8
Blast Furnace 8 - Flow Diagram
Schematic Depiction of Materials Handling
for Blast Furnace No. 8
Location of U. S. Steel Facilities - Land
Fill Sites
IMPACTS OF THE PROPOSED ACTION
Percent Reduction of USSC Contribution to
Ambient Particulate Concentrations for
Condition 5
USSC Contribution to Ambient Expected
Arithmetic Mean of Particulates for
Condition 1
USSC Contribution to Ambient Expected
Arithmetic Mean of Particulates for
Condition 5
S02 and Particulate Emissions - 1973
S02 and Particulate Emissions - 1978 (Projected)
'age No.
3-153
3-154
3-155
3-156
4-3
4-4
4-9
4-10
4-13
4-20
4-24
4-25
4-28
4-32
5-2
5-3
5-4
5-6
5-7
VI
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Figure No. Title Page No.
CHAPTER 6 DISCUSSION OF ALTERNATIVES
6-1 Southeastern City Market Areas 6-6
vn
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Table No.
CHAPTER 3
3-1
3-2
3-3
3-4
3-5
3-6
3-7
3-8
3-9
3-10
3-11
3-12
3-13
3-14
3-15
3-16
3-17
3-18
3-19
3-20
3-21
3-22
3-23
3-24
3-25
3-26
3-27
LIST OF TABLES
Title
ENVIRONMENT WITHOUT THE PROPOSED ACTION
Page No.
Existing Coke Batteries Rehabilitation and
Emission Control Plan 3-12
Summary of EPA Case Study of U. S. Steel New
Source Review Analysis - Particulate Emissions 3-14
Summary of Wastewater Treatment Facilities 3-17
Discharges From Ensley Works and Effluent
Limitations 3-20
Ensley and Wenonah Actual Mean for NPDES
Effluent Limitations 3-21
Fairfield Actual Mean and Effluent Limitations
as Measured at Opossum Creek Monitoring
Stations Outfalls 010-027 3-23
Pollution Control Residues Fairfield District
Works U. S. Steel Corporation 3-24
Slope Constraint Areas 3-54
Slope Coverage, Jefferson County, Alabama 3-55
Streamflow Data Available for Streams in
Jefferson County 3-69
Average 14-Day Low Flows 3-73
Summary For Various Times of Recursion For Each
Stream 14-Day Low Flow Condition 3-74
Storm of March 19, 1970 3-75
Water Usage (1970) - Jefferson County and
the State of Alabama 3-79
Public Sewer Coverage, Jefferson County,
Alabama 3-83
Chemical Analyses of Water from Selected
Wells and Springs in Jefferson County 3-93
Measures Water Quality Parameters - Opossum
Creek RM 2.77 - March 28, 1977 Storm Event 3-98
Weight Rates for Selected Water Quality
Parameters - Opossum Creek RM 2.77 -
March 28, 1977 3-103
CBODU and NOD - March 28, 1977 Storm 3-104
Description of Sampling Stations 3-106
Species Collected at Each Location 3-110
Results of Heavy Metal Analysis on White Fish
and Excised Liver and Muscle 3-111
Comparison of Heavy Metals Analysis of Fish
Tissue - Second Survey 3-112
Summary of Baseline Macroinvertebrate Taxa 3-114
Summary of Baseline Periphyton Data 3-115
Zooplankton Composition - Bankhead Reservoir 3-116
Mining and Agricultural Employment Trends 3-135
vm
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LIST OF TABLES (Cont'd)
Table No. Title Page No.
3-28 Manufacturing Employment Trends 3-136
3-29 Government Employment Trends 3-138
3-30 Service Employment Trends 3-139
3-31 Expected Arithmetic Mean of Particulates 3-145
3-32 Impact Analysis - BRPC Steel Simulation 1980
(Total Output Reduction) 3-166
3-33 Impact Analysis - BRPC Steel Simulation 1970
(Total Employment Reduction) 3-169
CHAPTER 4 DETAILED DESCRIPTION OF THE PROPOSED PROJECT
4-1 Anticipated Raw Material Demand Changes with
Blast Furnace No. 8 4-7
4-2 Additional Industrial Water Requirements - No. 8
Blast Furnace - Fairfield Works 4-8
CHAPTER 6 DISCUSSION OF ALTERNATIVES
6-1 Alternatives for Producing Steel - Fairfield
Works 6-3
6-2 BPTCA Effluent Limitations - Blast Furnace (Fe)
Subcategory 6-11
6-3 BATEA Effluent Limitations - Blast Furnace (Fe)
Subcategory 6-12
IX
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1. BACKGROUND
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CHAPTER 1
BACKGROUND
1.1. PROJECT DEVELOPMENT
The United States Steel Corporation plans to sustain
its iron and steelmaking capacity at Fairfield, Alabama by replacement
of certain facilities. Discussions between U. S. Steel Corporation
(USSC) and Region IV of the Environmental Protection Agency (EPA)
confirmed that an environmental impact statement would be necessary
with regard to the proposed activities. EPA determined (see Appendix
A) that the new blast furnace would be considered a new source under
the National Pollutant Discharge Elimination System (NPDES) Program,
and thus be subject to all provisions of the National Environmental
Policy Act of 1969 (83 Stat 852). Additionally, EPA determined that
all three new facilities—the third Q-BOP furnace, new coke oven, and
blast furnace—would be considered new sources under Section 110 of
the Clean Air Act.
Subsequently, EPA and USSC selected Associated Water and
Air Resources Engineers, Inc. (AWARE, Inc.) under a third party agreement
to prepare an environmental impact statement under the direction of the
Environmental Protection Agency. This document describes the existing,
replacement, and new facilities located at Fairfield Works and the
environmental impact of the blast furnace on the environmental baseline.
In the data acquisition, analysis, and evaluation
phases of the development of this impact statement, a large amount
of information was generated. Practical considerations preclude the
inclusion of all the information in this document. Consequently,
that information judged to be most pertinent and illustrative has been
included in this document and a Technical Support Document (TSD) has
been prepared. The TSD and its appendices contain all of the informa-
tion generated and thus complement and support the evaluations
presented herein.
1-1
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1.2. NEPA OVERVIEW
The authority for the preparation of an EIS as a
result of issuance of a new source NPDES permit was summarized in
the Federal Register on Tuesday, January 11, 1977, Part V, as
follows:
The National Environmental Policy Act
of 1969 (NEPA), 42 USC 4321 et seq implemented
by Executive Order 11514 of March 5, 1970 and
the Council on Environmental Quality's (CEQ's)
Guidelines of August 1, 1973, require that all
agencies of the Federal Government prepare
detailed environmental statements on proposals
for legislation and other major Federal actions
significantly affecting the quality of the
human environment. The object of NEPA is to
build into the Agency decision-making process
an appropriate and careful consideration of all
environmental aspects of proposed actions,
explain potential environmental affects of
proposed actions and their alternatives for
public understanding, avoid or minimize adverse
effects of proposed actions, and restore or
enhance environmental quality as much as possible.
Section 511(c)(l) of the Federal Water
Pollution Control Act as amended (FWPCA) (Pub L
92-500) authorizes the Administrator to apply
NEPA to the issuance of a permit under section
402 of the FWPCA for the discharge of any
pollutant by a new source as defined in section
308 of the FWPCA. The discharge of a pollutant
as defined in section 502(12) of the FWPCA means
an addition of any pollutant to navigable waters,
the contiguous zone or the ocean from any point
source. The Environmental Protection Agency
published proposed regulations in the Federal
Register (40 FR 47714) on October 9, 1975,
entitled "New Source NPDES Permits, Preparation
of Environmental Impact Statements."
1-2
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2. INTRODUCTION
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CHAPTER 2
INTRODUCTION
2.1. HISTORICAL AND GEOGRAPHICAL BACKGROUND OF EXISTING
FACILITIES
The steel industry originally located in the Birmingham
area due to both a diversity and an abundance of the raw materials
necessary for the making of iron and steel. These materials could be
found within a radius of eight miles of the Fairfield Works site in
Opossum Valley. The required minerals include:
1. Abundant deposits of red hematite iron ore (mining
was discontinued in 1962).
2. Coal from the Warrior coal fields located to the
immediate northwest. These deposits contain
coking grade coal necessary for iron making.
3. Abundant dolomite deposits, known as fluxstone,
a carbonate rock having a high lime content and
being well suited for steel refinement, also
located in Jones and Opossum Valleys.
The proximity of these mineral outcroppings attracted
many business entrepreneurs to the Birmingham region in the latter
part of the 19th century. Many small coal and iron ore mining and
coke and iron production facilities sprang up, died, or merged into
larger concerns. Colonel Enoch Ensley amalgamated several of these
large holdings into a single company in 1886. This he named the
Pratt Coal and Iron Company. It was this company which was the fore-
runner of the present-day U. S. Steel facilities located in the
Birmingham area.
The Pratt Coal and Iron Company later became part of
the Tennessee Coal, Iron and Railroad Company. The financial panic
of 1907 put this company into distress. At the urgings of then
President Theodore Roosevelt and various concerned business interests,
2-1
-------
U. S. Steel Corporation was persuaded to buy the struggling company
on November 1, 1907. From this point on, the company was to be a
vital economic factor in the further industrialization and growth of
the South.
The company has continued its steady growth since
this period, adding and replacing facilities until today it is the
South's major steel producer and only fully integrated steel complex.
In 1972, Fairfield Works' open hearth facilities
consisted of twelve 225-ton furnaces located at Fairfield, and five
145-ton furnaces located at Ensley. The Fairfield operations were
rated at 2.7 million net tons per year and the Ensley operations had
a rated capacity of 0.8 million net tons per year. During the first
six months of 1971, the two facilities' combined production was at
an annual rate of 3.5 million ingot tons.
Several years before air emission standards were
promulgated in Alabama, U. S. Steel was engaged in investigations to
replace open hearth steelmaking facilities at Fairfield Works with
basic oxygen furnaces as a means to achieve compliance with anticipated
standards.
About this time, U. S. Steel was investigating a
variant of the basic oxygen process (BOP), which became known as Q-BOP.
Research demonstrated that the grades of steel produced by Q-BOP would
cover the range of Fairfield product mix, including such items as
rails, axles, plates, and sheet and tin products. Also, the Q-BOP
product was comparable in quality to that produced in the conventional
basic oxygen process and open hearths. It was also demonstrated that,
compared to the BOP, the Q-BOP process had a potential for improved
yields and improved heat time. When it was clear the Q-BOP process
was an improved steelmaking technology, it was decided to install
large scale Q-BOP steelmaking equipment in the No. 1 open hearth shop.
Major facilities consisted of two 200-ton furnaces with auxiliaries,
including gas-cleaning equipment. Construction began in July, 1972.
2-2
-------
With the construction of the Q-BOP at Fairfield, the
elimination of air emissions and problems of obsolescence associated
with the open hearth furnaces at Ensley became matters of serious
concern for U. S. Steel. Studies were undertaken with the intent of
finding a method of meeting pollution control requirements. In
October, 1974 a plan was finalized which would idle both blast
furnace and uncontrolled open hearth operations at Ensley. This
proposal included a third Q-BOP, teeming facilities, new soaking pits,
a new coke battery, and a new blast furnace at Fairfield, maintaining
the production capability of Fairfield Works at 3.5 million net tons
per year.
2.2. CHRONOLOGY OF THE PROPOSED ACTION
The start-up of No. 8 blast furnace is expected to be
July 1, 1978, and the break-in period will be approximately 12
months with a maximum of 18 months. One Ensley blast furnace is
scheduled to come off January 1, 1979, and all three are scheduled
to be off by July 1, 1979. A detailed presentation of the chronology
of the proposed action, including an itemized listing of all replace-
ments and expansions of facilities from the inception of Ensley
operations in the 1880's, is presented in the Technical Support
Document (TSD).
2.3. EXISTING FACILITIES AND SUMMARY OF THE NEW SOURCE FEATURES
Existing Facilities. Fairfield Works, which includes
operations at Ensley, Fairfield, and Wenonah, Alabama is the largest
and most diversified steelmaking plant in the South. It converts raw
materials (iron ore, coal, and limestone) into a broad range of
finished and semi-finished steel products designed to serve the growing
southern markets. An overall view of U. S. Steel facilities in the
Birmingham area is shown in Figures 2-1 and 2-2.
2-3
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BIRMINGHAM AREA
Ipland l.ak
BIRMINGHAM
FIG. 2-1 UNITED STATES STEEL OPERATION IN THE BIRMINGHAM AREA
2-4
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PAGE NOT
AVAILABLE
DIGITALLY
-------
Continuing modernization and expansion programs have
enabled Fairfield Works to keep pace with the steel needs of the growing
southern economy. The primary iron and steelmaking process is presented
in Figure 2-3, as it occurs at Fairfield. Among products produced at
Fairfield Works are tin plate and a variety of steel sheets for use in
consumer products such as beverage and food containers, appliances and
pre-engineered steel buildings, in addition to steel plates and structural
shapes for railroad cars and construction applications, rails, and rail
accessories.
Iron ore is prepared for use in the blast furnaces at
the ore conditioning plant at Wenonah. The larger size ore is used in
the blast furnace and the small size, called "fines", is processed into
a material suitable for use in the blast furnace. The iron ore "fines"
and other iron-bearing material recovered from various operations at
Fairfield Works are mixed with coke and limestone and placed on a
traveling grate called a sinter machine. The grate containing the
"material blend" moves under an ignition furnace (operated at 2,500°F),
igniting the coke in the mixture. The heat generated by the burning
coke fuses the material into a clinker-like mass, called sinter. The
sinter is shipped to the blast furnace.
Iron is extracted from the ore in the blast furnace.
The furnace is charged (filled) at the top with measured quantities
of iron ore, sinter, or iron-bearing pellets, along with dolomite and
coke. Inside the blast furnace, which operates continuously, chemical
reactions take place at very high temperatures to produce the molten
iron. As the raw materials move downward through the furnace, they
react with the hot gases moving upward. Iron is reduced from the iron
ore through the combustion of the coke. Air is heated in hot blast
stoves (dome-topped cylinders located nearby) to an extremely high
temperature. The hot air traveling through the stoves is forced into
the blast furnace to aid combustion of the coke.
2-6
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OUTSIDE
SOURCES
no
i
CRUSHING
SCREENING
SINTERING
OUTSIDE
SOURCES
>FIG. 2-3. PRIMARY STEELMAKING PROCESSES
-------
As the chemical reactions continue inside the furnace,
impurities in the iron ore combine with the dolomite to form slag.
Slag and molten iron are drawn off every few hours. Iron is transported
in special insulated ladle cars to the steelmaking furnaces.
Gases produced during the process are collected from the
top of the furnace, cleaned, and used to heat the air in the hot blast
stoves. Blast furnace gas is also burned in the boilers to generate
electrical power for other parts of Fairfield Works.
Steel is produced in Q-BOP furnaces. The Q-BOP furnaces
are the first of their type in the Western Hemisphere to be built in
an existing open hearth steelmaking shop.
In the steelmaking process, molten iron from the blast
furnace and recycled scrap steel are charged (fed) into the Q-BOP
furnace. These materials are melted and refined by introducing oxygen
and flux, which are injected through openings in the bottom. Using
the most sophisticated instrumentation available, the furnace can produce
a wide range of carbon and alloy steels to satisfy customer requirements.
Particulate matter generated during the steelmaking
process is evacuated through a vacuum hood which covers the top of the
furnace. The particle-laden gases are quenched and scrubbed with water,
and the remaining carbon monoxide gas is converted into carbon dioxide
at the top of the flare stack located outside the building. Water used
to quench and scrub the gases is processed in a treatment facility
located nearby. It passes through a series of treatments including a
desilter bowl and clarifier. Sludges are dewatered on a vacuum filter.
Eventually, the water is returned for reuse in the gas scrubber system
at the Q-BOP.
After the molten iron and scrap in the Q-BOP are
processed, usually in about 40 minutes, the furnace is tilted and the
2,800°F molten steel is poured into a ladle. Special alloying elements
which can improve hardness or corrosion resistance or alter other
properties of the metal are added during the pouring or tapping process.
An overhead crane carries the ladle of steel to a "teeming" platform
2-8
-------
where the metal is tapped from the bottom of the ladle into ingot molds.
The steel is allowed to cool and solidify in the molds, which are later
removed (stripped). Steel finishing facilities are described in
Figure 2-4.
Ingots first go to the semi-finished mills where they
are rolled on separate mills into blooms, slabs, and billets. These
three semi-finished shapes then go to finishing mills. There they are
rolled into the principal finished forms listed below:
1. Structural steel and rails.
2. Plate, sheet, and strip.
3. Rods, bars, and bar flats.
Summary of New Source Features. The new blast furnace at
the Fairfield plant will be characteristic of the larger capacity, high
top pressure facilities being constructed by the industry during this
decade. The use of beneficiated fuels has increased output as well as
assisted control of the process for environmental considerations. These
three products of operation—molten iron, slag, and blast furnace gas--
are all of value and will be utilized.
Once in operation, the new blast furnace will require a
different charge than the older operating units. A detailed raw
material demand list before and after the installation of the new furnace
is presented in Chapter 3. The new furnace will receive coke, iron ore
pellets, sinter, and flux. The iron produced by this unit is estimated
to be approximately 1,825,000 tons per year, following break-in.
2-9
-------
ro
i
PRODUCTION
FACILITIES
FIG. 2-4.FAIRFIELD WORKS STEELFINISHING PROCESSES
-------
3. ENVIRONMENT WITHOUT THE PROPOSED ACTION
-------
CHAPTER 3
ENVIRONMENT WITHOUT THE PROPOSED ACTION
3.1. EXISTING ENVIRONMENT
3.1.1. Existing Facilities at Fairfield Works
A description is presented of those facilities which
may influence the environmental baseline or be affected by the blast
furnace, including a description of the treatment processes which
apply specifically to the control of the wastewaters or air emissions
from that process.
After completing the description of the specific pro-
cesses and related treatment facilities, a description of those
additional wastewater treatment facilities which serve more than one
process is provided.
During a characteristic period from September, 1975,
to December 31, 1975, the following facilities and processes were
operable at Fairfield Works:
Wenonah Operations
Sinter plant (4 strands operating)
Fairfield Operations
1. Coke and coal chemicals plant (7 batteries
operating)
2. Blast furnaces (3 operating)
3. Q-BOP's (2 vessels)
4. a. Plate mill (primary mill)
b. Billet mill (finishing mill)
5. Fairfield tin mill
a. Pickling
b. Cold rolling
c. Cleaning
d. Annealing
3-1
-------
e. Plating
f. Temper rolling
g. Side trimmers
6. Merchant mill
7. Cotton tie and hoop mill
8. Structural mill and rail products
9. Steel axles and forge shops
10. Fairfield sheet mill
a. Shears and trimmers
b. Cold roll finishing
c. Annealing
d. No. 1 continuous galvanizing
e. No. 2 continuous galvanizing
f. No. 4 continuous galvanizing
g. Temper rolling
h. Coil painting
11. Fairfield wire mill
a. Wire drawing
b. Wire annealing
c. Wire galvanizing
d. Woven fence
e. Barbed wire
f. Welded wire fabric mesh
g. Nails
Ensley Operations
1. Ensley steel plant
a. Blast furnaces (3)
b. Open hearths (3)
c. Primary mills (including rail mill)
d. Iron foundry
2. Rail transportation shop
3. Roll shops division of Fairfield Works
On December 31, 1975, one of the three remaining open
hearth furnaces at Ensley Operations was idled. On June 30, 1976, the
3-2
-------
the remaining two open hearth furnaces were shut down. The processes
within the existing iron and steel-making facilities at Fairfield
Works are described below. A discussion of the existing steel-making
facilities must begin with handling of the raw materials required for
steel making. This discussion will follow the process steps outlined
in Figure 3-1.
3.1.1.1. Raw Materials Handling
Iron Ore. The major raw materials required by Fairfield
Works are iron ore, iron ore pellets, coal, dolomite, and limestone.
Iron ore is transported by rail to the sinter plant. The iron ore is
screened. The 3/8 in. material from the screening plant is conveyed
to storage silos and loaded in railroad cars for shipment to the blast
furnaces as coarse ore. Ore pellets are taken directly to the blast
furnace area from pellet stockpiles for charging to the furnace. Iron
ore is taken to the sinter plant for treatment.
Fluxstone. Dolomite is required at the sinter plant
for inclusion in the blast furnace charge. The mineral mined is high
in calcium and magnesium. Dolomite and limestone for the blast furnace
require careful sizing, because the rate at which reactions proceed is
dependent upon the exposed surface area. The preferred size of dolo-
mite for sintering is less than 1/8 in.; the optimum size for blast
furnaces is 2 to 4 in. Limestone and dolomite to be used for sintering
are unloaded at the track hopper as needed. The limestone (fluxstone)
goes directly to the blending beds. The fluxstone, flue dust, and
coke are screened and the oversize (>l/8 in.) is ground in the rod
mill to
-------
CO
1
Structural
Mills
STRUCTURAL SHAPES
Angles
Cnannels
Beams
OTHDt SOURCES
Rail
Mill
RAU .JOINT BARS
Crane Rails
Standard Rails
1
Heat
Treaty
Healing
Furnace
Bor
Mill
Round Bcrs
SpiKe Bars
Bar Flats
Wire
Mill
Wire Fabric
Nolle
Fenca
Wire
FIG. 3-1. FLOW DIAGRAM SHOWING THE PRINCIPAL PROCESS STEPS INVOLVED IN CONVERTING RAW MATERIALS
INTO THE MAJOR PRODUCT FORMS, (EXCLUDING COATED PRODUCTS) AT FAIRFIELD WORKS.
-------
limestone in large rotary kilns. The process consists of a continu-
ous roasting of limestone that leaves a CaO residue. The residue is
pumped into trucks pneumatically using compressed air. The trucks
then transport the burnt lime to a pressurized vessel located near
the Q-BOP at the Fairfield plant. The burnt lime is fluidized by
the positive pressure.
Coal. Coal is mined at locations within Alabama and
at locations in other states. Concord and Oak Grove coal are washed
in the Concord coal preparation plant and then transported directly
to the coke plant via truck or railroad cars.
At an unloading station, coals of different composi-
tion are dumped and transferred into stock from which they may be
drawn in the proper proportions to provide the chemical blend neces-
sary for coking. From this point, the mixture is fed by conveyor
belt to overhead storage bins of two to four thousand tons capacity.
These bins, each of which is equipped with hopper-type openings at
the bottom, are fed by gravity into vehicles called larry cars which
run on tracks atop the coke batteries and discharge the coal as it
is required into the coke ovens.
3.1.1.2. The Coke Plant
Coal is received and sent to the coke plant at
Fairfield where it is put into bins. Bins are located so that each
serves two or more coke batteries. Each coke oven has, in its top,
four holes through which coal is charged from the four compartments
of the larry car. Fairfield Works currently has seven coke batteries,
with a total of 489 ovens.
The ovens are sealed and then heated from below. The
volatile gases contained by the coal are driven off by the heat and
trapped in distillation apparatus for by-product recovery. The result
of this heating process is a material of low moisture content and high
carbon content (coke). The hot coke is pushed out of the opened ovens
into cars and subsequently quenched with water.
3-5
-------
The volatile gases driven off during the coking process
are scrubbed with water in a separate system to distill and recover
the various valuable chemicals contained within the hot gas. A
detailed description of the procedures for coking will be presented
subsequently.
3.1.1.3. Sinter Plant
A sintering plant agglomerates finely divided iron
ore and various iron-bearing materials, such as blast furnace flue dust,
mill scale, turnings, borings, and similar iron units generated within
a steel plant. The sintered materials are then suitable for blast fur-
nace feed because of the resulting improved physical properties of the
agglomerates together with higher iron content and reduced moisture.
A sintering machine is a continuous traveling grate
called a strand. A mixture of fine ore, crushed dolomite, and fine
coke (breeze) is placed on a grate traveling over a series of windboxes.
The mixture is ignited with a burner, and the fire moves down through
the mixture as air is drawn down through the ore by fans. The generated
heat sinters the particles together into a realtively hard, porous
mass.
The use of sinter in blast furnaces has significantly
improved furnace performance and productivity. Two important innova-
tions have been to utilize sized sinter and to incorporate dolomite
in the sinter, which serves as a fluxing agent in the blast furnace.
The latter is a favorable alternative to separately charging flux-
stone to the top of the furnace because it reduces the alkali required
in the furnace charge. It also tends to reduce coke consumption
because the dolomite in the sinter is calcined on the sintering grate,
rather than in the blast furnace. The sinter plant has a limited
capacity and is presently operating at the maximum sinter burden all
of the time. Construction of the new No. 8 blast furnace will increase
potential iron production and there will be a corresponding potential
for increase in the basicity of the sinter. The small amount of
increase of basicity up to approximately 1.4 should have little or no
3-6
-------
effect on the resistivity of the emissions. With sized sinter, small
particles are screened out prior to charging; this has also improved
blast furnace performance. Sinter from No. 4 sinter strand is air
cooled, while sinter from Nos. 1, 2, and 3 strands are water cooled.
3.1.1.4. Blast Furnaces
Reduction of iron from iron ore sources is accomplished
in the blast furnaces using coke as fuel and dolomite as a flux to aid
the process. These basic ingredients are processed and prepared by the
initial processes discussed previously. These materials are charged
to the blast furnaces for iron smelting. A detailed discussion of the
process and methods of operation is provided in a later chapter.
3.1.1.5. Q-BOP's
The Q-BOP essentially is a furnace in which molten iron
is transformed to molten steel by blowing a jet of oxygen into the
bottom of the molten bath and adding fluxes to form a slag or layer
of impurities on top of the bath. A complex chemical interaction
takes place which lowers the carbon content of the iron, causing it to
change to a mild steel. The furnace is then tapped. The steel drains
into the tapping ladle and the resultant slag is poured into a slag
pot.
3.1.1.6. Teeming
Heats of molten steel, which have been tapped into
steel ladles at the Q-BOP, are transported to the pit teeming plat-
forms by the overhead ladle cranes, and positioned directly over a
trip of ingot molds. By use of a stopper rigging incorporated in the
steel ladle, a stream of steel is allowed to flow from the bottom of
the ladle into the ingots mold positioned directly under the ladle.
Each ingot mold is poured to a desired height before closing the
stopper. After pouring, the ingot mold is transported from the
3-7
-------
teeming platform to the stripping yard where the mold is stripped
from the ingot.
3.1.1.7. Soaking Pits
A soaking pit is a refractory-lined, gas-fired heating
chamber. Ingots are placed in these pits in a vertical position
before being rolled and are allowed to gradually "soak up" heat over
a period of several hours until they have reached a uniform tempera-
ture throughout each ingot. From the soaking pits, the steel ingots
are taken to the primary mills to be shaped into blooms and slabs.
3.1.1.8. Primary Mills
The term primary mill is generally used to describe a
mill that produces billets, blooms, and slabs. The primary operations
convert ingots into a semi-finished steel and the semi-finished steel
product into pieces of desired cross-section and weight. Auxiliary
operations include heating, cropping, conditioning, cutting to length,
and collecting and assorting crops, roll scale, and other by-products
that are returned to the steel-producing and blast furnace departments.
Ingots are removed from the soaking pits when they reach rolling tem-
perature and delivered to the ingot feed table of one of the primary
mills. Ingots are then given several passes between the mill rolls.
An ingot is turned several times during rolling.
The steel flow diagram splits into three streams during
primary rolling: blooms go to the structural, axle and rail mills;
billets go to the rod and bar mills; slabs go to the plate and hot
strip mills (see Figure 3-1).
3.1.1.9. The Tin Mill
Hot Rolling Mills. The primary mills deliver steel in
the form of slabs 5 in. to 9 in. thick to the hot strip mill within
the tin mill. The slabs enter a scale breaker which removes scale from
the flat surface of the slab. The hot strip mill uses roughing
3-8
-------
stands, scale breakers, and finishing stands to reduce the hot slab
to a strip of uniform, specified thickness.
Pickling. Raw coils from the hot strip mill are
delivered to the pickle lines where they are cleaned and pickled.
Pickling is done with a solution of hot sulfuric acid or hydrochloric
acid. In the hot strip operation, steel was rolled at elevated
temperatures in the presence of air. This caused an oxide, commonly
referred to as scale, to form on the surface.
The scale on the surface of the hot rolled strip is
removed by a process called pickling. The pickler consists of:
1. An uncoiler
2. A welder or stitcher for joining coil ends
3. A scale breaker
4. A horizontal tank containing sulfuric acid or
hydrochloric acid
5. A tank of rinse water
6. End shearing and side trimming equipment
7- A recoiler and oiler
After pickling and oiling, the coils are placed in
storage awaiting the next operation, or are sold as hot rolled,
pickled coils.
Cold Reduction. After the strip is cleaned, pickled,
and oiled, it is recoiled for cold reduction. The coil is cold
reduced on Tandem Mills Nos. 3 and 4.
Electrolytic Cleaning. The lubricants applied to the
strip must be removed prior to coating. The strip passes through a
cleaning line in which it is immersed in a bath of detergent solution.
The detergent solution cleans the steel and serves as a conductor of
electric current between electrodes and the product being cleaned.
Annealing. Before being coated, the steel strip is
softened by annealing to eliminate the brittleness caused by cold
reduction rolling. The strip is annealed in an atmosphere of inert
3-9
-------
gas to eliminate surface oxidation. The gas conditioning system
provides an oxygen-free gas (reducing atmosphere) which prevents
oxidation.
Coating. The final process at the tin mill is to
coat the strip with a thin layer of tin. Fairfield Works has three
of these electrolytic tin lines.
3.1.1.10. The Sheet Mill
All steel processed at the sheet mill is received in
coil form from the tin mill in railroad cars. The coils are then pro-
cessed through the mill into the following products:
1. Painted coils
2. Galvanized or zinc-coated coils and sheets
3. Cold-rolled and hot-rolled steel which has been
processed through various operations of the mill
4. Corrugated materials
Those strips which are to enter one of the galvanizing
lines pass through enclosed tanks containing a mild caustic solution
which removes any dirt or grease which has accumulated on the surface
of the strip in prior operations. After cleaning and rinsing, the
strip passes into a controlled atmospheric furnace. The strip passes
from this furnace into the kettle of molten zinc where it picks up the
galvanized coating.
Galvanized sheets begin with a steel coil delivered to
the entry end of a galvanizing (zinc-coating) line. The steel strip
travels through a continuous strip annealing furnace where the strip
is softened and brittleness is reduced.
The cleaned and softened steel strip is then ready for
a protective coating which is applied when the strip passes through a
bath of molten zinc and between two jets of air that wipe the strip,
leaving a coating of molten zinc at the prescribed thickness.
After being galvanized, the strip is cooled, chemically
treated, and cut into sheets or recoiled. Galvanized steel is then
ready for shipment.
3-10
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Some galvanized coils are delivered to the paint line
where a wide variety of combinations of prime and finish coat enamels
are baked on. The paint line prepares painted sheets and coils ready
for shipment.
3.1.1.11. The Wire Mill
Before being drawn into wire, steel rods are pickled
in hot sulfuric acid, rinsed, and neutralized in a lime bath. Steel
wire, before being zinc-coated, is drawn through a hot hydrochloric
acid bath which cleans the wire.
Wire lengths are drawn and cut to form nails. Nails
are hardened by quenching. Nails at the wire mill are coated by
applying a cement coating to the nails. Nails are cleaned in the
Nos. 1 and 2 degreasers.
3.1.1.12. Emissions Projections
The processes operating at Fairfield Works generate
particulate emissions during the manufacture of steel and various
intermediate products. Each emission source operates under a permit.
Control techniques are employed to reduce the final particulate con-
tent of the gas vented to the atmosphere below an amount specified by
the process control weight table in the Jefferson County rules and
regulations.
The Universal Transverse Mercator (UTM) coordinates
for each emission source used in the Air Quality Display Model are
presented in Appendix A-3 of the Technical Support Document. A list
of identifiable air pollution control devices and resultant residue
disposal methods is also presented in Appendix A-6 of the Technical
Support Document. A list of procedures for emissions control and
rehabilitation of existing coke batteries (maintenance plan) is
presented in Table 3-1.
The Environmental Protection Agency, on April 15, 1976,
prepared a case study concerning designated new source construction in
3-11
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TABLE 3-1
EXISTING COKE BATTERIES REHABILITATION AND EMISSION CONTROL PROGRAM
MAINTENANCE PLAN
Item of Uork
No. 9
Nos. 3 & 4
No. 7
No. 8
Nos. 5 & 6
CO
ro
1. Ovens*
2. Buck Stays
3. Jamb Castings
4. Chuck Doors
5. Oven Doors
(Replacement)
6. Oven Doors
(Relines)
7. Charging Hole
Castings
8. Joints & Glands
9. Battery Machinery
10. Face Plates and
Parapet Walls
11. Tie Rods
12. Off-Take Assemblies
(Goosneck &
Standpipes)
13. Quench Stations
* Brick count
Rebuild walls in 23
ovens not operating
Replace 23 on coke
side. Replace 23
on pusher side.
Replace 30 on coke
side.
Replace 12
Replace 30 on coke
side. Replace 12
on pusher side.
Reset 40 percent.
Repair paving.
Repack 63 goosneck
and damper glands.
Repair
Adjust 100 percent
transverse tie rod
springs.
Replace 23
Rebuild & install
baffles (1 station
serving Nos.7,8,9)
24,600
Extensive spot brick
replacement of all
walls & end flues.
Replace 22 on coke
side of No. 3. Re-
place 22 on coke
side of No. 4.
Replace 60 on coke
side. Replace 30
on pusher side.
Replace 30
Replace 24 on coke
side. Replace 12
on pusher side.
Reset 75 percent.
Repack 146 goose-
neck and damper
glands.
Repair
Replace face plates.
Adjust 100 percent
transverse tie rod
springs.
Replace 58
Rebuild & install
baffles (2 stations
serving Nos. 3 & 4)
22,800
Extensive spot brick
replacement of all
walls & end flues.
Replace 10 on coke
side.
Replace 25 on coke
side. Replace 12
on pusher side.
Replace 12
Replace 12 on coke
side. Replace 12
on pusher side.
Reset 75 percent &
patch all others.
Repack 63 gooseneck
and damper glands.
Repair
Adjust 100 percent
transverse tie rod
springs.
Replace 30
Rebuild & install
baffles (1 station
serving Nos.7,8,9)
16,900
Spot brick replace-
ment in 30 walls plus
repairs to end flues.
Replace 17 on coke
side.
Replace 23 on push-
er side.
Replace 63 on coke
side. Replace 24
on pusher side.
Replace 36
Replace 12 on coke
side. Replace 12
on pusher side.
None
Repack 63 gooseneck
and damper glands.
Repair
Point up parapet
walls on both sides.
Replace longitudinal
tie rods, adjust 100
transverse tie rod
springs.
Replace 20
Rebuild & install
baffles (1 station
serving Nos.7,8,9)
23,800
Spray patch end flues
and replace brick as
necessary.
Replace 32 on No. 5
Replace 12 on No. 6
Replace 30 on coke
side. Replace 12
on pusher side.
Replace 12
Replace 12 on coke
side. Replace 12
on pusher side.
Reline 18 doors on
No. 5. Reline 13
doors on No. 6.
Replace 35 on No. 5
Replace 88 on No. 6
Repack 154 gooseneck
and damper glands.
Repair
Adjust 100 percent
transverse tie rod
springs.
Replace 26
Rebuild & install
baffles (2 stations
serving Nos. 5 & 6)
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non-attainment air quality areas. One of the two examples in the study
was the proposed changeover from open hearth technology to basic oxygen
furnace technology at U. S. Steel's Fairfield Works. The analysis was
later modified to reflect revised emission data. The revised analysis
appears in the Technical Support Document (Appendix A-2).
The EPA projections, which are listed in Table 3-2 pro-
vide estimates of past and future emission levels for the Fairfield/
Ensley complex. U. S. Steel reviewed this study, and while concurring
with the conclusions, they do not necessarily agree with the indi-
vidual EPA calculations; however, United States Steel did agree to the
use of the calculations for determining the incremental impact of the
proposed facilities. Changes in emission levels are shown in
Figure 3-2.
3.1.1.13. Effluents Inventory
The processes operating at Fairfield Works also gener-
ate effluents during the manufacturing of steel. The wastestreams
generated from each process are individually treated where required.
Effluent streams with less stringent treatment requirements are con-
solidated and treated in one of the wastewater treatment plants
located on each wastewater stream at Fairfield operations. The
treated effluent from each of these plants is then directed to a
final effluent control pond with the exception of the wastewater
treatment plant effluent from the wire mill operations. This water
enters Opossum Creek directly. A permanent automatic sampling station
on Opossum Creek below both U. S. Steel outfalls monitors the charac-
teristics of the total plant discharge, including treated process
water, cooling water, and run-off. An overall schematic of the
effluent treatment plan for Fairfield operations is presented in
Figure 3-3 and a summary included in Table 3-3.
Outfalls 002 through 009 are the discharges from Ensley
Works. The State-imposed discharge limitations for each of these out-
falls are on a net milligram-per-liter basis--TSS, 50 average/100
3-13
-------
TABLE 3-Z
SUMMARY OF EPA CASE STUDY OF u. s. STEEL
NEH SOURCE REV I EH ANALYSIS
P/WTICULATE EMISSIONS
(Ton/Year)
r.
I. Blast Furnace
Top Gas
Cast House
Stack House
Material Loading
Leaks and Kicks
Storage Piles
Total 1
II. Q-BOP
Stack
Fugitive
Total
III. Coke
Coal Handling
Charging 2
Leaks
Pushing 2
Quenching 1
UnderMrtng Stacks
Coal Storage Piles
Coke Screening
Coke Handling
Total 8
IV. Open Hearth
Stack 32
Fugitive _6
Total 38
TOTALS:
March
Pre 1972
Emission Levels
airfield Ensley
355.7 3,188.6
377.5 261.0
21.7 15.0
147.5 102.0
217.0 150.0
36.5 25.2
.155.9 3,741.8
140.2
,474.0
362.9
.538.0
,979.2
643.3
44.5
8.9
--
.191.0
,130 9,520
J26 _i,9p4
,556 11,424
63.068.7
, 1976, B1rm1
Ingham, Alabama
Unconstructed
New Facilities
~HTiho~ut urn;
BACT
56.3
392.2
22.5
153.3
225.4
38.4
888. 1
4.7
234.0
239.3
99.4
49.4
31.7
165.4
789.6
78.3
—
<6.3
1
1.2Z0.1
Ll»*
"A" F«1rf1eld Horks pre-1972 emissions, "B" - emissions from I
"C- °B" with BACT, "0" - emissions from Falrfleld Horks after
•E" Falrfleld Horks pre-1972
with control devices
BACT
56.3
225.4
22.5
1.5
225.4
38.4
569.5
4.7
2.3
7.0
99.4
49.4
31.7
5.0
19.7
39.1
—
6.3
250.7
1?7.2
T~
!. F. 18 and
completion
Post
Moderni-
zation
Emissions
404.1
761.3
43.7
297.5
437.5
72.8
2,016.9
14.2
703.8
718.0
167.6
109.6
92.5
1,971.6
1,752.9
173.8
71.7
10.7
_„
4,300.4
1,035.3
Pre 1972 Post
Emissions Modernization
With Control B. F. Plus Old
Falrfleld Ensley C(
355.7 579.7
377.5 261.0
21.7 15.0
147.5 102.0
217.0 150.0
36.5 25.2
1,155.9 1.13?. 9
140.2
123.7
124.9
2,538.0
1,979.2
196.3
44.5
8.9
--
5,155.7
100.2 77.3
6jl26.0 1^904^0
6,606.2 1,981.3
16^032
)ke Batteries
579.7
261,0
15.0
102.0
150.0
25.2
1,132.9
5.0
249.9
254.9
48.3
42.6
43.0
874. 2
681.8
67.6
15.3
3.1
--
1,775.9
3,163.7
replacement facilities,
of modernization,
on emissions, "F" - emissions from to-be-replaced old facilities.
3-14
-------
EPA
U.S. STEEL I4'°°°
CASE STUDY
NEW SOURCES REVIEW ANALYSIS 12,000
Birmingham, Alabama
March, 1976 IOP°°
EMISSIONS
(Tons per Year) 8,000
6,000
4,000
2,000
Case
BLAST FURANCE
Q-BOP
FAIRFIELD
COKE
OPEN HEARTH
ENSLEY
BLAST FURNACE
OPEN HEARTH
•
^ K
~~"""* \
r K
"
-
-^*i\
V-,
Pre 1972
Fairfield
Ensley
Complex
"A"
1
(
Unconstructed
New
Facilities .
1 B " with
BACT
11 Bu "C" ]
1,155.9 888.1 569.5
239.3 7.0
8,191.0 1,220.1 250.7
38,556.0
3,741.8
11,424.0
TOTAL (Tons per Year) 63,068.7 2,347.5 827.2
•^vJ
Completion
of the
Vlodernization
Program
" D"
IO,UO£
^Ais^
^
Estimate if
Control
Devices
had been
used on
A
" E"
Additional
Emissions
Associated
with " D" if
old iron and
coke facilities
continue
production
"F"
2016.9 1,155.9
718.0 254.9
4,300.4 5,155.7 1,775.9
6,606.2
1,132.9 1,132.9
1,981.3
7,035,3 16,032 3,163.7
FIG. 3-2.EMISSION LEVELS, PRE-1972 LEVELS AND SUBSEQUENT
TO COMPLETION OF THE MODERNIZATION PROGRAM
-------
Monitoring Stations
CO
I
FINAL EFFLUENT
CONTROL
POND
TIN MILL
DITCH
MONITORING
STATION
FIG. 3-3. OVERALL EFFLUENT TREATMENT SYSTEM
FOR FAIRRELD OPERATIONS
-------
TABLE 3-3
SUMMARY OF WASTEWATER TREATMENT FACILITIES
Sintering Plant
Sintering & Ore Conditioning Plant - Settling Basins
Sintering Plant - Septic Tank & Bio Filter - Settling Basins, also
COKE & COAL CHEMICAL DIVISION
Sanitary Sewer System - Wastewater Treatment Facilities
Ammonia Stills
Contaminated Water Collecting System
Recycle Coke Quenching
Primary Gas Cooling Tower
Final Gas Cooling Tower
BLAST FURNACE
Fairfield Blast Furnaces Nos. 5, 6, & 7 - Wastewater Treatment
Facilities
- Recycle Underflow & Treat Overflow - Hydrothickener
- Gas Cleaning - Water Treatment & Sludge Handling System
Ensley Blast Furnace Nos. 1, 2, & 3 - Gas Cleaning - Water Treatment
& Sludge Handling System
STEEL PRODUCTION
Q-BOP - Gas Cleaning Facilities - Water Treatment & Sludge Handling
HOT ROLLING
Ensley Mills - Treat (or recycle) mills wastewater
3-17
-------
TABLE 3-3 (Cont'd)
SUMMARY OF WASTEWATER TREATMENT FACILITIES
Tin Mill
Pickle Line No. 3 - Spent Acid collecting system
Pickle Line No. 4 - Spent Acid collecting system
Tin Mill Ditch - Wastewater Treatment System
collecting system
collecting system
collecting system
rinse water to Wastewater
Plant - tank, pumps & piping
Electrolytic Tinning Line No. 3 - Chem-treat rinse water to Wastewater
Treatment Plant - tank, pumps & piping
Pumps and Piping Transfer Facilities to
Electrolytic
Electrolytic
Electrolytic
Electrolytic
Pickle Lines 3 & 4 -
Tinni
Tinni
Tinni
Tinni
ng
ng
ng
ng
Li
Li
Li
Li
ne
ne
ne
ne
No.
No.
No.
No.
1
3
4
1
- Spent Acid
- Spent Acid
- Spent Acid
- Chem-treat
Treatment 1
Spent Acid
Deep Well
Sheet Mill
Acid Neutralizing Plant & Sludge Ponds
No. 4 Galvanizing Line - Spent Acid Collecting System
Paint Line - Collecting System for Paint Line Waste
Hauling waste to Tin Mill Ditch
Galvanizing Lines - Collecting system for chrome wastes
Hauling waste to Tin Mill Ditch
Outfall 022 - Pump station and piping to intercept and transfer waste-
water to Dolomite system
Wire Mill
Nail Quench Tank - Use of septic tank truck
Rod Pickling - Spent acid collecting system
Galvanizing Lines - Spent acid collecting system
Wastewater Treatment Facilities
Coke Plant - Biological Treatment Plant
Wire Mill - Chemical Treatment Plant
Deep Well, Surface Facilities & Emergency Lagoon
Wastewater Treatment Plant - Modifications
Coke Works Ditch - Pump Station & Piping to transfer wastewater to
final effluent Control Pond
Tin Mill Ditch - Chrome treatment facilities
Seven (7) Monitoring Stations
Effluent Control Pond
Facilities
ng Pond
Dolomite Recirculating System - Oil Removal Facil
Dolomite Recirculating System - Mill Scale Settli
Dolomite Recirculating System - pH Control
Shops Steam Plant - Reclaimed Oil Burning Facilities
Ensley Mills Wastewater - Chlorinating System
3-18
-------
maximum; zinc, 1 average/2 maximum; and pH, 6.0 to 9.0. The actual
net mean discharge concentrations (mg/1) of oil and grease and total
suspended solids are presented in Table 3-4. These values are in
compliance with State-imposed effluent limitations. In addition to
the State's effluent limitations, EPA has imposed additional net mean
discharge rate (Ib/day) limitations for ammonia, cyanide, and phenol.
These limitations and the current mean discharge rate from outfall
002, expressed in net Ib/day, are also presented in Table 3-4. These
Ib/day loadings can be converted to mg/1 by the use of an average flow
of 6 mgd. Additional data are provided in Table 3-5. The effluents
from Ensley enter Village Creek at approximately river mile 27.5.
The net mean concentrations noted in Tables 3-4 and
3-5 represent the current quality of discharges from Ensley Works.
After the Nos. 1, 2, and 3 blast furnaces are idled, flow from out-
falls 002 and 004 (a total of 8.6 mgd) will be essentially terminated
and approximately 0.6 mgd from outfall 003 will be terminated. The
result of the idling of blast furnaces 1, 2, and 3 will be a deletion
of the ammonia, cyanide, and phenol (outfall 002) loadings from
Ensley Works to Village Creek and a reduction of the overall flow from
Ensley Works to Village Creek of approximately 9.9 mgd. The quality
of the remaining effluent will continue to meet the State-imposed
effluent limitations for total suspended solids, oil and grease, zinc
and pH.
The quality of the discharge from the Wenonah plant
will not change with the facility changes at either Ensley or the
Fairfield plants. The current net mean values (mg/1) for the
Wenonah discharge in terms of BOD, oil and grease, total suspended
solids, and fecal coliform, as well as the NPDES effluent limitations
expressed in terms of mg/1 at average and maximum, are also presented
in Table 3-5. In addition to the values shown in the table, a pH
limitation of 6.0 to 9.5 is specified in the NPDES permit. As noted
above, the quality and quantity of the current discharge from the
Wenonah plant will not be changed as a result of any of the facility
3-19
-------
TABLE 3-4
DISCHARGES FROM ENSLEY WORKS
AND EFFLUENT LIMITATIONS
Outfall
Flow
(mgd)
Net Mean (mg/1)
Oil & Grease
TSS
002
003
004
005
006
007
008
009
6
1.5
2.6
1.7
0.2
0.001
7.3
2
7.4
4.7
3.3
4.6
3.7
9.8
4.5
6.2
15
0
10
28
13
9
9.5
0
All outfalls meet flow weighted state imposed limits of:
TSS 50 mg/1 average
0 & G 15 mg/1 average
Fe 5 mg/1 average
Zn 1 mg/1 average
pH 6.0 - 9.0
100 mg/1 maximum
30 mg/1 maximum
10 mg/1 maximum
2 mg/1 maximum
For 002 the following net mean Ib/day values also apply:
Mean BPT Avg. BPT Max.
NH3
CN
Phenol
103
13
1.8
472
57
15
1,416
171
45
When the Ensley B.F. is down, Outfalls 002 and 004 are reduced
by 8.6 mgd and Outfall 003 is reduced by 0.5 mgd.
3-20
-------
TABLE 3-5
ENSLEY AND WENONAH ACTUAL MEAN*
FOR NPDES EFFLUENT LIMITATIONS
Outfall
Ens ley
002
(Ib/day)
(lb/day)
(Ib/day)
003
004
005
006
007
008
009
Wenonah
029
(Gross
mg/1)
Parameter
TSS
0 & G
Fe
Zn
NH,
CNJ
Phenol
TSS
0 & G
Fe
Zn
TSS
0 & G
Fe
Zn
TSS
0 & G
Fe
Zn
TSS
0 & G
Fe
Zn
TSS
0 & G
Fe
Zn
TSS
0 & G
Fe
Zn
TSS
0 & G
Fe
Zn
BOD
0 & G
TSS
F. Coll.
Mean
15
7.4
103
13
1.8
0
4.7
10
3.3
28
4.6
13
3.7
9
9.8
9.5
4.5
0
6.2
7.6
6.4
21
NPDES
Average
50
15
5
1
472
57
15
50
15
5
1
50
15
5
1
50
15
5
1
50
15
5
1
50
15
5
1
50
15
5
1
50
15
5
1
30
10
40
200/100
NPDES
Maximum
100
30
10
2
1,416
171
45
100
30
10
2
100
30
10
2
100
30
10
3
100
30
10
2
100
30
10
2
100
30
10
2
100
30
10
2
45
20
60
400/100
aAll net mg/1 unless indicated
3-21
-------
changes discussed in this report. The discharge from Wenonah enters
Valley Creek at river mile 50.0.
The combined flows from Fairfield discharges (orig-
inally outfalls 010 through 027) are monitored at the Opossum Creek
monitoring station. Opossum Creek then flows into Valley Creek at
river mile 41.4. The net mean loading (Ib/day) monitored at the
Opossum Creek monitoring station represents the present quality and
quantity of the Fairfield discharge, adjusted for the third Q-BOP fur-
nace, as shown in Table 3-6.
The new coke battery replaces existing batteries, and
treatment to the new battery will be comparable to that which was
provided for discharges from the old batteries.
3.1.1.14. Solid Haste Residues
Residues are generated by operation of the various air
and water pollution control devices. These residues are identified by
source and disposal methods at Fairfield Works in Table 3-7, which lists
the eleven identifiable residues from polluton control equipment at this
facility. As noted, most of these materials are either directly reused
in the sinter process or placed in stock for anticipated recycle at a
later date.
3.1.2. Proposed Replacement Facilities
3.1.2.1. Coke Battery No. 2
A new 57-oven coke battery is scheduled to replace exist-
ing coke batteries Nos. 3, 4, 7, and 8. EPA has designated this new
battery as a replacement facility. Prior to considering the emissions
from coke battery No. 2, a description of the coking operation is pre-
sented which relates to emission control. The replacement facility
will occupy the site of former coke batteries 1 and 2.
Coke Handling and Preparation. Coking coal is supplied to
the Coke Department by truck and by rail. Truck receipts are discharged
directly to ground storage. Railroad car receipts can be discharged
3-22
-------
TABLE 3-6
FAIRFIELD ACTUAL MEAN AND NPDES EFFLUENT LIMITATIONS
AS MEASURED AT OPOSSUM CREEK MONITORING STATION
OUTFALLS 010 027
(Net Ib/day Unless Indicated Otherwise)
Parameter
Flow
Temp.
PH
Spec. Cond.
TSS
0 & G
BOD5
COD
FeTD
CuT
Zn,
T.D. Solids
NH3-N
Phenol
Arsenic
Cr*5
Sn
Crp
CrTD
F
Pb
Antimony
Mn
CN
Hg
D.O.
FeT
Cd
Consent
Decree
Avg.
(Assumes 20 mgd
95°F
6.0
1,200
450
5,000
12,000
300
16
30
NPDES
Permit
Max. Avg. Max.
flow)
105°F 95°F
8.5
4,000 4,125 8,050
1 ,000 780 1 ,641
7,500
18,000 12,690 21,074
600 300 600
30
60 36 72
84,000
155
10
230
20
15
100
2 mg/l-min.
1 ,740 1 ,740
35 35
8
1
310 155 310
30 10 30
10 30
345 609 959
30
22.5
150
50 50
0.1
15 mg/l-avg.)
\4 mg/l-min./
2
Net
Mean
707
319
6,726
8
167
75,489
1,113
1.78
4.1
0
4.37
1.51
340
15.5
2.45
34.9
13.1
0
0.21
Avg. Limits
BPT BAT
11,621 1,469
4,350 547
35 35
49 5
1,949 115
44 6
0.05 0.05
233
30 0.05
201
490
Consent decree limits without Q-BOP and other adjustments
NPDES permit limits are final including third Q-BOP
Mean limits are projected from ten dry day test data to include third Q-BOP impact at 1.5 x 2 Q-BOP values
and assumes no effect from new coke battery
Net mean Zn» monitoring has been in compliance with NPDES limits since 7/1/77
3-23
-------
TABLE 3-7
POLLUTION CONTROL RESIDUES
FAIRFIELD DISTRICT WORKS
U. S. STEEL CORPORATION*
Source
Annual Quantity
Residue - dry tons
Residue Produced/ Disposition
Ton Q-BOP Steel** of Residue
(Percent)
DUST
Sintering
Blast Furnace
Q-BOP
SLUDGE
Sintering
Blast Furnace
Rol 1 i ng
Pickling
FILTER CAKE
Lime/Bio-Mass
Tin Mill
Treatment Plant
SCALE
Rolling Mills
SLUDGE & FILTER CAKE
Q-BOP
TOTAL
15,500
73,800
6,480
23,600
13,290
15,600
1,600
3,300
15,800
84,700
15,200
0.6
2.7
0.2
0.9
0.5
0.6
0.1
0.1
0.6
3.1
0.6
10.0
Sinter
Sinter
Sinter
Stock
Sinter
Stock/Sinter
Landfill
Landfill
Landfill
Sinter/BF
Sinter
Landfill
* Taken from EPA study entitled "Managing and Disposing of Residues
from Environmental Control Facilities in the Steel Industry" - 12-15-75,
** Q-BOP production of 2,500,000 tons/yr in 1975.
3-24
-------
into railroad track hoppers at coal unloading stations Nos. 2, 3, and
4 (No. 1 has been dismantled). Normally, railroad cars are to be un-
loaded at No. 3 station. No. 2 station is to be used only as a standby
for No. 3. Coal unloaded at No. 2 station cannot enter the new coal
handling and preparation system but must be conveyed directly to coke
batteries Nos. 5, 6, 7, 8 and 9 only. Coal unloaded at No. 4 station is
conveyed directly to ground storage or via a pulverizer and then to
ground storage. When reclaimed, this coal can be transferred to No. 2
station or to the reclamation system serving No, 2 station and the new
coal preparation system.
Truck-hauled coal placed in ground storage can be re-
claimed via mobile equipment and diverted to either the No. 2 station
or to the new coal preparation system.
Railroad car receipts dropped into the track hoppers at
the No. 3 station can be conveyed to the new 10,000-ton silos or can
be diverted to ground storage for later reclamation.
High volatile coal is handled separately from medium
volatile coal through first stage pulverization. Therefore, high
volatile coal is diverted to two of the 10,000-ton capacity silos while
medium volatile coal is diverted to the third silo.
Methane is evacuated from the top of each silo via an
exhaust fan and duct system. There, the ventilation unit circulates
the air avoiding a methane buildup. Each of the three 10,000-ton stor-
age silos will employ baghouses with design mass emission rates of
1.003 Ib/hr (0.02 g/scf) and design removal efficiencies of 98.5 per-
cent. See Attachment I to Appendix A-2 of the Technical Support
Document for the calculation of the emission rate and all subsequent
emission rates in this section.
Each 10,000-ton silo discharge is provided with a pair
of variable speed feeder belts. Only one belt in each pair can run
at a time. Each of the three pairs is provided with a bag-type dust
collector and each pair of feeder belts discharges to a conveyor
which tranfers its load to first stage pulverizers (5 units). Dust
generated in the pulverizer building is again collected by a bag-type
dust collector with a design mass emission rate of 2.69 Ib/hr
3-25
-------
(0.02 g/scf) and a design removal efficiency of 98.5 percent. Once
pulverized, the high and medium volatile coals are placed onto a
common conveyor and carried to the mixer building. Again, a bag-
type dust collector serves this building with a design mass emission
rate of 0.725 Ib/hr (0.02 g/scf) and a design removal efficiency of
98.5 percent. The high and medium volatile coals are thoroughly
mixed. Oil is added for bulk density control if the coal mix is
destined for use in batteries Nos. 5, 6, 7, 8 and 9. No oil addition
is made if coal is destined for the preheat facility and No. 2 coke
battery. When the coal leaves the mixer building, it is conveyed to
a 100-ton bin from which it can be directed to batteries Nos. 5, 6,
7, 8 and 9 or to the new No. 2 battery. This bin is provided with a
bag-type dust collector which has a design mass emission rate of
0.583 Ib/hr (0.02 g/scf) with a design removal efficiency of 98.5
percent.
If the coal is to be diverted to No. 2 battery, it is
conveyed to the top of a 3,500-ton capacity silo provided with a
methane evacuation system. From the 3,500-ton silo, the coal flows
onto one or the other of two variable speed feeder belts which dis-
charges to a conveyor feeding the secondary pulverizers (2 units).
A bag-type dust collector serves the equipment below the 3,500-ton
silo as well as equipment in the secondary pulverizer building. The
design mass emission for this process is 4.52 Ib/hr (0.02 g/scf)
with a design removal efficiency of 98.5 percent.
From the secondary pulverizer building, coal is con-
veyed to the preheat building as shown in Figure 3-4. The design
mass emission rate for this process is 0.876 Ib/hr (0.02 g/scf).
Coal Preheating. A coal preheating and charging
system will be installed in conjunction with the No. 2 coke oven
battery at Fairfield Works. In this system, pulverized, wet coal
from the coal handling and preparation section will be preheated to
approximately 450°F and conveyed hot to the 500-ton coal bin mounted
above the No. 2 battery. The hot coal will then be withdrawn through
rotary feeders from the 500-ton bin into fixed-position, pre-weighing
3-26
-------
CONVEYOR BELTS
UNLOADING
HOPPER
FOR FURTHER
PROCESSING
OR FOR FUEL
FLUSHING LIQUOR
FLUSHING
LIQUOR
DECANTER
TAR
OEHYDRATOR
PRIMARY
COOLER
DECANTER
SILOS-
PRE -HEATING
COKE OVENS
RAW
GAS
PRIMARY
COOLER
QUENCHING
STATION
OKE
USHER
^
METALLURGICAL COKE
COKE SCREENINGS
COKE
WHARF
GAS FOR UNDERFIRING COKE OVENS
FROM BY-PRODUCTS PLANT
SCREENING
STATION
CHEMICALS FOR
RECOVERY ELSEWHERE
FIG. 3-4. FLOW SHEET SHOWING THE MAJOR STEPS INVOLVED IN
THE PREHEATING AND CARBONIZATION OF COAL
-------
hoppers which will hold the coal until the charging car moves into
position below. The coal is then withdrawn from the hoppers via
rotary feeders into a waiting coal charging car. When filled, the
coal charging car then carries the preheated coal to the oven scheduled
for charging. Preheating is accomplished in two identical lines of
equipment at the rate of approximately 100 ton/hr-line. Coal dust
emissions from each preheated coal premetering bin will be controlled
by wet scrubbers with a total design mass emission rate of 0.0408
Ib/hr (0.02 g/scf) and design removal efficiencies of 99.8 percent.
(See Attachment I to Appendix A-2 of the Technical Support Document
for the calculation of the emission rate).
Drying and heating of the coal in each line is carried
out in a vertical duct into which coal is introduced by a controlled
mechanical device. Coal is transported through the duct by a stream
of high velocity flue gases which both heat the coal and transport it.
This drying and heating medium of gases is produced in a highly effi-
cient combustion chamber and forced through the system by a fan. A
dry cyclone separator removes the coal particles from the carrier gas
stream. Material collected in the cyclone is withdrawn via rotary
valves into a chain conveyor for transfer to a mixer. From the mixer
the hot coal is conveyed via a chain conveyor to the 500-ton bin
above the No. 2 battery. When the carrier gas stream has passed
through the final piece of equipment and the final process separation
of coal and gas has been made, the carrier gas is then divided by
controls into two streams--one for recycle to the system through the
combustion chamber and the second stream, passing through a cleaning
device, to the atmosphere. This stream is discharged vertically
above the preheat building through a waste gas stack in conformance
with environmental regulations.
The cleaning devices which will be used on each of the
two preheat lines are variable venturi throat wet scrubbers, each
having a design removal efficiency of 99.876 percent. The total
design mass emission rate from both the preheat lines is 6.60 Ib/hr
(0.02 g/scf).
3-28
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The coal preheating stack is characterized as
follows:
Height above grade--220 ft (approximately)
Inside diameter at exit—3 ft, 5 in. (approximately)
Gas discharge rate (design rate)--9,850 scfm (dry)
Exit temperature--!85°F (approximately)
A process schematic is presented in Figure 3-5. Particulates produced
are estimated to be less than 30 Ib/hr, allowed by the regulations.
Assuming 0.5 percent sulfur in the coal, the S02 emission rate is
estimated to be 98.6 Ib/hr or 424 ton/yr. Calculations used to find
the coal preheater emission rate for SOo and particulates are shown
in Appendix A-5 of the Technical Support Document.
Coal Charging. Coal charging will be accomplished by
a hot coal charging car ("hot" larry). After the larry car is filled
at the coal line, it moves to an empty oven where it is discharged.
This type of charging car will be the first of this particular design.
While there are no emissions data specifically for stage charging, the
system which will be installed is equivalent to good stage charging
and is estimated to be approximately 95 percent effective compared to
uncontrolled.
Coking. The coke oven is a refractory chamber with
vertical flues where fuel gas is burned. Heat from combustion is
transmitted to the coking chamber through the silica brick. The ovens
are arranged side by side. The new battery will consist of 57 ovens.
Coking chambers are rectangular in form, with an average height to the
coal line of 19 ft, 2 in.; length of 47 ft, 7 in.; and an average
width of 18 in. The chambers are air tight. Covering both ends of
each chamber are tight-fitting doors which are removed for the dis-
charge of coke. The heating walls, spaced between the coking chambers,
are heated by the "half-divided oven" system. In this system a
section of flues extends from each side along the length to the middle
of the oven. Air and gas are introduced into one section of flues
where combustion takes place and the hot exhaust gases pass down
3-29
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Particulates
S02
5.48 Ib/hr
96.8 Ib/hr
Vent to atmosphere
Wet Coal
PULVERIZER
LO
O
SCRUBBER
DRYING
AND
HEATING
COLUMN
Dry hot coal to
coke battery
Recycle Gas
FIG. 3-5. COAL PRE-HEATING SCHEMATIC FOR COKE
BATTERY NO. 2
-------
through the other section to the regenerators where the remaining
heat is absorbed in the mass of brickwork under the ovens. Every
20 to 30 minutes the cycle is reversed and those flues which have
been used for the exhaust become combustion flues. The necessary
air for burning is pulled through the hot regenerative chamber,
being preheated before it is mixed with the fuel gas. As the heat
passes through the flue walls of the coking chambers, the coal begins
to coke and fuse, and volatile gases are driven from it. Coking
starts at the walls and proceeds inward, and the gases evolved pass
outward through the partially coked mass, forcing their way to the
top of the chamber. They are collected and pulled, with the gases
collected from the other chambers in the battery, into a large col-
lecting main from which they are withdrawn through a suitable pipe
system and pass to various processing operations.
When the coke is ready for removal, a track-mounted
door handling machine on each side of the battery moves to the oven
to be emptied, and doors on both sides are removed. On the machine
at the discharge side is a guiding device which, when placed in
front of the oven, directs the coke into a quenching car waiting on
a track below. The track-mounted machine on the opposite side is
equipped with a ram of approximately the same proportions as those
of the coking chamber. At a signal, the ram is forced into lumps as
it falls into the quencher car. The coke at this point is at a
temperature of about 2,000°F.
The coke is pushed into a closed coke quench car in
which emissions will be contained and carried by induced draft for
action through the inter-connecting duct work, the quencher, a
variable throat wet scrubber, the moisture separator and induced
draft fan stack. The quencher lowers the gas temperature while the
scrubber cleans it. The scrubber water is dumped into a sump near
the quench station and, following solids separation, clean water is
recycled to the system.
3-31
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The wet scrubber will remove coke fines with a design
mass emission rate of less than 7.54 Ib/hr (0.02 g/scf) as shown by
the following calculation:
(44,000 scfm)(0.02 g/scf)(60 min/hr)/(7,000 g/lb) = 7.54 Ib/hr
with a design removal efficiency of greater than 99.7 percent.
Coking Emissions. The following measures have been
included in the design of this battery to minimize particulate
emissions:
1. Hot coal charging car with sealing capabilities
to prevent blow-back.
2. Mechanical gooseneck cleaners.
3. Mud-sealing oven lids and gooseneck lids.
Doors of an improved design will be tested at other
U. S. Steel facilities to determine the most effective sealing edge
in reducing emissions. The most effective design will be used for the
Fairfield battery. The doors which will be installed will meet a ten
percent door leakage standard.
The design data for the individual ovens are as follows:
1. Number of ovens--57
2. Average oven width--!8 in.
3. Oven height--20 ft, 2 in.
4. Oven height to coal line—19 ft, 2 in.
5. Effective (coal) volume--!,374 cu ft
6. Oven length--47 ft, 7 in.
Characteristics for the underfiring stack are:
1. Height above grade--350 ft
2. Inside diameter at exit--16 ft, 9 in.
3. Gas temperature at exit--500°F
4. Gas velocity at exit--660 ft/min
5. Emissions (see Figure 3-6) particulates in
gas--94 tons/yr or 21.46 Ib/hr
6. Emissions (see Figure 3-6) S02 assuming 0.5 per-
cent sulfur in gas--454 Ib/hr or 1,987 ton/yr
3-32
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Coal 150 tons per hour
103 tons per hour
of furnace coke
u>
U)
COAL PREHEATING
--O
PREHEAT
SYSTEM
STACK
Hot Coal
BATTERY
STACK
S02 - 454 Ibs/hr
Particulates- 21.5 Ibs/hr
NO. 2 COKE BATTERY
534,000 SCFH
Coke Oven gas from existing
by-products plant
1,776,000 SCFH
Coke Oven gas to
existing by-products
plant
FIG. 3-6. COKE BATTERY PLUS PRE-HEAT SCHEMATIC
-------
7. Calculations used to determine emissions for
particulates and SCL are given in Appendix A-5.
Quenching. After being loaded, the quencher car is
moved quickly to a quenching station at the end of the battery.
Emission control at the quenching station is achieved using baffles
to minimize the emissions of particulate matter.
The quencher car is then moved from the quench station
to the coke wharf where the coke is discharged onto the wharf. After
cooling on the wharf, the coke is raked at a controlled rate onto a
belt and conveyed to a three-inch stationary screen. Oversized
material from the stationary screen passes through a crusher to assure
that all coke is reduced to a size less than three inches. All coke
is then transferred via chute to a conveyor which transports the
material to the No. 8 blast furnace stockhouse or to railroad cars.
Emission control at the coke transfer building will be accomplished
utilizing a baghouse with a design mass emission rate of 1.44 Ib/hr
(0.02 g/scf) and a design removal efficiency of 98.5 percent.
Coke By-Product Plant. The new coke battery at
Fairfield Works will not increase the overall coke-making capacity.
As a result, emissions at the by-product plant will not increase. The
calculations used to determine particulate emissions, 0.875 ton/yr,
are given in Attachment II to Appendix A-2 in the Technical Support
Document. By-products recovered from the coal carbonization process
include coke oven gas, tar, ammonium sulfate, light oil, naphthalene,
creosote, pitch, and coke breeze.
The principal equipment consists of coal handling
facilities, coke ovens, primary and final gas coolers, turbo-exhausters
and turbo-boosters for gas, ammonia saturator, benzene scrubbers,
light oil separating stills, wastewater treatment plant, ammonia
stills, a fuel gas distribution system, and pitch plant. A detailed
description of the processes using this equipment follows:
Gas released during the coking process passes from the
ovens through standpipes into gas collector mains. The temperature of
3-34
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the gas is reduced in the collector mains from approximately 1,200°F
to around 175°F by flushing liquor sprays in the mains. As the gas
cools, the tar condenses out and drains by gravity along the bottom
of mains to the tar flushing tanks. After the tar and weak liquor
is dropped out in the trap and drain leg, the gas bypasses the
flushing tanks and goes to the primary coolers.
There are three flushing tanks for batteries 5, 6, 7,
8, and 9. These tanks receive the flushing liquor and tar from the
collector mains and decant (separate by gravity) the tars from the
liquor. The bottoms (settled tar) are pumped to storage and the
liquor is recirculated to the batteries. Surplus liquor is fed to
ammonia stills for recovery of ammonia.
Raw coke oven gas, under the suction of the exhausters,
passes through 18 primary gas coolers. The coolers are of the shell
and tube, multipass, counter-flow type and use water as the cooling
medium. In passing through the units, gas is cooled to approximately
95°F, thereby condensing the entrained water and tar, which are
drained through seals to a sump and pumped to a tank for gravity sepa-
ration. The tar is then pumped to storage tanks for further dehydra-
tion by steam heating.
Leaving the primary gas coolers, the gas passes to the
turbo-gas exhausters, from which it is driven at a positive pressure
of 40 ounces per square inch through the remaining recovery apparatus.
These facilities comprise seven turbo-gas exhausters, driven by steam
turbines.
Gas discharged from the exhausters is passed through a
baffled tar precipitator for the removal of the last traces of en-
trained tar; thence through reheaters and saturator for recovery of
the ammonia content. The saturator is a stainless steel vessel
within which a solution of weak sulfuric acid is sprayed in direct
contact with the coke oven gas. The ammonia content of the gas com-
bines with the acid and forms ammonium sulfate, a crystalline salt,
which is precipitated and collected in a crystallizer, from which
it is pumped to a slurry tank and dried by centrifugal driers. The
3-35
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dried salt, containing in excess of 25 percent NH3, is conveyed by
pneumatic tube to the sulfate storage building. From storage it is
loaded into railroad cars for shipment to the customer.
As the gas, free of ammonia, leaves the saturators,
the remaining acid is removed by an acid separator adjacent to the
saturator. From the neutralizer the gas is forced to the final
coolers. There are five gas coolers which employ the direct cooling
method.
The gas enters the bottom of the coolers and flows
upward to pipes at the top. Water, sprayed from the top of the
coolers, comes in direct contact with the gas and washes or pecipi-
tates out the crude naphthalene. The crude naphthalene water flows
continuously from the coolers to the naphthalene recovery area.
The effluent water, containing naphthalene, is directed
to the naphthalene flotation cells. In these cells, rotating skimmers
rake the floating naphthalene in the water. The recovered naphthalene
flows to a sump and is allowed to rise to the top of the remaining
water. After the naphthalene has accumulated on top, steam coils
melt it so it can be pumped to drying tanks.
The naphthalene is allowed to dry in these tanks to
insure that only a small amount of water remains. This crude naphtha-
lene is then ready for shipment to the tar plant.
From the final gas coolers the gas, now free of tar,
ammonia and naphthalene, flows to the scrubbers where the benzene
products are removed. All the gas from the coolers enters No. 4
scrubber. As the gas leaves No. 4 scrubber, it is split. One-half
goes to Nos. 3, 2, and 1 scrubbers and the rest goes to 5, 6, and 7.
The gas enters the base of each scrubber and as it
flows upward to exhaust pipes, absorbent or wash oil is sprayed from
the top. These wash oil sprays wash the benzene products from the
gas. The oil is recirculated through the scrubbers until it absorbs
a considerable amount of the benzene products. It is then pumped to
the light oil still building for distillation.
3-36
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The benzolized oil passes through a heat exchanger
and then to the light oil still column. The benzolized oil enters
the top of the still and comes in contact with the steam as it passes
downward. The steam separates the light oil from the wash oil and
carries it, as a vapor, back up through each tray section. After
passing through the series of trays, the vapors enter a heat exchanger
where much of the heat is absorbed by the incoming wash oil.
The partially cooled vapors leave the heat exchangers
and are cooled in a dephlegmator. The secondary oil and water con-
densing in the dephlegmator are drained to the secondary oil decanter
tank where they are recovered. The primary light oil vapors enter a
condenser where they are cooled with water. The primary light oil and
water enter another decanter tank where they are separated with the
light oil going to a storage tank. From this tank oil is trucked to
Port Birmingham for shipment to Clairton Works.
The debenzolized wash oil is cooled in spiral heat
exchangers and piped back to the scrubbers to be used agaio.
The gas which was routed through Nos. 1, 2, 3, 4, 5,
6, and 7 scrubbers is routed back to the batteries to be used for
heating ovens and constant pressure of 15 in. of HLO is maintained by
two gas holders. A steam driven gas booster pumps the gas from the
low pressure system and compresses it to approximately 4.3 Ib. The
booster gas is piped to Ensley, Fairfield Steel, or to the Fairfield
Tin Mill.
The pitch plant is designed to process continuously a
maximum of 80,000 gallons per day of heavy tar recovered primarily
from the hydraulic mains of the batteries.
Major equipment of the pitch plant consists of a crude
tar feed tank, natural gas-fired heater, tar flash tank, chemical
oil shell and tube condensers, pitch storage tanks, chemical oil
storage tanks, pitch upgrading unit, a hot oil heating system for
the pitch storage tanks and a thermal electric heating system.
3-37
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The pitch plant is designed for the continuous
distillation of heavy tar into chemical oil and specification elec-
trode pitch.
The above equipment and tanks vent to the atmosphere.
The last survey made of the by-products plant was in December, 1977,
when Research Triangle Institute contracted with EPA to do a study
on the verification of priority pollutants.
3.1.2.2. Process Effluents
Separate facilities will be required for the tar and
flushing liquor system, such as separating predecanters and decanters.
Flushing liquor and tar transfer pumps will be furnished, as will tanks
for flushing liquor surge and tar transfer. An existing biological
treatment unit has the capability to treat effluents from the new
No. 2 coke battery.
3.1.2.3. Third Q-BOP Furnace
An additional Q-BOP furnace is scheduled to replace
steelmaking capacity lost at Ensley with the closing of the open
hearth furnaces at that facility. Completion of this Q-BOP furnace
will allow U. S. Steel Corporation to maintain its 3.5 million ingot
ton/yr steelmaking capacity at Fairfield Works. The third Q-BOP will
be located in the same building as the other two Q-BOP furnaces.
Method of Operation. The basic oxygen furnace used in
the Q-BOP process is shown in Figure 3-7. The barrel-shaped furnace
is mounted on trunnions. These enable it to rotate completely about a
horizontal axis. The bottom of the Q-BOP is equipped with a series
of tuyeres for oxygen injection. The furnace further consists of a
middle cylindrical section called the barrel, and a cone section that
tapers concentrically to a nose or mouth at the top. Located in the
lower section of the cone is a tap-hole which separates the steel
from the slag during the tap. A refractory brick lining protects the
steel shell from erosion.
3-38
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LO
OJ
PHOTOGRAPH OF AN EXISTING Q-BOP.
-------
A gas-collecting hood is installed just over the mouth
of the furnace in its vertical position. The charging side of the
furnace is fitted with a separate enclosure during all phases of
operations except during charging of scrap, hot metal additions, and
sampling.
In operation, the furnace is rotated toward the charging
side and, after opening the shielded doors, charged with predetermined
weights of scrap and hot metal. This limits the amounts of scrap that
can be melted. Charges usually range from 70 to 86 percent hot metal,
the balance consisting of various scrap mixes. While charging the fur-
nace, low pressure nitrogen is blown through the tuyeres; however,
immediately prior to rotating the furnace to a vertical position, a
high pressure gas is blown through the tuyeres to prevent any metal
from flowing into the tuyeres and the refining of iron to steel
commences. Lime is injected with oxygen on a programmed basis to maxi-
mize the removal of phosphorus and sulfur while using a minimum amount
of lime. The oxygen and lime impinge directly into and through the
bath, which greatly contributes to a positive physical as well as
chemical interchange. During the blow, other fluxes such as fluorspar
and limestone can also be injected with the oxygen through the bottom.
When the programmed amount of oxygen and lime has been blown, normally
10 to 13 min in duration, the furnace is turned down and the oxygen
flow switched to low and any adjustment to carbon and/or temperature
can be made by reblowing or by adding additional fluxes, or both.
When the steel composition and the temperature are as required, the
furnace is tapped, utilizing either the taphole or lip tapping.
When the steel has completely drained into the tapping
ladle and a thin insulating layer of slag covers the heat, the furnace
is rotated to allow the remaining slag to be dumped into a slag pot
positioned on a transfer car. The furnace is then positioned to
receive the charge for the next heat. Meanwhile, the ladle transfer
car has been moved into the teeming area where a crane picks up the
ladle and proceeds to teem the steel.
3-40
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All Q-BOP furnaces at Fairfield Works (two existing
and one new) will be equipped with improved water cooled doors and
improved labyrinth seals will be installed. An additional baghouse
will be utilized to handle secondary emissions. In addition, a
secondary hood system will be installed on the inside of the "doghouse"
of each furnace which will exhaust at a larger rate.
Blowing, charging, and tapping operations at each
furnace generate waste gases which are collected in a closed-system,
water-cooled hood and directed into a variable venturi primary and
secondary wet scrubber before being exhausted to a flare stack where
non-combusted gases are burned prior to discharge into the atmosphere.
Dust concentrations in the emission are maintained at less than 0.02
grains per standard cubic foot for the two existing vessels and will
be 0.01 grains per standard cubic foot for the new vessel. Sludge
collected from the dual venturi system is transported to a dump site.
Recovered water is recirculated in the gas cleaning system.
Each furnace is provided with a transfer car track to
carry two power-driven transfer cars: one a 210-ton teeming ladle, and
the other a 500-cubic foot slag pot. A mobile carrier removes the
filled slag pot for disposal and replaces it with an empty slag pot
for each heat.
Emissions Process. During the blow, large quantities
of gas, principally carbon monoxide and carbon dioxide, and lesser
amounts of iron oxide fume and lime dust, are released from the bath.
These gases are pulled up into the water-cooled collecting hood by
induced draft fans located at the back end of the gas cleaning system.
The Q-BOP is a partial combusion system where the
opening at the furnace mouth is restricted, thus limiting the heat
generated by burning gases and permitting collection of gas which
is flared to the atmosphere. In addition the partial combustion system
results in a minimum quantity of gas being exhausted thus limiting
the total quantity of particulate matter being emitted.
3-41
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Limestone and other fluxing agents are transported in
pulverized form through pneumatic conveying systems. Dust from the
transport systems is collected in bag filters and recycled into the
process.
Emission control at the limestone truck unloading area
will be accomplished using a baghouse with a design mass emission rate
of 0.198 Ib/hr:
(9.250 scfm)(.0025 g/scf)(60 min/hr)/(7000 g/lb) = 0.198 Ib/hr
and a design removal efficiency of 99.9 percent.
The gases produced are carbon monoxide and carbon
dioxide with finely divided iron oxide particles. These gases issue
from the furnace mouth and are collected in a water-cooled hood. They
are then removed in a venturi scrubber. The gas exhaust and cleaning
system will function independently of each of the other two Q-BOP's.
Figure 3-8 is a schematic of the process.
The carbon monoxide is ignited and burned to carbon
dioxide at the top of the stack. The estimated quantity of carbon
monoxide gas ignited at this location is approximately 81,000 scfm at
an exit velocity of 105 ft/sec. The mass emission rate is
(.0081 lb/ton)(3,500,000 ton/yr)/(2,000 Ib/ton) = 14.1 ton/yr
Therefore the amount of iron oxide dust entrained in this gas is
designed to be no more than 3.2 Ib/hr or 14.1 ton/yr.
The dust particles removed in the scrubber are settled
out of the scrubber water in a thickener and the sludge is filtered in
a vacuum filter and is taken to a landfill. Process slag is impounded
for future reclamation.
The clarified water, less the blowdown for dissolved
solids control, is recycled to the process. The maximum make-up water
required for the unit will be 200 gpm.
3.1.3. Operations Changes
3-42
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Gas
Water
Scrubber
Quencher
Dust
Scrubber
Quencher
^
^^
OJC5 Fan
i
O Stack
Dust
Pi
Fan
Stack
Sludge
Sludge •
Slowdown to
^_ Final Effluent
Control Pond
Drum
Filter
Scrubber
Quencher
I
Dust
XL
Fan
Stack £)
FIG. 3-8. FINAL THREE Q-BOP GAS CLEANING SYSTEM AT FAIRFIELD
-------
3.1.3.1. Changes In Fairfleld Operation
In order to maintain the existing 3.5 million ingot
tons per year capacity and to be in compliance with air emission
implementation plans, the following changes in Fairfield operations
are anticipated.
1. Installation of a third Q-BOP furnace.
2. Installation of a modern 57-oven coke
battery including coal preheating and
coal handling facilities.
3. Installation of blast furnace (No. 8) and
auxiliaries.
4. Provision of four additional soaking pits.
5. Idling of old coke batteries (Nos. 3, 4, 7, and 8).
Coke batteries Nos. 3 and 4 which are the oldest batter-
ies at Fairfield Works, will be dismantled approximately three months
prior to and No. 8 retired immediately prior to commencement of opera-
tion of the new coke battery No. 2. Coke battery No. 7 will continue
to operate until the end of its economic life.
These changes at Fairfield will continue existing coking
capability at Fairfield, and replace existing blast furnace operations
at Ensley which will also restore lost Ensley steelmaking capability
caused by shutting down of the uncontrolled open hearth furnaces. Reli-
able operation of No. 8 blast furnace at design specifications will
permit phase-out of Ensley Blast Furnaces 1, 2, and 3 and result in
increased iron production above pre-1972 capabilities of 602,900 ton/yr.
At the 3.5 million ingot ton per year production capa-
city, the screening and sinter operations at Wenonah operate at full
capacity. This operational status will not change with the new faci-
lities.
Third Q-BOP. The third Q-BOP furnace will allow the
required maintenance to ensure that the two Q-BOP shop will consis-
tently produce the 3.5 million ingot ton capacity for which the shop
3-44
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was designed. Treatment facilities existing at this shop were
designed for the operational capacity of 3.5 million ingot tons yearly
production and will not change. Oxygen supply facilities will pre-
vent simultaneous operation of all three Q-BOP furnaces at any time.
Consistent operation of the Q-BOP shop with implementation of Blast
Furnace No. 8 will increase the effluent from this facility from 1.0
mgd to 1.3 mgd to the final effluent control pond.
Coke Battery No. 2. The long-range program to replace
four old coke batteries with a new modern coke oven battery will not
result in added effluent discharge from the Coke Plant.
3.1.3.2. Changes in Ensley Operations
Cessation of operations of the blast furnaces at Ensley
will cause substantial reductions in the wastestreams entering Village
Creek. Flow from Outfalls 002, 003, 004, and 005, which consisted of
water cooling operations and blowdowns, will be decreased an estimated
9.9 mgd. The flow from Outfall 003, which comes from the cooling towers,
will continue at a reduced flow since the cooling towers will be re-
quired for remaining Ensley operations. Flow from Outfalls 002 and 004
will cease with the closing of the three blast furnaces.
3.1.4. Meteorology and Climatology
3.1.4.1. General
The climate of the Jefferson County area is temperate
and continental with relatively short moderate winters and long warm
summers.
For the period of record, Jefferson County's monthly
temperatures show a range from a January mean of 44°F to a July mean
of 80°F. This 36°F annual range reflects (a) the effect of the
station's location with respect to the Gulf of Mexico to the south and
(b) the invasions of relatively cold air from the continental north
and west.
3-45
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The Jefferson County area receives an average annual
rainfall of 55 in. Precipitation has two maxima each year, one during
the winter months, and another, slightly lower, in July with a minimum
occurring during October. The greatest chance of flooding occurs in
the winter and early spring (December through March) when frequent
migratory storms bring general rains of high intensity. The second
peak occurs in July, in the form of conventional thunderstorms, during
the growing season. The maximum monthly snowfall of 11.8 in. occurred
in January of 1936, with 11.0 in. occurring in a single 24-hr period.
Historically, however, snowfall is seldom heavy enough to be important.
The geographic location keeps Jefferson County safe from the destruc-
tive winds of hurricanes but not from tornadoes. During the period
from 1930 to 1974 only one violent tornado (NOAA class F4 or F5)
touched down in Jefferson County and five strong tornadoes (classes
F2 and F3) occurred.
The location of the county's industrial belt, prevailing
southwesterly-northeasterly wind from June through November, and Red
Mountain have encouraged temperature inversions and hindered the dis-
persion of industrial and other air pollutants generated within Jones
and Opossum Valleys. Under clear skies and light winds a ground radia-
tion fog forms in these valley locations often. An inversion layer
forms directly above the fog but below this inversion layer pollutants
are emitted into an originally stable layer within the fog and are
brought to the ground in relatively high concentrations. Under opti-
mal conditions as a part of diurnal cycle such fogs can persist for
days in the valley, maintaining a lid to vertical dispersion.
3.1.4.2. Ambient Air Quality
A review of the data developed by the end of 1977
indicates that Jefferson County's primary air quality problem is sus-
pended particulate matter in the atmosphere and photochemical oxidants.
The areas with the highest total suspended particulates (TSP) concen-
trations center around the North Birmingham-Tarrant City area as well
3-46
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as much of the Leeds area. However, the Fairfield air quality sampling
station nearest to the Fairfield Works meets the primary ambient air
quality standards for particulate matter. Jefferson County has
recommended that the more intensive developments including industrial,
commercial, and residential land uses be encouraged within "cleaner"
areas. In addition to particulates, other pollutants currently
measured in Jefferson County include sulfur dioxide, carbon monoxide,
nitrogen dioxide, and total nonmethane hydrocarbons, all of which meet
Ambient Air Quality Standards according to the Jefferson County Board
of Health.
General trends over the past four years (1971-1975)
indicate that there have been substantial reductions in both total and
point source emissions. The total point source emissions in 1971 were
151,321 tons per year which is 93.5 percent of the total emissions,
but by 1975 there was a 62 percent reduction achieved and the point
source emissions were down to 57,180 tons per year.* It was evident
from the data provided by Jefferson County that these reductions in
total point source emissions were still continuing in the years 1976
and 1977, but the running averages of TSP obtained at the Jefferson
County monitoring stations are not significantly different than the
Air Quality Standards in 1977. To obtain a plan for attainment for
1977 and maintenance of air quality standards in Jefferson County both
the state and county programs have been assigned tasks to analyze and
define the additional control requirements necessary to achieve the
Federal Air Quality Standards.
As a result of the measured violations of Federal Primary
Ambient Air Quality Standards for TSP in some areas of Jefferson
County, and photochemical oxidants, the U. S. Environmental Protection
Agency designated the entire county as a non-attainment area and thus
the schedule established by the State is for the development of non-
attainment SIP revisions.
*Annual Progress Report of Jefferson County Health Department,
October 1975 - September 1976.
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3.1.5. Topography and Geography
3.1.5.1. Plant Site Location
The plant site is located in southwestern Jefferson
County, Alabama. Jefferson County, Alabama, with the City of Birming-
ham as its principal urban center, is situated within a geologically
complex terrain. The topography of the county imposes natural controls
upon land use and will continue to do so in the future. Urbanization
in and surrounding the City of Birmingham has taken place where these
natural controls are not so restrictive. Elsewhere the parallel
northeast-trending ridges and valleys tend to guide and even restrict
development to a linear pattern.
To the south and east of the plant site lies Red
Mountain (elevation 950 ft). To the north of the plant site lies Sand
Mountain (elevation 700 ft). Between the Red Mountain and Sand Mountain
formations lie Jones and Opossum Valleys. These valleys are in turn
divided by a low ridge known as Enon Ridge or West Red Mountain to the
northeast and Flint Ridge to the southwest. Opossum Valley is also
known as Pinson Valley in its northeasterly extremity. Both Jones and
Opossum Valleys are wide, flat bottomed valleys.
Elevations within Opossum Valley range from 500 to 540
ft. near the project site. The valley is about one mile wide in this
vicinity. Located to the immediate southeast of Opossum Valley, over
Flint Ridge in the larger Jones Valley is much of the City of Birming-
ham. Jones Valley, approximately 8 miles in length, ranges from 2 to
4 miles in width.
3.1.5.2. Drainage Pattern^
The drainage patterns of the streams of the Jefferson
County vary with the underlying geologic provinces. Drainage patterns
in the Cumberland Plateau section in the western part of the county
are dendritic in form.
In the Valley and Ridge province in the eastern half of
the county drainage follows the trellis pattern of flow. To the
3-48
-------
northwest of the Opossum Valley plant site the topography is generally
of moderate relief and representative of the Cumberland Plateau. It is
sparsely populated with development generally restricted to the upland
areas as the low order streams occur in gorgelike and heavily tree-lined
valley sections.
Three principal streams are potentially affected by the
proposed action within Jefferson County. These streams are Village,
Valley, and the Locust Fork of the Warrior River, Figure 3-9. The
headwaters of Village and Valley are within the metropolitan boundary
of Birmingham and adjacent urbanized communities. Urbanization, there-
fore, has some effect on these streams. Extensive development has
taken place and is continuing on the flood plains along these two
streams. Development is primarily through encroachment into the
flood plains by filling with materials from grading operations for new
commercial and industrial building sites, highways, and residential
development adjacent to the flood plains.
Valley Creek flows southeasterly through Jones Valley
receiving the flow of Opossum Creek draining the southwestern part of
Opossum Valley. Valley Creek, at a point west of Bessemer, then
sweeps westerly to the Warrior River. These two streams drain the
parallel Opossum and Jones Valleys. Each follows the trellis pattern.
The trellis stream system form can be characterized by a modified
dendritic (finger-like) configuration with parallel tributaries and
short parallel gullies at perpendicular angles. The pattern is indi-
cative of the underlying bedrock structure, which is tilted inter-
bedded, sedimentary rock in which the parallel channels follow the
strike of the beds.
For Valley Creek the length of the study reach included
is about 29 miles and drains about 85 square miles. Streambed slopes
average about 10 feet per mile with maximum slopes of approximately
20 ft/mile. Characteristics of the basin include steep to gently
rolling topography. Urban development (industrial, commercial, and
residential) has occurred primarily within the upper miles of the
reach. The main channel has been partially modified by channelization
3-49
-------
GO
i
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o
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£
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73
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LEWIS SMITH
RESERVOIR
-------
and urban development and some overland drainage devices such as
curbing, guttering, and storm sewering exist.
Village Creek flows southwesterly along the floor of
the northeastern part of Opossum Valley to Ensley then runs westerly
to the Warrior River. Five Mile Creek flows westward from the Pinson
Valley into the Warrior River. In addition, there are numerous other
tributaries of these streams that follow this same generally westward
flow. The creek locations are depicted in Figure 3-10 with the topo-
graphical map designations.
Slopes. The preceding discussion of topography pro-
vides an indication of the development problems posed by the predomin-
ant slope conditions in Jefferson County. Figure 3-11 reveals the
areas within the county meeting different slope criteria. Areas having
slopes ranging from 0 to 10 percent are suitable for most types of
development and should be prime industrial development areas from the
standpoint of this factor. Commercial, residential and agricultural
development generally are suitable for areas having a 0 to 10 percent
slope as well as 10 to 20 percent slope areas, but generally are not
recommended for the areas exhibiting slopes in excess of 20 percent.
Industrial development is generally not recommended for areas having
slopes greater than 10 percent.
The relative proportions of Jefferson County falling
into the various slope categories are shown in Tables 3-8 and 3-9.
The areas of relatively level lands are concentrated in the Jones,
Opossum, Pinson and Shades Valleys.
3.1.5.3. Erosion
The identification and subsequent control of critical
erosion areas is of prime importance in any water quality management
program. This is especially true in areas of urban development such
as Opossum and Jones Valleys where soil erosion can increase to as
much as 25,000 tons per year on a square mile of land. Areas subject
to erosion in Jefferson County include most areas of sloping soils
where the protective vegetation has been removed, such as cuts and
3-51
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C—' j-J
GREENWOOD
U. S. Steel Facility
FIG. 3-10.
USGS TOPOGRAPHIC MAP SMALLSCALE
COVERAGE OF JEFFERSON COUNTY AND
U. S. STEEL CORPORATION PLANT SITE
-------
. S. Steel Facility
FIG. 3-11
SLOPE MAP
LEGEND
SYMBOL SLOPE
cn
0- 10%
10-20%
20% or MORE
-------
TABLE 3-8
SLOPE CONSTRAINT AREAS
DEGREE OF SOIL LIMITATION DUE TO SLOPE
LAND USE
Septic Tank Absorption Fields
Sewage Lagoons
Shallow Excavations
Dwellings
Sanitary Landfill
Local Roads and Streets
Road Fill
SLIGHT
0 - 8%
Less than
2%
0 - 8%
0 - 8%
0 - 15%
0 - 8%
0 - 15%
MODERATE
8 -
2 -
8 -
8 -
15
8 -
15
15%
7%
15%
15%
- 25%
15%
- 25%
SEVERE
More than
More than
7%
More than
15%
More than
15%
More than
25%
More than
15%
More than
25%
3-54
-------
TABLE 3-9
SLOPE COVERAGE, JEFFERSON COUNTY, ALABAMA
AREAS ACRES SQUARE MILES % OF COUNTY
0 - 10% Slope 246,297 384.8 47.8
10 - 20% Slope 112,827 175.2 16.4
20% Slope or More 328,852 515.0 35.8
TOTAL 687,976 1,075.0 100.0
3-55
-------
fills, road banks, mining areas, as well as those areas undergoing
development for subdivisions and industrial sites.
Areas with a high potential for erosion can be
identified both by steepness of the slopes and the associated soil
credibility factors. These areas can be located by using technical
data and soil maps available for the Jefferson County area. Each
soil is assigned an credibility factor. This factor, combined with
the percent slope, gives a potential erosion value. This value can
be used in determining those areas that need special care during site
development to prevent severe erosion problems. These sites benefit
from control measures such as quick revegetation, use of sediment
basins, grassed waterways and other methods which reduce water velocity
and trap sediment.
The site of the new blast furnace and associated facili-
ties has been designed so that all storm water drainage passes through
a final effluent control pond before release to Little and then Opossum
Creek. Primary treatment in the Final Effluent Control Pond consists
of sediment removal prior to release of storm water drainage from the
plant confines.
3.1.5.4. Outcroppings - Mineral Resources
The Birmingham anticline is the major structural feature
in the Fairfield Works area. It is a breached, asymmetrical anticline,
trending northeast, and is underlain by limestone, shale, sandstone,
chert, dolomite, and some iron ore seams. Rocks ranging in age from
Cambrian to Pennsylvanian crop out in the Fairfield area. The
Paleozoic sediments in the vicinity generally dip to the southeast
except where folded or faulted.
3.1.6. Geology
Jefferson County, Alabama, lies partly in the Valley and
Ridge province and partly in the Cumberland Plateau. The boundary
between the two crosses the county on the northwest side of Opossum
Valley and passes through the U. S. Steel Fairfield Works site.
3-56
-------
3.1.6.1. Geologic Provinces
The Valley and Ridge Province. The Valley and Ridge
province in Alabama represents the southern end of the great Appala-
chian Valley that extends northeastward to Canada. It slopes gnerally
southwest and is drained by the Coosa and Cahaba Rivers and is shown
in the series of northeasterly trending local subdivisions in
Figure 3-12. Local subdivisions include the Weisner Ridges, Coosa
Valley, Coosa Ridges, Cahaba Valley, Cahaba Ridges, and the Birmingham-
Big Canoe Valley. The rocks of this region are sandstone, shale,
limestone, and dolomite of Paleozoic age that have been strongly
folded so that they lie in great arches* and troughs.** The di-
stinguishing topographic feature of this province is the series of
parallel ridges and valleys all having a northeast trend. The valley
floors range in altitude from 500 to 900 feet and the ridges from 1,000
to 2,100 feet above sea level Cahaba Valley, lying between the Coosa
Ridges and the Cahaba Ridges, extends for 75 miles northeastward
across Bibb, Chilton, Shelby, Jefferson, and St. Clair Counties. The
Birmingham-Big Canoe Valley, which lies west of the Cahaba Ridges,
is an anticlinal limestone valley 4 to 8 miles wide that extends for
90 miles from Etowah County into Tuscaloosa County.
The Birmingham-Big Canoe Valley subdivision is divided
into Opossum Valley on the northwest and Jones Valley on the southeast.
Each part of the Birmingham Valley follows the crest of an anticline.
They are separated by a low synclinal ridge, which becomes Blount
Mountain, to the northeast.
Extending the length of Jefferson County on the east
side of Jones Valley is Red Mountain, formed by the southeastward-
dipping beds of the Red Mountain formation, which stand in a prominent
northwestward-facing scarp conspicuous from any point in the Birmingham
Valley.
*anti dines
**synclines
3-57
-------
FIG. 3-12. PHYSIOGRAPHIC PROVINCES OF ALABAMA
3-58
-------
The rocks of the Valley and Ridge are folded, faulted,
otherwise deformed by mountain-building processes in the geologic past.
It is this history of deformation that caused the belted pattern of
rock formations shown in Figure 3-13 and is responsible for belts of
the same formation appearing repetitively across the grain (northwest
to southeast).
The last major episode of erogenic activity affecting
the south end of the Valley and Ridge province of the Southern Appa-
lachians occurred toward the end of the Paleozoic Era, when sediments
collecting along the eastern edge of North America for many millions
of years were buckled and fractured into a long, high range of moun-
tains. This mountain building episode has been called the Allegheny
orogency. It resulted in the basic structure of the Valley and Ridge
province that extends from Alabama northeast to Canada. In Jefferson
County, as elsewhere throughout the Valley and Ridge province in
Alabama, the structural trend is southwest. A series of anticlines
and synclines, paralleled by thrust faults and cut by cross faults,
extends across the county.
The stream courses of the Valley and Ridge are closely
related to the structure and composition of the rocks. Erosion sub-
sequent to mountain building etched resistant rocks into ridges
whereas areas of "weaker" (softer) rocks became valleys. Most of the
smaller streams are in the northeast-southwest trending valleys.
However, the larger streams turn to the northwest, flowing at
essentially right angles to this structural "grain," possibly having
originally been guided by rock fractures perpendicular to the grain.
The Valley and Ridge province is underlain by sedi-
mentary rock strata now tilted and folded. Valleys are generally
floored by shales and limy shales, or by limestones. The dolomites
and sandstones form ridges. The floors of the anticlinal valleys,
Opossum and Jones, rise above the elevations of the Warrior Basin
causing drainage from the two Valleys to the Warrior Basin to the
northwest.
3-59
-------
ALABAMA
FIG. 3-13. MAJOR STRUCTURAL FEATURES IN NORTHWESTERN ALABAMA
3-60
-------
The Opossum-Murphrees anticline brings up rocks of
Cambrian and Ordovician ages. These outcrop in the northern part of
Birmingham and extend to the northeast along Murphrees Valley. The
Birmingham anticline, occupied by Jones Valley, extends to the north-
east where it joins the anticline occupied by the Coosa River in
Etowah and Cherokee Counties. Separating the anticlinal valleys is
the Blount Mountain syncline, which is low in the vicinity of the
U. S. Steel Fairfield Works site and the City of Fairfield, but forms
Blount Mountain in the northern part of the county.
3.1.6.2. Structural Considerations of Regional Geology
Jefferson County is geologically underlaid by deposits
of sandstones, shales, chert, dolomites, and limestones (Figure 3-14).
The Hartselle sandstone is a stable rock with a high weight-bearing
capacity, often occurring in steep terrain. Its weight-supporting
capacity is generally superior, but excavation can be a problem. The
Red Mountain formation, consisting of sandstones, shales and hematite
beds, contains many load bearing and excavation similarities to the
Hartselle sandstone. QTG consists of terrace gravels and sand,
generally offering a relatively stable foundation for construction as
contrasted to QAL which consists of alluvial flood plain deposits of
questionable value because of their location. These geological forma-
tions, except for QAL, run along the crest of the Red Mountain ridge
throughout its extent and spread out in patchy deposits in the north-
eastern portion of the county.
Construction in Jefferson County in areas underlaid by
limestones should be preceded by an engineered site analysis of the
foundation conditions.
Local geologic conditions at the plant site have been
further delineated by test borings at the location of the proposed
Blast Furnace No^ 8. Twelve test borings were drilled at the locations
shown in Figure 3-15. Each boring was advanced through the soil
overburden to the top of rock by a wash-boring method without sampling
3-61
-------
AREAL GEOLOGY
LEGEND
GEOLOGICAL FORMATION
HARTSELLE SANDSTONE, QTG, and RED MT.
FORMATION
FORT PAYNE CHERT
POTTSVILLE FORMATION
KNOX GROUP, KETONA, CHEPULTEPEC, BIBB,
and BRIERFIELD DOLOMITE ALLUVIUM, PEN-
NINGTON SHALE, CONASAUGA. BANGOR,
CHICKAMAUGA, WARSAW LITTLE OAK and
GASPER LIMESTONES
BROOKSIDE
ADAMSVILL
'"0. PLEASA^f^ GROVE
-------
LU
g
O
500 S
LU
§
LU
z
LU
CTt
CO
600 S -
PROFILE 1
B-14
B-13
PROPOSED FURNACE CENTERLINE
700 S -
PROFILE 2
PROBABLE
BOUNDARY LOCATION
800 S -
B-3
FIG. 3-15. BORING PLAN
-------
of the soils penetrated. When refusal (indicated top of rock) was
attained, wireline drilling tools were introduced into the bore hole.
The findings of the test borings indicate the location
of the geologic boundary between the Ketona Dolomite and the Consauga
Formation. Coring B-18 is located roughly 120 feet west of the pro-
posed furnace center and encountered Ketona Dolomite throughout its
depth. Borings B-19 and B-21 encountered interbedded limestones and
dolomites which are believed to be a transitional phase between the
two units. The rock is similar to that found in B-2 of the Preliminary
Investigation and probably belongs to the Ketona Dolomite. The
probable boundary location is shown on the Boring Plan.
The boring data also indicate that the proposed furnace
location overlies a zone of deep weathering and cavitation as indicated
on the Generalized Boring Profiles shown in Figure 3-16. The "Base
of Serious Weathering" is derived from visual inspection of the rock.
While these data are interpolations between borings and smaller,
deeply-weathered zones may be present east of Boring B-ll, the trends
present in Borings B-13A, B-14, and B-15 are obvious.
3.1.6.3. Geologic Structures Influencing Ground Water and Ground
Water Resources
The rocks that crop out in Jefferson County near the
project site can be divided into seven groups, based on the character
and occurrence of the ground water which they contain. In these groups
are found rocks of similar lithologic character and physiographic
expression. The formations from the most ancient to the geologically
youngest are:
1. The Rome formation.
2. Conasauga limestone.
3. Cambrian or Ordovician dolomites.
4. Ordovician limestones.
5. Red Mountain formation.
6. Mississippi chert and limestones.
7. Pottsville formation.
3-64
-------
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B.T. 1-°
RELATIONSHIP OF RQD AND ROCK QUALITY
DESIGNATION (RQD)
ROCK QUALITY
.00-.25
.25-.50
.50-.75
.75-.90
.90-1.00
Very Poor
Poor
Fair
Good
Excellent
B-16
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B.T.
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LOSS OF
DRILLING FLUID*
WATER TABLE —
TIME OF BORING
WATER TABLE —
24 HOURS
DOLOMITE
VOID OR
FILLED CAVITY
BASE OF SERIOUS WEATHERING
(INTERPOLATED BETWEEN BORING)
DRILLING IN SOIL
RECOVERY
T95~ROCK QUALITY DESIGNATION (RQD)
END OF CORE RUN
B.T. BORING TERMINATED
EXISTING GROUND SURFACE
B-20 B-19 B-21
oo
84~
%-WQ
7/ '78
f^-100
^ .80
B.T. el
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B.T.
FIG. 3-16. BORING PROFILE
-------
These formations are shown as they occur in the follow-
ing generalized geological cross section of the Fairfield Works area
(Figure 3-17). A detailed discussion of each of these groups is pre-
sented in the Technical Support Document.
3.1.7- Soils
3.1.7.1. Soil Types Occurring
Jefferson County is divided into two major soil areas
with subdivisions based on the geological character of the parent
materials from which the soils were formed. The two major soil areas
of Jefferson County are the Limestone Valleys and Uplands area and the
Appalachian Plateau area. A detailed discussion of these soil types
is presented in the Technical Support Document.
Soils of Site. Soils of the U. S. Steel Corporation
plant site are in a disturbed condition due to the activities associa-
ted with past construction and industrial activities. Excavations
as well as fills and grading operations have greatly altered the sur-
face distribution of natural soils occurring over the entire plant site.
Based on test boring records of the Law Engineering Company, fills
have been identified at the site of No. 8 Blast Furnace that range from
0.7 feet deep to 12.5 feet deep. The fill overlies a thicker layer of
firm to very stiff red, silty clay which in turn overlies a hard, red
and tan silty clay.
3.1.8. Hydrology
3.1.8.1. General
In the Birmingham area, water is available from surface
streams and groundwater aquifers. Due to the wide variability of flow
exhibited by the natural surface water streams, flow-regulated reser-
voirs are necessary to guarantee water availability. The median flows
of unregulated streams in Alabama range from 7 to 75 percent of their
3-66
-------
L-r-t , f . /. / .''COPPER RIDGE DOLIMITE
/ /_—_-t _X ~-L—*-, r-~ r— T* 7—*~
/_ / 7 7 7 I I .A
FIG. 3-17. GENERALIZED GEOLOGICAL CROSS SECTION OF F AIRFIELD AREA
SOURCE: GEOLOGICAL SURVEY OF ALABAMA
-------
average flows. In general, for the State of Alabama, the median
streamflow is approximately 60 percent of the average streamflow.
Groundwater serves as the dry weather source to area
streams as well as a source of water supply for many users. In
Jefferson County, groundwater is found in both water table and
artesian conditions.
3.1.8.2. Black Warrior River Basin
Fairfield Works, the site of the proposed new source,
is located within the Black Warrior River Basin. This is the second
largest river basin in the State of Alabama with a drainage area of
approximately 6,300 square miles. Figure 3-9 depicts the Black Warrior
River System above Bankhead Lock and Dam.
Approximately one (1) million people are found within
the area drained by the Black Warrior River System. Rivers within
this system display a flashy response to high rates of rainfall.
However, geological formations do not permit sufficient sustenance of
dry weather flow by groundwater reservoirs. Consequently, low flow
is a limiting factor from the standpoint of water quality attainment
within the Basin.
For the Basin, the average annual precipitation is 52
inches and is approximately evenly distributed throughout the year.
The average annual runoff is approximately 20 inches.
3.1.8.3. Stream Flows
Normal Flows. The major tributaries to the Black
Warrior River are Sipsey Fork, Mulberry Fork, and the Locust Fork.
Table 3-10 presents a summary of published streamflow data (United
States Geologic Survey and Alabama Geologic Survey) for Jefferson
County. Very little extended monthly or daily flow information exists
for streams in the western portion of the county, with the exception
of Turkey Creek. Turkey Creek has been monitored continuously since
1944 and mean monthly hydrographs are exhibited in Figure 3-18 for a
period from 1951 through 1970. Given this extended period of record,
3-68
-------
co
i
<£>
TABLE 3-10
STREAMFLOW DATA AVAILABLE FOR STREAMS IN JEFFERSON COUNTY
Station
Number
StreamfloH
02423570
02423573
02423580
02423620
02423623
02423625
02423630
02423639
02455800
02455990
02456000
02457000
02457500
02457650
02457700
02458150
02158200
UP.158500
02459000
02459300
02459500
02460000
02460500
Hit 60505
02461400
02461500
02462000
02462040
02462080
Station Dally or Annual Peaks
Name Monthly figures (water years)
(calendar years)
Shades Creek at Irondale 1960-71
Shades Creek near 1968-
Mountaln Brook
Shades Creek at Momewood 1968-
Little Shades Creek at
Alabama Hwy 150 near
Bessemer
Unnamed tributary to Little
Shades Creek near Bessemer
Shades Creek at Hopewell , 1968-72
Shades Creek at 1964-65; 1966- 19661
Greenwood
Mud Creek near Greely
Gurley Creek near Trafford
Turkey Creek at Morris 1944-1
i i
five Mile Creek at Ketona 1953-50 1959-
Flve Hlle Creek at larrant 19361
City
Five Hlle Creek at Cardiff ,
Five Hlle Creek at Lynn 1965
Crossing
Village Creek at East Lake
In Birmingham .
Village Creek at Apalachce "7I~
Street In Birmingham .
Village Creek at Ensley 1936 ,
Camp Branch near Ensley 1909-10
Bayvtew Reservoir
Venison Branch near Hulga . -
Village Creek near Mulga 1909; 1910 ' ,
Village Creek near 1953-58; 1964-65 , 1959-64; 1966-72
Adamsvtllc 1973-
Vlllage Creek at
Porter
Valley Creek at
Brighton .
Valley Creek near Bessemer 1936
Valley Creek near Oak 1936: 1953-50: 1959-63; 1966
Grove 1964-65'
Grove
Mud Creek near Oak Grove
. , - ., , . _. ..
Low Flow
Measurements
(water years)
1948. 1964
1971, 1972
1971, I
-------
FIG. 3-18.MONTHLY MEAN HYDROGRAPHS FOR GAGING STATION ON TURKEY CREEK
-------
the Alabama Geologic Survey has constructed a flow-duration curve for
Turkey Creek (Figure 3-19). If it is assumed that this relationship
is applicable to the major tributaries of the Black Warrior River, the
following flow frequencies could be expected.
Flow Expectancy
Drainage Area (mgd)
Stream (sq mi) <1% <25% <5%
Sipsey Fork 1,000 10,000 1,000 100
Mulberry Fork 2,366 23,660 2,366 237
Locust Fork 1,227 12,227 1,227 123
Black Warrior River 6,300 63,000 6,300 630
Drought Flows. The Alabama Geologic Survey has tabulated
extreme low flow data, for several streams in the Black Warrior River
Basin, in sufficient detail to permit prediction of the magnitude of
extreme low flow to be expected at recurrent intervals. Based on this
collection of data, the most extreme drought per year of 14-days dura-
tion was selected to represent adverse conditions from water quality
conditions. A graphical technique (Gumbel) was used to calculate
recurrence intervals for critical drought flows. A summary of this
investigation is presented in Tables 3-11 and 3-12. The reader is
referred to the Technical Support Document for details.
Flooding. The highest stages on record for several
streams in Jefferson County were observed following the storm of
March 19, 1970. The National Weather Service at Birmingham Municipal
Airport recorded 6.91 inches of rainfall with 4.73 inches falling
within a six-hour period beginning at 6 AM. The durations, intensities,
and recurrence intervals for this storm were computed from the records
of the Birmingham Municipal Airport and are presented in Table 3-13.
Figure 3-20 provides a map of the flood prone areas
near Fairfield Operations for the 100-year storm. Inspection of this
map reveals that the area of flooding does not include Fairfield
Operations to any appreciable extent.
3-71
-------
100-
at
-J
UJ
3
o
o:
UJ
a.
-------
TABLE 3-11
AVERAGE 14 DAY LOW FLOWS
Location
Discharge (cfs) Period Averaged
Sipsey Fork at Sipsey (Pre-Dam) 52.6
Mulberry Fork at Cordova 122.4
Locust Fork at Sayre 52.1
Locust Fork at Bessemer 181.7
(Before Inland Dam)
Five Mile Creek at Ketona 7.1
Valley Creek at Oak Grove 114.0
1929
1901
1946
1929
1936
1911
1962
1935
1954 - 1957
1954 - 1957
3-73
-------
TABLE 3-12
SUMMARY FOR VARIOUS TIMES OF RECURSION FOR EACH STREAM
14-DAY LOW FLOW CONDITION
3 yr
A 41.0
B 29.0
C 70.0
D 36.0
E 6.0
F 65.0
G 108.0
4 yr
32.0
25.0
57.0
30.0
5.4
0
103.0
5 yr
27.0
22.0
49.0
29.0
4.9
0
100.0
6 yr
23.0
20.0
43.0
28.5
4.6
0
98.0
10 yr
10.5
12.0
22.5
28.0
3.7
0
92.0
20 yr
0
4.0
4.0
27.5
2.4
0
79.0
40 yr
0
0
0
23.5
1.2
0
75.0
50 yr
0
0
0
23.0
0.8
0
71.0
A - Sipsey Fork, Sipsey
B - Mulberry Fork, above
C - Mulberry Fork, below
D - Locust Fork, Sayre
E - Five Mile Creek
F - Locust Fork, Bessemer
G - Valley Creek
3-74
-------
TABLE 3-13
STORM OF MARCH 19, 1970
Elapsed Time Accumulation Intensity Recurrence Interval
(hr) (in.) (in./hr) (yr)
0.5 0.90 1.80 1
1.0 1.32 1.32 1
2.0 2.42 1.21 2
3.0 3.12 1.04 5
6.0 4.56 0.76 20
12.0 6.57 0.55 40
24.0 7.07 0.29 30
3-75
-------
fW® ^
° l-wi i••-•.4\ • • px^-vMwlr^w^
i /A \\11 U---; 'r4 « ? aV/,'/ / CJx.' i', / < . 5: IS ^°/;v l;/^'.
FIG. 3-20. MAP OF FLOOD PRONE AREA FOR THE 100-YEAR FLOOD
NEAR FAIRFIELD OPERATIONS
3-76
-------
3.1.8.4. Groundwater Aquifers
Figure 3-21 depicts the availability of groundwater in
Jefferson County. Several formations are present which are important
from water supply considerations.
The Conasauga Formation supplies a number of wells in
Birmingham with yields ranging from 50 to 100 gallons per minute (gpm)
The Conasauga formation is a limestone formation and, as such, is
comprised of large reservoirs (solution channels) and also areas in
which these solution channels are widely spaced. These latter areas
provide relatively low yields to dug wells. The Conasauga formation
feeds some large springs, e.g. Picket and Spencer Springs on the out-
skirts of Bessemer.
Other groundwater formations in the Jefferson County
area include the Ketona, Copper Ridge, Chepultepee, Chicamauga, Fort
Payne, Bangor, and Pottsvilie formations.
3.1.9. water Quality
3.1.9.1. Existing Water Uses
3.1.9.1.1. Consumptive Uses of Water
A consumptive use of water is one which alters one
or more of the physio-chemical properties of the water. Consumptive
uses of water in Jefferson County include water supply, agriculture,
forestry, waste disposal, and mining.
Potable and Process Water Supply. Table 3-14 presents
information concerning the quantities of water utilized for various
purposes in Jefferson County. Inspection of this table reveals that
surface waters are a major source of public water supply while ground-
water provides the principal source of rural domestic water supply.
For the Birmingham area, important sources of water supply include
Lewis Smith, Lake Purdy, Inland Lake, and the Cahaba River.
3-77
-------
I
Water-bearing rock
Limestone, dolomite
and chert
Above + Sandstone
Above + Shale
Yield
Greater
than 0.5 mgd
0.1 to 0.5 mgd
Generally less
than 0.1 mgd
Maximum well
depth (feet)
300-500
300-350
250-300
U)
00
j^KIMBERLY
Q MORRIS
FIG. 3-21. GROUNDWATER AVAILABILITY - AQUIFER DEPTH AND YIELDS
-------
TABLE 3-14
WATER USAGE (1970) - JEFFERSON COUNTY
AND THE STATE OF ALABAMA
Use
Self-Supplied
Industry
Thermo-Electric
Jefferson County
Groundwater Surface Water
(MGD) (MGD)
5.10
69.55
Source: Alabama Geologic Survey, 1970.
Alabama
Groundwater Surface Water
(MGD) (MGD)
Public Water Supply
Rural Uses
Domestic
Livestock
Irrigation
Catfish Fanning
4.18
4.68
0.18
0.07
0.00
131.40
-
0.13
0.16
0.02
103.07
62.86
12.81
5.37
6.59
362.74
-
14.50
12.48
5.36
90.93
996.26
Power
Total
0.00
14.21
0.00
201.26
2.70
284.33
5,021.10
6,412.44
3-79
-------
Agriculture. Agriculture is not a major activity in
the Birmingham area due to lack of suitable land. Agricultural
activities in the Birmingham area are limited primarily to truck
farming. Consequently, consumptive use of water within the area
due to agricultural activities is minimal.
Forestry. Large portions of northwestern Jefferson
County and adjacent counties are forested and support a range of
industrial roundwood products. The woodlands are a mixed hardwood
and softwood stand that is primarily in private ownership. Harvest-
ing is accompanied by increased sediment loads to the receiving
streams.
Waste Disposal. The streams of Jefferson County
receive a variety of wastewaters from both point (municipal, industrial,
and commercial) and non-point (urban runoff, strip-mine runoff, etc.)
sources. Storm events cause a flushing of pollutants, accumulated
as a result of a myriad of activities associated with urban-industrial
areas, into receiving streams. Figure 3-22 exhibits schematically
many of the point source discharges to streams in the Birmingham
area.
Municipal sewage treatment plants serve portions of
Jefferson County (Figure 3-23). Currently only 97 of a total of 1,075
square miles of Jefferson County are serviced by public sewers. A
summary of existing and projected public sewer coverage for Jefferson
County is presented in Table 3-15. Figure 3-23 exhibits areas serviced
by public sewers in Jefferson County.
Mining. The Warrior coal field constitute a major
mineral resource of the area. Surface mining of coal modifies natural
surface drainage patterns and exposes earth materials as spoil banks
which contain soluble toxic materials. Mining operations create mill
tailings and processed materials which impair water quality and add
suspended materials to the streams.
3-80
-------
Co
I
CO
VILLAGE CREEK
VALLEY CREEK
FIG 3-22 SCHEMATIC SHOWING RELATIVE LOCATIONS OF INDUSTRIAL AND
' MUNICIPAL WASTE DISCHARGE POINTS VILLAGE CREEK
-------
. S. Steel Facility
FIG. 3-23.
PUBLIC SEWER SERVICE AREAS
LEGEND
CATEGORY
SYMBOL
PRESENTLY SERVED BY PUBLIC
SEWER SYSTEM
PROJECTED TO BE SERVED BY
PUBLIC SEWER SYSTEM
PROJECTED NOT TO BE SERVED
BY PUBLIC SEWER SYSTEM
-------
TABLE 3-15
PUBLIC SEWER COVERAGE, JEFFERSON COUNTY, ALABAMA
Existing
Projected for 2000
Non-Sewered for 2000
Total
Acres
61,918
81 ,869
544,189
687,976
Square Miles
97.0
128.0
850.0
1,075.0
% of Total
9.0
11.9
79.1
100.0
Source: Birmingham Regional Planning Commission.
3-83
-------
Figure 3-24 exhibits overall land use practices in
Jefferson County and delineates the extent of industrial and com-
mercial land, residential land, agricultural land, surface extraction,
and open land.
3.1.9.1.2. Non-Consumptive Water Use
Activities in the Birmingham area which utilize water
in a non-consumptive manner include recreational activities, naviga-
tion, and hydroelectric power generation.
Recreation and Fishing. Commercial and sport fishing
exist in Bankhead Reservoir on the Black Warrior River and certain of
its tributaries. Other types of water related activities such as
boating, water skiing, and camping are also pursued.
Navigation. There is both commercial and pleasure craft
traffic on the Locust Fork of the Black Warrior River. Commercial
vessels serve as the link connecting the industries of the Birmingham
Region with the Gulf of Mexico. These vessels bring raw materials for
industry up the Black Warrior and transport various finished products
downstream to the Gulf. Navigation on the Black Warrior River is
possible through four locks and dams built by the U. S. Army Corps of
Engineers to provide a navigable channel from Mobile, Alabama to the
confluence of Locust and Mulberry Forks with the Black Warrior River.
Port Birmingham, a major water transportation facility
located in the Birmingham industrial area, provides a major terminal
for supply of raw materials to industries within the area. Cargo is
shipped by barge using the Warrior-Tombigbee River System.
The Waterway has provided a major feeder for commercial
traffic with present commercial traffic exceeding ten million tons
annually. The Waterway passes through 16 counties within the State of
Alabama with a number of these counties including the State's most
heavily developed areas. These counties consist of approximately 30
percent of the State of Alabama; 40 percent of its manufacturing
establishments; 44 percent of its industrial workers; and 50 percent
of its industrial payrolls.
3-84
-------
. S. Steel Facility
FIG. 3-24.
EXISTING LAND USE
LEGEND
SYMBOL CATEGOR\
tffiffij INDUSTRIAL and COMMERCIAL
i1 RESIDENTIAL
px?H AGRICULTURAL
I I SURFACE EXTRACTION
| | OPEN SPACE and PUBLIC
-------
Hydroelectric Operations. In 1963, the Alabama Power
Company constructed a 45,000 kw turbo-generator unit in the right
bank at the end of the gated spillway of Bankhead Lock and Dam. Con-
trolled releases for power generation are used to meet power peaking
demands.
On the Sipsey tributary to the Mulberry Fork of the
Warrior River, the Lewis M. Smith Hydroelectric Dam at river mile
451.3 provides water power to Birmingham and flow augmentation to the
downstream dams.
3.1.9.1.3. Existing Water Quality Management Plants
In accordance with PL 92-500 section 208, the 208 Study
for the Birmingham area is underway at this time.
The Birmingham 208 Study encompasses four counties:
Jefferson, Walker, Shelby, and St. Clair. Of these counties, Shelby
and St. Clair counties are in the Cahaba River Basin. The 208 Study
is an analysis of all water quality problems in the area, in which sig-
nificant point sources, stormwater runoff, and other non-point sources
are considered. The 208 Study will recommend water quality monitoring
and surveillance locations; review and update waste load allocations,
institutional and managerial arrangements; and evaluate and define
recommended environmental improvement alternatives.
The 201 Study, authorized under Public Law 92-500
section 201 has been completed for Jefferson County. A new facility
is being built for the Five Mile Creek STP* approximately eight river
miles downstream from the existing facility. The plant is scheduled
to be completed in the summer of 1977. Activated sludge and nitrifica-
tion processes are utilized.
A plant expansion for the Valley Creek STP continued
through the summer of 1976. The existing facility was upgraded with
activated sludge and nitrification processes. Break-in of this facility
is now underway.
*Sewage Treatment Plant
3-86
-------
Activated sludge and nitrification processes are now
being installed at the Village Creek STP. Plant expansion is scheduled
for completion in April 1978.
Black Creek Lagoon, Docena Treatment Facility, and
Westwood WTP will all be abandoned, and wastewater flows will be
diverted to Village Creek STP. Fultondale STP wastewater flow will
be diverted to Five Mile Creek STP. Valley Creek STP will receive
the flow from Carriage Hills STP which will be abandoned.
In June of 1976 the Alabama Water Improvement Commission
completed the water quality management plan for the Black Warrior
River Basin in accordance with Section 303 (e) of PL 92-500. This plan
summarizes information as to existing water quality, point and non-
point sources, wastewater treatment requirements and costs, and water
quality surveillance network needs. Projections to future needs are
also outlined.
3.1.9.2. Surface Water Quality
3.1.9.2.1. Existing Environment
As a result of the comprehensive water quality surveys
performed on Opossum, Valley, Village Creeks, and Bankhead Reservoir,
an accurate description of the water quality conditions occurring
during the period of the survey was obtained as presented in detail
in the Technical Support Document.
The results of the water quality surveys on Opossum
and Valley Creeks reveal that pollutants enter these streams from
both point and non-point source activities. Dissolved oxygen con-
centrations upstream of the confluence of Opossum/Valley revealed
oxygen deficits (indicating some biological activity). It must be
indicated that as a result of the biological surveys discussed else-
where in this document, only limited biological activity occurs in
either of these streams. After the junction of the two streams,
dissolved oxygen deficits and/or BOD data indicate continued bio-
logical activity and a high reaeration potential.
3-87
-------
The results of the water quality surveys with regard to
carbonaceous and nitrogenous oxygen demand and the dissolved oxygen
concentrations for Opossum and Valley Creeks (fall survey) are pre-
sented in Figures 3-25, 3-26, and 3-27.
The concentrations of zinc and iron drop off signifi-
cantly with distance down Opossum and Valley Creeks.
Generally, Opossum and Valley Creeks must be character-
ized as streams conducting large quantities of organics and nitrogenous
compounds capable of consuming significant quantities of oxygen. The
contribution of pollutants to these receiving streams results from
point and non-point source discharges.
Existing conditions occurring on Village Creek can
be characterized by streams conducting large quantities of organic and
nitrogenous oxygen-consuming materials with a substantially lower
impact on dissolved oxygen deficit due to the presence of inhibitory
materials. Dissolved oxygen concentrations measured on Village Creek
were low (approaching 0 mg/1) in certain portions of the stream
upstream of Bayview Lake.
During the period of this investigation, large quanti-
ties of primary treated municipal wastes were being discharged to
Village Creek as a result of the extensive construction activities
occurring at wastewater treatment facilities in the Ensley area. Con-
centrations of many pollutants appeared to be high above the discharges
of the municipal plant and the U. S. Steel facilities on Village Creek.
As previously indicated, the decay of carbonaceous materials did not
appear to be as inhibited on this stream as on Valley Creek and nitri-
fication appeared to be occurring in those segments of Village Creek
in which adequate oxygen was present for nitrifier activity.
Inspection of these data through Bayview Lake and the
lower end of Village Creek reveals that Bayview Lake served as a sink
for pollutants and tends to stabilize materials prior to their dis-
charge to the lower segments of Village Creek. Additionally, high
reaeration as a result of discharge over the dam on Bayview Lake and
the high reaeration occurring in the lower portions of Village Creek
3-88
-------
(Jj
do
/ /
FIG. 3-25. ULTIMATE CARBONACEOUS OXYGEN DEMAND - OPOSSUM AND VALLEY CREEKS - FALL SURVEY
-------
uo
OD
o
F,G. 3-26. NITROGENOUS OXYGEN DEMAND - OPOSSUM AND VALLEY CREEKS - FALL SURVEY
-------
FIG. 3-27. DISSOLVED OXYGEN BY WINKLER METHOD AND D.O. PROBE - OPOSSUM AND VALLEY CREEKS -
rALL
-------
tend to sustain dissolved oxygen levels which under other conditions
would be substantially suppressed as a result of the biological
activity of the large quantities of nitrogenous and organic oxygen-
consuming materials.
3.1.9.2.2. Existing Conditions on Bankhead Reservoir
Surveys were conducted on Bankhead Reservoir to estab-
lish existing water quality conditions and to evaluate the influence
of Village and Valley Creeks on Bankhead Lake. The majority of con-
taminant concentrations in Bankhead Lake were found to increase below
the confluences of Village and Valley Creeks. However, high concen-
trations of zinc and iron were measured upstream of the confluence
with Village Creek in Bankhead Reservoir. The pollutants observed
in Village and Valley Creek are substantially diluted by the larger
receiving body. The dissolved oxygen levels were not reduced below
7.1 mg/1 during any of the measurements of surface water taken in this
investigation.
In summary, it appears that Opossum, Valley, and
Village Creeks all are substantially influenced by point and non-
point discharges in the Birmingham area. The poor water quality con-
dition occurring in each of these receiving streams will preclude the
accurate projection of improved water quality conditions and discharge
levels. It further appears that the contaminants being discharged to
Village, Valley, and Opossum Creeks influence these streams throughout
their entire length and contribute substantially to the pollution load
occurring in Bankhead Reservoir.
3.1.9.3. Groundwater Quality
A number of wells have been completed and are operated
within Jefferson County. Chemical parameters have been analyzed for
some of these wells and for a number of springs by the Alabama Geologic
Survey (Table 3-16).
3-92
-------
TPSLE S 1*
CHEMICAL ANALYSES OF UATEK FROM SELECTED HELLS UK SPRINGS IN JEFFERSON COUNTY
co
i
vo
co
Water-bearing unit (geologic unit and rock type): Geologic unit; Ppv, Pottsvllle Formation; PHpw, Parkwood Formation; HI, Floyd Shale: Mb, Bangor Limestone; Hh. ilartselle Sandstone; Mfp, Fort Payne
Chert; Oc; Chickamauga Limestone; OCcu, Chepultepec Dolomite and Copper Ridge Dolomite undiffcremated; Ck, Ketona Dolomite; Ce, Conasauga Limestone. Rock type: ch, chert; dol. dolomite- Is lime-
stone; sh, shale; ss, sandstone.
Milligrams per liter
Hardness
as CaCO,
Well Owner
f Trafford
Town of Trafford
Warrior Ice Company
Birmingham Uater Uorks
Birmingham Water Uorks
Birmingham Water Uorks
Birmingham Water Works
City of Trussvllle
City of Trussvllle
City of Trussville
City of Trussville
City of Trussville
City of Trussvllle
City of Trussville
Birmingham Water Uorks
Birmingham Uater Uorks
City of Trussville
City of Trussvllle
City of Trussvllle
Birmingham Uater Uorks
Birmingham Uater Uorks
Birmingham Udter Works
r .
Town of new lastle
Town of New Castle
Birmingham Water Works
Birmingham Uater Uorks
Birmingham Water Works
Birmingham Water Uorks
Birmingham Water Works
Birmingham Water Uorks
Birmingham Water Uorks
Date of
collection
1950
1952
10-25-28
11-29-50
1951
9-2-52
12-12-69
2-8-68
2-9-68
1960
3-24-36
8-29-52
12-11-69
3-24-36
11-26-57
12-12-69
4-25-50
9-17-52
12-11-69
1953
7-26-58
12-12-69
3-17-50
9-26-52
6-6-46
1-29-47
8-28-52
10-2-52
1960
1-11 -61
1-15-61
Water-
bearing
unit
IP v ss
IPpv, ss
IPpv, ss
Ck, dol
Ck, dol
Ck, dol
Ck, dol
Mb 1 s
Mb. Is
Mb, Is
Mb, Is
Mb, Is
Mb, Is
lib. Is
OCcu, dol
OCcu, dol
Mb, Is
Mb. Is
Mb, Is
OCcu, dol
OCcu. dol
OCcu, dol
]P pv ss
IPpv. ss
OCcu. dol
OCcu, dol
OCcu, dol
Ck, dol
Ck, dol
Ck dol
Ck, dol
Well
deoth
(feet)
300
300
701
208
208
208
208
21 9
219
15C
18G
130
186
186
237
237
320
320
320
264
157
157
450
450
160
160
160
>
5
S
Silica
(Si02)
13
10.1
10. Q
8.9
9.2
10.0
-
5.1
6.0
-
6.3
8.1
7.8
13
7.8
3.5
3.5
3.4
12.4
14
6.3
10.8
8.4
9.7
5.5
Iron
(Fe)
.4
1.3
.6
. IS
.12
.03
.5
.7
.10
.00
.2
.1
.05
.16
2.1
.00
.3
.1
.02
1.3
2.9
.3
.25
.02
.47
.2
Cal-
cium
(Ca)
2B.3
40
26.9
25.7
32
34
50.1
39.3
48
44
32.5
31.2
32
54.6
49
55
17.6
13.0
30
45.2
24
24.3
25.4
29
32
42.2
Magne-
sium
9.2
14
14.0
11.1
16
IB
1.5
3.7
2.7
2.6
3.3
14.0
15
3.5
3.9
3.1
9.6
4.0
15
9.7
11
8.9
12.7
14
18
21.9
So-
ilum
._
23
4.0
1.2
l.B
-
2.4
1.5
1.7
4.2
.2
1.0
1.9
1.9
2.4
--
-
1.2
_
75
5.4
—
.8
1.2
1.9
Po-
tas-
sium
(K)
„
3.2
-
.4
1.0
-
.03
.7
1.2
-
.6
1.2
-
.8
1.0
-
—
.8
3.1
1.9
-
.2
.6
2.2
Bicar-
bonate
(HC03)
160 4
105.1
153
82.6
134 2
166
186
1 S6
156
158.6
122.0
152
149
127.5
164.7
164
100.1
170
172
61.7
158.6
162
110.2
287
123.1
133.0
145
175
236.4
Car-
bon- Sul-
ate fate
(C03) (SO,)
Q
.0
0
.0
Q
0
0
0
0
0
0
0
0
0
0
0
.0
0
0
.0
0
0
g
0
0
0
0
0
0
1 5 3
11.7
«.2
4.3
3 2
2.0
4.8
._
.9
18.9
2.2
3.3
2.3
2.0
2.3
3.6
3.4
3.9
3.3
1.2
2.7
30.9
28
trace
.8
1.2
1.6
8.2
Chlo- Fluo-
ride ride
(CD (F)
142
8.7
50
6.2
7 ]
2.5 0.0
2.7 .0
2.8
2.8
8.3
3.7
3.2 .1
2.4 .1
6.5
4.0 trace
:.a .1
5.3
2.5 .0
4.0 .1
7.9
6.8
2.3 .1
35
3.8 .0
9.9
2.8
2.8 1
2.8 .1
--
Dissolved
III- solids
trate (residue
(N03) at 180°C)
0.2
-
3.2
1.7
—
-
.05
.9
.0
-
1.6
1.5
-
1.1
3.0
-
—
1.4
.4
.3
-
3.4
. 5
-
21 7 0
274.0
288
129.0
136 0
143
155
—
128.0
-
143
135
-
225.2
146
169.0
160
163
79.0
132.0
142
225
305
-
143.0
123
144
321.8
Cal-
cium,
mag-
ne-
sium
QC 7
79. /
104.4
157
128.0
146
159
161
79
135.5
113. .1
131
121
94.8
136.8
142
154.1
138
150
84.8
90.0
137
1578
105
100.7
115.7
130
154
197.6
208
210
Specific
conauct-
Non- ance
car- (micro-
bon- mhos .it
ate 25°C pM
— 7.2
7.8
32
;.6
7 3
10 266 7.6
6 269 7.5
33 335 7.3
0 339 7.7
77
6.65
6 245 7.6
0 315 7.3
7.4
'/•. 5
7 251 7.4
7.4
0 268 7.6
9 274 7.3
7.6
7.6
4 251 7.4
7 0
0 491 8.0
7.6
7.3
11 235 7.6
10 278 3.0
7.5
6.2
6.9
Temperature
"C °F
16
—
IS
-
1 4
-
-
17
-
-
-
16.0
—
20
15.0
-
—
16.0
18
—
—
18
16
-
15
"
62
-
64
-
53
--
-
63
-
-
—
61
—
67
59
—
-
61
65
--
--
64
62
-
59
-------
3.1.9.4. Non-Point Water Quality
A storm event occurred on March 28, 1977, over the Opossum
Creek watershed. The rainfall was 0.67 inches. The runoff from this
storm was sampled by AWARE, Inc. in an attempt to characterize the loadings
to Opossum Creek as a result of non-point sources.
The Opossum Creek watershed is shown in Figure 3-28. This
watershed consists of all areas tributary to the U. S. Steel monitoring
station at river mile 2.77. This is a total tributary area of 10.05 sq mi
(6,450 acres). Of this total, 3.48 sq mi is in lower to lower-middle
class residential housing; 3.35 sq mi is in the heavy industrial land use
category. The remaining land is primarily unused and classified as fields
or wooded areas.
The rain storm that occurred on March 28, 1977, between
8:10 a.m. and 11:30 a.m. was the fifth storm event to have occurred over
the watershed during the month of March. The distribution and intensities
of the preceding storms are shown in relationship to the evaluated storm
event in Figure 3-29. The preceding storm events were greater in magnitude
than the measured event and spaced so that the antecedent moisture level in
the surface soil of the watershed was fairly high. The three preceding
storms could be expected to have provided a reasonable "flushing" effect of
surface pollutants by both their magnitude and the intervals between them.
A time of nearly 6 3/4 days elapsed between the last of the three major
storms and the smaller storm event that was monitored.
Figure 3-30 is the combined storm hyetograph-hydrograph for
the March 28, 1977, storm. The rainfall event had a duration of approxi-
mately 3 hr at an average rate of 0.22 in/hr. The hydrograph peak occurred
4 hr after commencement of significant rainfall and 1 hr after cessation
of significant rainfall. The surface runoff accounts for approximately
23 percent of the total rainfall which was consistent over the general
area (0.67 in. measured on site/0.66 in. at Birmingham airport).
Eight water quality samples for the parameters shown in
Table 3-17 were taken during the event. The stormwater hydrograph is
shown in Figure 3-30. Six of the water quality samples were taken on
3-94
-------
-------
2.59'
oo
1
S .98"
^r> I\A -«
I.
677 Hav« . •
\i
1.58"
1 "Storm Modeled"
9^ ,. „. fa "73 fit\ri < , —
i 111 it liti
5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
(DAYS OF THE MONTH OF MARCH)
FIG. 3-29. STORM EVENTS AND MAGNITUDES IN MARCH, 1977 PRECEEDING MARCH 28 STORM
-------
Q
(cfs)
160
150
140
130
120
110
100
90
80
70
60
SO
40
30
20
10
Opossum Creek RM 2.77
Tributary Area = 8.5 sq mi
Flow and Rainfall vs. Time
Baseflow 45 cfs
Legend
• Flow measure
O Sample point
1200 1300
© (§)
Time of day, hrs
1400 1500 1600 1700
FIG. 3-30. STORMWATER HYETOGRAPH-HYDROGRAPH OPOSSUM CREEK
MONITORING STATION RM 2.77 March 28,1977
-------
GO
I
CO
TABLE 3-17
MEASURED WATER QUALITY PARAMETERS - OPOSSUM CREEK RM 2.77 - MARCH 28, 1977 STORM EVENT
SjmpU1
No.
1
2
3
4
5
6
7
8
1 line
(hi]
0812
0848
09 1(.
0946
1015
1045
1145
1333
Alk.
(ms/l)
61
60
58
57
61
59
48
50
Cl
CN
(mg/l) (mg/l)
249
24.2
22.9
20.9
18.1
16.5
14.9
17.1
0.11
0.15
0.14
0.11
0.15
0.09
0.10
0.10
F
(mg/l)
1.39
1.88
1.00
1.10
1.30
0.90
090
1.48
Hard
(mg/l)
307
297
295
302
292
260
227
222
NI13-N
(mg/l)
.2
6.4
3.7
6.4
7.2
1.3
6.4
13.0
NO3-N NO2-N
(mg/l) (
mg/l)
1.66 2.20
.83
.69
1 05
8.15
3.81
.94
.69
.89
.90
.54
.18
.02
.92
.53
TKN
(mg/l)
12.2
10.5
10.5
6.7
10.4
10.1
17.6
16.1
O*G
(mg/l)
.6
.4
.2
1.2
10.2
6.6
5.4
.2
pH Phcnu
(mg/l)
7.1 .012
7.2 .012
7 2 .021
7.2 .059
7.2 .175
7.2 1 60
7.2 4.45
7.2 3.14
*.P04
(mg/l)
.06
.03
.03
.07
.05
.03
.03
.04
TP04
(mg/l)
0.40
0.40
0.40
1.3
.52
.65
.65
.65
55 IDS
(mg/l) (mg/l)
46 480
17 432
26 446
50 482
265 658
410 734
442 695
211 524
S04
(mg/l)
202
211
189
208
181
179
134
149
0
(cf<)
51.7
558
61.6
69.8
70.0
122.3
145.5
129 4
CBODU NOD
(ms/l)
24.1
25.2
303
32.0
32.3
39.2
41.6
35.6
(mg/l)
55.3
47.6
47.6
30.7
46.3
44.9
77.2
71.4
Cd
(mg/l)
<03
.07
.07
04
07
.07
.11
<03
Cr
(ug/l)
6
6
5
18
107
156
I81
34
Cu
ug/D
12
9
10
15
43
39
42
27
r>
(mg/l)
2.34
1.91
2.75
4.03
21 2
25.8
20.8
9.5
Mn Sn
(mg/l) (mg/l)
0.52 <06
0.55
0.55
0.65
1.14
1.01
1.51
0.52
Zn
(mg/l)
.27
.22
.27
.42
2.46
3.46
5.4
1.36
*Phenol discharges of 1.60, 4.45, and 3.14 mg/l are atypical. No explanation can be
given for these atypical phenol concentrations. They have not been measured at such
high levels before or since these figures were recorded, even during precipatation
events.
-------
the rising side of the hydrograph both to establish pre-storm water
quality conditions and to capture the first flush of the water quality
parameters. Samples were also taken at what proved to be the peak
of the stormwater hydrograph and on the declining side of the
hydrograph.
The peak mass-rates of many of the water quality para-
meters occurred simultaneously with the stormwater hydrograph peak
(Figures 3-31, 3-32, and 3-33) and declined more precipitously than
the stormwater hydrograph. This may indicate that for many of the
parameters, the storm "flushed" portions of the watershed of the sur-
face loading accumulated since the last major storm. A list of import-
ant parameters and their fluctuations during the stormwater discharge
follows in Table 3-18. The weight-rates recorded at times 0812 and
0845 reflect the ambient water quality conditions within Opossum Creek
prior to the introduction of appreciable portions of the non-point load
due to rainfall. The peak weight-rates recorded at times 1145 and
1333 for the heavy metals are a factor of 10 or more greater than the
ambient weight-rates recorded in the stream before the stormwater
flow.
Organics such as oil and grease, phenol, and cyanide
vary in their response to the storm. Oil and grease displays a defin-
ite early peak and returns to ambient concentrations in the stream.
Phenol rises to high levels and gradually declines with recession of
the storm hydrograph. The BOD and nitrogen series (except nitrate)
parameters do not have an early response to the hydrograph but increase
and decrease with the peak flow. This suggests that for some of
these important parameters, the rainfall recorded was inadequate to
mobilize and remove the pollutant. Concentrations and weight rates
are shown for CBODu and NOD in Table 3-19.
The stormwater quality study of the March 28, 1977
storm established the loading rates for the majority but not all of
the water quality parameters within the watershed because the flushing
effect of the storm may have been inadequate to fully remove accumu-
lated waste loadings.
3-99
-------
oo
I
o
o
1600
1700
FIG. 3-31. WEIGHT RATES HEAVY METALS DURING 3/28/77
STORM HYDROGRAPH OPOSSUM CREEK RM 2.77
-------
CO
o
7,000|
6,000 -
5,000-
4,000 -
3,000-
2,000 -
1,000
0800
0900
1000
1100
1200
1300
1400
1500
1600
FIG. 3-32. WEIGHT-RATES OF PRODUCTION OF WATER QUALITY PARAMETERS
MARCH 28,1977 STORM AT OPOSSUM CREEK RM 2.77
1700
-------
GJ
I
O
no
[mg/lj
(cf$) kg/day
140 28,000
10
0800 0900
1000
1100
1200
1300
1400
1500
1600
1700
TIME
FIG. 3-33. CONCENTRATIONS AND WEIGHT RATES OF C BODU and NOD MEASURED DURING
THE STORM HYDROGRAPH MARCH 28, 1977 OPOSSUM CREEK RM 2.77
-------
CO
o
CO
TAniE 3-18
WIGHT RA1ES TOR SflttltO MATER qWALITT PAn«HElEH5 - OPOSSUM CKftKS
RIVED NILE 2.77. MARCH 28, 1977 - S10RH EVENT
BOO
[CBOOMJ
Flo*
(cfij" ISgTTT
nitrogen Series
[rai3] [no,] (««] [«03] [DIG]
I*g735y7 HgTclayT (kg/day) ITgVaiyT (kg/day)
0812 [5l.7ja 24.1 3,014 23.1
0815 52.0
0846 55.5
OMB [55.8] 25.2 1,401.5 141.2
0900 57.2
0916 [61.5] 30.3 4,515 110.0
0932 66.0
0946 [69.8] 32.0 5.400 177.0
1000 73.5
1015 [90.0] 32.3 7.030 241.5
1030 106.0
1045 [172.3] 39.2 11.600 139.4
1100 138.5
1145 [145.5] 41.6 14.500 364.0
1200 145.5
1300 134.5
1333 [129.42 35.6 11.100 466.«
1437 119.5
1642 90.5
271
255
7113
260
257
302
272
1.526 208
1.417
1,565
1.131
112
103
177
2,264 1,774
J.9IU! 1,127
6,122 327
479 5,040
216
75.0
54.0
29.8
203.0
2,220.0
1.953.0
I,878.0
63.0
a[] m-tm Interpolated fltm.
b - Ptwnol discharges at 1045 hrs. 1145 hrs. and 1333 nri
an based on the atypical msuremits recorded In
Table 6-25
1.6
3.1
4.1
38.1
473.4
1,550.0
Heavy Metals
- TcdJ tcTT IcST ""
TKg73Jr7 CRTJSyT
•~TRT~
Tfg73ayT
13.8 <3.75
20.3
20.9
IP. 6
32.7
2S.6
34.8
9.45
10.4
6.8
15.?
20.7
3H.3
0.75
0.01
0.75
3.04
2J.3
16.2
63.0
1.50
1.21
1.50
2.53
9.4
11.5
14.6
983.0 31.3
8.5 2,970
293
258
410
600
4,615 240
7,63? 299
7,235 525
72
82
110
40.2
70.9
536.0
1.024.0
1 ,81)0. 0
163
-------
CO
o
TABLE 3-19
CBODU and NOD - MARCH 28, 1977 STORM EVENT
Time
(hrs)
0812
0848
0916
0946
1015
1045
1145
1333
Q
(cfs)
51.7
55.8
61.6
69.8
90.0
122.3
145.5
129.4
[CBODu]
(mg/1)
24.1
25.2
30.3
32.0
32.3
39.2
41.6
35.6
[TKN]
(mg/1)
12.2
10.5
10.5
6.7
10.4
10.1
17.6
16.1
[N02 ]
(mg/1)
2.2
1.89
1.90
1.54
1.18
1.02
0.92
1.53
[NOD]
(mg/i )
55.27
47.56
47.57
30.72
46.34
44.87
77.23
71.41
/CBOD 1
1 uf
(kg/day)
3,014
3,401
4,515
5,403
7,032
11,597
14,642
11,143
INODJ
(kg/day)
6,912
6,420
7,088
5,187
10,089
13,274
27,182
22,353
[] denote concentration
I denote mass rates
v /
-------
The study does not indicate that non-point sources
will dominate the observed water quality of the stream during rain-
fall events of a modest magnitude or greater. The watershed, com-
posed of nearly equal portions of highly urbanized, highly industria-
lized, and undeveloped land will contribute significant quantities of
toxic and oxygen consumptive compounds during the storm events which
may be a significant source of the measured sediment parameter values
and impaired biologic conditions. The known problems of major point
source contributions and high fluctuations of these loadings were
exceeded by the greater fluctuations and magnitudes measured during
the March 28, 1977 storm event. A second storm event was sampled
during the fall survey at the 19th Street Station in Valley Creek.
The results of this survey are reported in the Technical Support
Document.
3.1.10. Biology
Due to the fact that the proposed new source will be
constructed on an existing industrial site and will not require the
clearing of previously undeveloped properties, the development of a
biological inventory for the proposed plant site is not deemed per-
tinent to this investigation. However, all available literature has
been reviewed in order to determine if the plant site falls within
the transient range of any rare or endangered species of terrestrial
and aquatic fauna and flora. Additionally, field studies were con-
ducted in order to determine the status of the aquatic communities
associated with the streams impacted by the proposed modernization
project, i.e., Opossum Creek, Valley Creek, Village Creek, and
Bankhead Reservoir. Biological sampling stations are described in
Table 3-20, and their locations are depicted in Figure 3-34. The
results of these studies along with the available literature are
presented and discussed in detail in the Technical Support Document.
From a biological standpoint, the three streams of
the Black Warrior Drainage Basin included in this survey are all
stressed. These conclusions are based upon the following:
3-105
-------
TABLE 3-20
DESCRIPTION OF SAMPLING STATIONS
Station No. Location
1 Opossum Creek @ the end of 1-59
River mile 4.12
2 Opossum Creek just below U.S.S. Monitoring
Station - River mile 2.8
3 Opossum Creek just below Koppers - River mile
1.8
4 Opossum Creek 100 yd upstream from Valley Creek
Confluence - River mile 0.1
2 Valley Creek @ First Bridge upstream from
the Confluence with Opossum Creek - River mile
43
1 Valley Creek - 100 yd upstream from Confluence
with Opossum Creek - River mile 42.7
3 Valley Creek @ 19th Street Bridge - River mile
41.7
4 Valley Creek @ Highway 54-36 Intersection -
River mile 38.5
5 Valley Creek @ Highway 36 - River mile 33.1
7 Valley Creek @ Highway 54 - River mile 19.5
8 Valley Creek @ Highway 23 Bridge - River mile
11.2
9 Valley Creek Slack Water Area - River mile 0.2-3.0
9A Valley Creek Confluence with Bankhead Reservoir -
at the point on upstream side of Confluence
10 Black Warrior River, approximately 1 mile
upstream from the Confluence with Valley Creek -
River mile 382
3-106
-------
TABLE 3-20 (Cont'd)
DESCRIPTION OF SAMPLING STATIONS
Station No. Location
11 Black Warrior River, approximately 1 mile
downstream from the Confluence with Valley
Creek @ bridge piling #6 - River mile 380
1 Village Creek @ Avenue F, Birmingham above
U. S. Steel - River mile 28.8
2 Village Creek @ Docena Road - River mile 25.5
3 Ernbayment @ Confluence with Bayview Lake
(south bank) - River mile 22.6
4 Bayview Lake (east bank) - River mile 22.6
5 Village Creek @ Shady Grove Road - River
mile 17.3
6 Village Creek below Woodruff Bridge - River
mile 9.7
7 Upstream of Alabama Power @ bridge crossing -
River mile 2.5
8 Upstream of Confluence with Locust Fork -
LF RM 406
9 Downstream of Confluence with Locust Fork -
LF RM 404
3-107
-------
(Benthos)
HG. 3-34.LOCAT.ON OF B.OLOG.CAL SAMPL.NG STATIONS ,N THESTUPV AREA
-------
Fish. The numbers of fish collected by electroshocking
and seining efforts were exceptionally low with 38 percent of the
stations sampled yielding no fish at all (Table 3-21). Those fish
collected from Valley and Village Creeks were exclusively forage or
rough fish. No fish were collected from Opossum Creek. In these
streams, Gambusia were collected in greatest numbers and its presence
as a dominant species is a strong indication of pollution (Ramsey,
1975). The absence of some particular species is also indicative of
a stressed situation. With the good habitat available for sedentary
species in Valley and Village Creeks species such as Percina and
Etheostoma (darters) as well as sculpins (Cottus) should be found in an
unpolluted situation.
Levels of selected heavy metals were determined in
livers, flesh, and whole fish and are reported in Table 3-22. Com-
parison of these data with in-stream concentrations (see Water Quality
Section) reveals that all of these metals are bioaccumulated to an
appreciable extent. Evaluation of the data revealed that the values
for cadmium were atypically high when compared to other heavy metals.
Consequently, a second survey was performed at which time zinc was
also run for verification. The results of the second survey are
presented in Table 3-23.
Invertebrates. The use of diversity indices allows
comparison of one population to another. "A community dominated by
a few very common species, with only a few species with small to very
small populations is characteristic of much more severe pollution
than a community with a few very common species and many species with
small to very small population" (Patrick, 1969).
"In general, high diversity at the various trophic
levels, as evidenced by numerous species with rela-
tively small populations that are able to maintain
themselves in associations over time, has been
recognized by many as giving stability to the com-
munity, for it increases the flexibility of the
community to respond to changing environmental
conditions. High diversity is probably also im-
portant in predatory-prey relationships "
(Patrick, 1969).
3-109
-------
TABLE 3-21
SPECIES COLLECTED AT EACH LOCATION
Opossum Creek
So-cies Collected Stations Valley Creek Stations abb * h b
bp.cies Loiiec,ea 1234 1 2 3 4 5 7 8 9a 9Aa 10b 11b 1 2 3 4 5 6 7 3b 9b
Mosquito Fish (Gambusia affinis) '
Golden Shiner (Notemigonus crysoleucas)
Creek Club (Semotilus atromaculatus)
Bluegill (Lepomis machrochi rus)
Stoneroller (Campostoma anomalum)
Green Sunf ish~[lepomis cyanellus)
Skipjack Herring (Alosa chrysochloris)
S
n
s
31 816
6
1 3
1
_ _ ~
f 1 - - - - 1
2 -
2 34
2 -
62 - 3 5
33-1
1
S
S
^
i
7 - 1
4
Gizzard Shad (Dorgsoma ceped^anum) "S ~S ~S "S ---"S - - - 3 14 3 2 "§-13-1515-23' 1
Golden RedhorselTlbxostoma erythruram) +j4JJ->+J_ ^ _ j i -t-1 •*-> •<->•>-' 44
Blacktail Redhorse (Moxostoma poeilurum) <£ £ £ £ _ . _ ^ _ _ _ 4 ? 4 R aJ.a!_^^2-^
Black Redhorse (Moxostoma duguesnii) -5^00 ---•£---- . _ i -. -.--.. 7
Larqe Mouth Bass (Hicropterus salmoidesj <-><-> o o ___<->.__. R . _ °_°_<-J<-J___
Spotted Bass (Micropterus punctulatus) •=-=-=•= . . . -= . . . . i . . -5 -•=.-=•=.
Channel Catfish (Ictalurus punctatus) ;r ;r ;r ;r - - - ;r - - - - 10 1 - £-£-££- ^ Q
Blue Catfish (Ictalurus furcatus) „„„„ _._„.._. 7 _ _ m.^-^^.__
Carp (Cyprinus carpio) ^ ^ ^. -z. _ _ _..
Bullhead Minnow (Pimephales vililax)
Drum (Aplodinotus qrunniens)
Shortnose Gar (Lepisosteus Rafinesque)
White Bass (Morone chrysops)
Warmouth Bass (Chaenobryttus gulosus)
Total Species
Forage - %
Rough.- %
Game - ••,%
'
^
IX* J
'
-
- - -
_
.
1 3 3
100 100 100
- - -
- - -
^
= ---- 1-1 ^.^.^^.T.
1
1
1
1
1
21 1 6 10 5 11
100 100 100 83 40 40 27
- 17 40 60 55
20 - 18
'
_
-
.
_
1
100
-
-
^ S
_
-
_
_
0
s
1 1
- - —
-
277
50 43 28
50 57 72
^ -
6 Net Nights (collected 3/21-3/27, 1977)
3 Net Nights (collected 5/3-5/4, 1977)
Gambusia observed but not collected
-------
TABLE 3-22
RESULTS OF HEAVY METAL ANALYSIS ON WHOLE FISH & EXCISED LIVER 8 MUSCLE
Station
Station 5
Valley Creek at
19th Street
(KM 11.7)
Valley Creek at High-
way 54
(RH 19.4)
Valley Creek at High-
way 23
(RM 11.2)
Valley Creek at
Confluence with
Black Warrior
(RH 0.2-0.5)
Valley Creek at
Confluence with
Black Warrior
(RH 0.0-0.2)
Black Warrior
(RH 303)
Village Creek at
Confluence with
Locust Fork
(Black Warrior RM 405)
Village Creek at
Confluence with
Locust Fork
(Black Warrior RM 403)
Black Creek*
Fish
Creek Chub (Liver)
(Flesh)
TflliOTe)' '
Mosquito (Whole)
Fish (Whole)
(Whole)
(Whole)
Stoneroller(Whole)
(Whole)
Green (Whole)
Sunfish (Whole)
(Whole)
(Whole)
Bluecat (Liver)
(flesh)
(LTverT
(Flesh)
Large Mouth(Flosh)
Bass (Liver)
(Flesh)
(Liver)
(Flesh)
Bluegill (Liver)
(Flesh)
Channel (Liver)
Catfish (Flesh)
Bluegill (Liver)
(Flesh)
Car (Liver)
Green (WholeJ
Sunfish (Liver)
(Flesh)
Bluegill (Liver)
(Flesh)
(Liver)
(Flesh)
Green (Liver)
Sunfish (Flesh)
(Flesh)
Channel (Liver)
Catfish (Liver)
(Flesh)
(Flesh)
(Liver)
Bass (Flesh)
(Liver)
g(dry wt.)
Cd**
0.0216
0.1659
"• 0.1132
0.1625
0.1749
0.1242
0.2278
1.2164
0.9861
0.3656
0.7026
0.6439
0.5488
0.5305
0.3098
0.0602
0.3659
1.0746
1.1026
1.2819
1.2870
0.9364
0.0949
0.2800
0.7229
0.4773
0.1111
0.3922
0.9273
1.7272
0.0405
0.6107
0.1505
0.5004
0.0315
0.4035
0.0174
0.3090
1.0023
0.6759
0.7758
0.6023
0.7191
0.5368
0.4532
0.2529
Sn
<20.0
17.0
' TTO" '
63.5
45.0
88.0
75.0
30.1
32.3
66.9
43.3
51.5
70.5
22.0
22.0
38.0
24.0
33.3
20.3
25.9
27.8
39.7
4.0
41.0
29.0
17.6
15.0
37.0
97.8
28
<10
27
8
21
<10
17
<20
19
31.7
47.3
28.1
26.6
27.0
51.0
6.4
8.1
Metal -
Fe
350
63
200
412
872
1,600
295
677
1,450
317
139
156
850
550
99
1 ,300
58
116
400
56
515
98
1 ,110
295
640
212
1,140
61
720
270
510
26
442
46
810
25
1,200
51
180
550
1,820
59
59
420
410
1,100
dig/g)
In
120
50
?0l '
330
320
250
230
148
172
160
130
132
140
87
64
231
98
71
45
46
54
51
155
62
120
49
193
25
114
123
110
29
146
28
100
38
90
29
52
95
81
78
50
110
54
131
Cu
10
3
11
20
13
7
8
10
10
10
7
7
5
19
8
2~0~~
2
9
9
5
7
6
18
2
45
16
20
2
12
9
10
2
12
3
21
3
12
3
15
8
10
34
6
8
38
55
Cr
<20
5
4
8
10
20
6
4
5
6
3
6
6
2
4
<1
2
" 3
1
2
3
9
3
4
4
30
1
7
8
<10
1
3
<1
<13
1
24
<1
2
3
2
10
3
3
2
5
Mn
10.0
3.0
39.0
57.0
55.0
60.0
46.0
41.0
82.0
161.0
79.0
78.7
.44.0
5.8
5.0
50TO
15.0
3.6
4.3
2.0
7.0
3.0
20.0
1.0
7.8
3.0
30.0
1.0
12.0
82.2
7.0
1.0
18.0
3.0
20.0
3.0
60.0
3.0
3.8
8.1
15.0
4.0
4.6
4.0
2.0
8.0
'Received from area fishermen.
**Cd data deleted due to unresolved analytical error.
Cd data developed during verification study is presented in Table 3-23.
3-m
-------
TABLE 3-23
COMPARISON OF HEAVY METALS ANALYSIS
OF FISH TISSUE - SECOND SURVEY
Species
Micropterus
salmoides
Micropterus
salmoides
Micropterus
salmoides
Pomoxis
anulams
Pomoxis
anulams
Pomoxis
anulams
Lepomis
macrochirus
Lepomis
macrochirus
n
ii
Ictalurus
punctatus
Wt
(Grams)
359
235
66,5
133
121
90
64
43
38
32
83
170
*
Age
(Yr)
3
2
0
1
1
1
3
2
2
2
Tissue
Sampled
Muscle
Liver
Kidney
Muscle
Liver
Muscle
Liver
Muscle
Liver
Muscle
Liver
Muscle
Muscle
Liver
Muscle
Liver
Muscle
Liver
Muscle
Liver
Muscle
Liver
Liver
Cd
(mg/kg Dry Wt)
**
0.40 (0.20)
0.86
5.50
6.80 (0.30)
1.20
0.32 (0.53)
2.50
0.27 (0.47)
1.00
6.10 (0.13)
4.10
0.38 (0.75)
0,55 (0.20)
4.30
0.90 (0.25)
3.10
0.75 (1.33)
4.7
0.72 (0.74)
5.80
1.10 (0.38)
6.20
2.10 (2.04)
Zn
(mg/kg Dry Wt)
105 (44.57)
73.3
85.5
175 (46.26)
81
21.7 (33.27)
96.3
2.50 (26.54)
66.30
330 (25.82)
86.6
72.7 (27.11)
38.30 (20.44)
114
40.4 (35.86)
92.5
52.40 (46.16)
120
24.70 (41.42)
107
36.90 (27.27)
97.70
124 (108)
•K
Age - Determined using scale method
**/
( ) - Determined by Tennessee Technological University
Average Zn concentration for species collected during first survey:
Micropterus salmoides - Muscle
Liver
Lepomis macrochirus
Ictalurus punctatus
- Muscle
Liver
- Muscle
Liver
56.00 mg/kg
49.50 mg/kg
43.40 mg/kg
174.0 mg/kg
70.33 mg/kg
146.0 mg/kg
3-112
-------
Wilhm and Dorris (1968) have found that values of D are usually less
than one for areas of heavy pollution, from one to three in areas of
moderate pollution, and greater than three in unpolluted water. The
calculated diversity indices (D) for each station were seldom greater
than two and, consequently, are below the D" accepted as indicative of
a healthy stream and in fact fall into the stressed range. In addi-
tion to the numerical comparisons, the observation of large numbers of
Oligochaeta and Chironomidae taxa indicates moderate pollutional
stress (Table 3-24).
Periphyton. The health of the periphyton as indicated
by the chlorophyll a_, pheophyton a_ ratio falls into the "mixed" range.
This indicates a population with both intact and viable cells as well
as cells which are disrupted and decaying. Only two stations had
populations where no decaying cells were observed. This is tempered
by the fact that the population examined was a winter collection and
no seasonal numbers are available for comparison. It is expected,
however, that these streams exhibit a summer maximum and winter mini-
mum. (Baseline periphyton data are presented in Table 3-25.)
Zooplankton. Zooplankton samples taken at the conflu-
ence of Valley Creek with Bankhead Reservoir and one mile above and
one mile below the confluence indicate that relatively enriched
zooplankton populations existed at the time of the seining (Table
3-26). Such populations are common for areas receiving moderate
organic pollution.
Rare and Endangered Species. No rare or endangered
species were collected or observed during the field survey efforts.
A review of the publication "Rare and Endangered Vertebrates of
Alabama" revealed that no known populations of rare and endangered
vertebrates are listed for the specific study area.
Migratory Wildlife. The only wildlife of significance
that use the Jefferson County, Alabama region as a migration route
are waterfowl, songbirds, and birds of prey. Other than these groups,
migratory patterns are not of consequence in studying wildlife habits.
3-113
-------
TABLE 3-24
SUMMARY OF BASELINE
BENTHIC MACROINVERTEBRATE TAXA
Class
Nem.
Oil
Hlr
Cru
Cru
Cru
Cru
Cru
Ins
Ins
Ins
Ins
Ins
lr,s
In*
Ins
Ins
Ins
Ins
Ins
Ins
Ins
Ins
Ins
toda
}ochaeta
dinea
t ce
t ce
t ce
t ce
t ce
cu
eta
Ctd
eta
eta
eta
eta
eta
eta
eta
eta
eta
eta
eta
eta
eta
eta
Insecta
Archnlda
Gastropoda
Gastropoda
Gastropoda
Gastropoda
Bivalula
Bivaluia
Order
Isopoda
Amphf poda
Decapoda
Decapoda
Ostracoda
Col lembola
Plecoptera
Odonata
Odonata
Ephemecoptera
Ephemeroptera
Ephemeroptera
Trichoptera
Diptera
Olpter
Dipter
Dipter
Dipter
Dipter
Dipter
Coleoptera
Coleoptera
Acarina
Basommatophora
Basonimatophora
Basomnatophora
Hesogastropoda
Heterodontida
Heterodontida
Family
Asellidae
Gammaridae
Astaeidae
Astacidae
Astacidae
Poduridae
Perlodidae
Coenagri idae
Coenagrtidiie
Baetidae
Heptageniidae
Heptageniidae
Pyralididae
Culiddae
Tipulidae
Ceratopogonidae
Chironomidae
Tobanidae
Do] ichopodidae
Empidldae
Elraidae
Elmidae
Elmidae
Unionicolidae
Physidae
Physidae
Physidae
Bithyniidae
Corbiculidae
Sphaeriidae
Gf-nuS Species Opossun Creek Stations
1234
... 2
42 13 18
Cranqonyx — ....
Cambarus -- ....
1
UoperlA -- -
Coenaqnon -- -
Pseudocloeon .. ....
Stenon^ma — _
Synclitus .. .
Chaeoborus _. ....
Tipula .. ....
.346
Lara ...
Dubiraphia _. ....
Op^ioservus ._ ....
Physa _
LhO§J. Integra 1
Pisidium rnan1tt«ns1s
1443
Vlllsne Creek Stations Valliy Creek Stations
12^567 123456789
2-11-1 3-11151-1
293 - 35 76 444 46 171 15 28 249 1 300 545 309 56 1 953
21 - 1175
i
i - - - -
1 .... 4 - - 10 1
5-1194 40 - 5 6 370 78 21 619 122
1 1 .... 6 6 - 1 1
1 - - - 1 - 1 30
416464 51439741510
10
498
2
-
31
7
89
1
277
16
a
11
75
2914
7
3
11
3
a
3
203
15
eo
2
12
-------
TABLE 3-25
SUMMARY OF BASELINE PERIPHYTON DATA6
co
i
01
Pnyliai Order Faislly Genus
'
81at-vbiceae Centrales Cgslpgdlscaceae Kelosira
Ptnnale* Frejl'arlaceae Astronell*
lhatcwa
ArJ.nantheS
CoctoneTT
Eunotlaceae TCiiotia
Gjrosig.io
Pinnu'lana
_Pjnnularta_
P*nnu]«ri_a_
_&npjlfiii~
IIJU£EJ1
T^ticVij
jUJicKu
Jurreljac^ae Surlrella
Surirella
Cy*r»opSy ta Ose 1 11 a tori A 1 « JRiwill«Isrlas*2S OscnigtgrMa
TOTAL SPECIES
Species
-
varlans
(ireneghenlana)
formosa
vulgara
(coimclnd)
fencstrata
fasclcu'.ata
goulf rdl 1
ulna
cincisa
(cyclopum)
lancelota
deHexia
placeitula
melsteri
dentlcula
(perpusilla)
secreto
(species)
(attenuatum)
hllsesna
bra.it.ii
caudUta
(species)
(kriegeri)
abbrevlatum
subc lava turn
parvjlum
arqur
afftnts
clstula
(ven?ta)
pa lea
dissipatae
1 Inearis
navlcularU
tryblionelli
(cuspidata)
JClarls
lancelota
sinuata
ovata
biserfata
Opossum Creek Stations
Variety 1234
—
..
truncata Z
fluveatlMs
Z
Itneata \
*
—
*
:: :
mextcanum 2
-
7. I
8
3
IS
.
Z
2
3
4
2
•
Z
3
-
5
1
t
17
- 1455
152
22
22
238
195
- 2145
-
108
87
108
22
65
216
.
16
- 2356
55
63
294
26
28
55
•
37
18
.
76
18
18
; ; :
419
23
Valley Creek St
22
12
16
•
-
-
-
28
8
8
3
20
a
14
18
10
33
1044
40
13
14
6
91
102
-
115
30
.
169
22
18
9
62
107
1076
36
-
27
133
213
-
89
30
9
293
71
16
atfons
7 8 9
27
40 36
36 174
27 101
409 507
45 76
5
5 •
-
5
125 327
36 97
-
38
67
.
98 76
27 38
122 19
10 11
TKTC 2030
TKTC WC
319 1SS6
60 22
59 45
239
119 1711
ft
237 5933
15
156
22
30
74 556
30 400
74
89
22
115 67
45
22
22
22
IS 25
Village Creek Stations
1 2 3 4 5 «
-
4]
4
13
76
13
22
4
9
4
9
-
J
IS
6
6
38
3
6
3
12
3
6
27
44
24
16
-
-
148
2740
667
148
.
296
75
1259
148
370
74
17
-
-
22
333
.
22
- 4823
- 2578
133
311
22
13
7
-
-
23
14
783
;
61
611
260
14
27
27
58
27
14
() Most Probable Taxa
TNTC Too Numerous to Count
anumber per mm2 (arithmetic mean of 3 samples)
-------
TABLE 3-26
ZOOPLANKTON COMPOSITION-BANKHEAD RESERVOIR
Zooplankton
Taxa
COPEPODA
Cyclopoida
Cyclops vernal is
Mesocyclops edax
Calanoida
Diaptomus floridanus
Nauplii
CLADOCERA
Bosmina sp.
Bosmina coregoni
Bosmina longirostris
Daphinia ambigua
Daphnosoma leuchtenberganum
Alona sp.
ROTIFERA
Asplanchna sp.
Brachionus caljciflorus
Brachionus angularis
Keratella cochlearis
Platius patulus
Philodinia sp.
Polyarthra vulgaris
Synchaeta sp.
1
3.4
3.4
10.6
13.1
1.9
1.9
3.3
.32
.08
5.2
19.6
.08
.08
.08
.24
36.5
Station No.*
2
(Frequency-%)
11.0
12.0
14.6
29.8
9.5
2.6
5.4
.53
8.7
6.6
.26
.08
.08
4.8
3
7.0
7.1
10.1
55.6
2.0
3.0
4.3
.28
2.6
2.6
.28
.28
.86
3.8
*1 - At Confluence with Valley Creek
2 - One mile downstream of Confluence with Val
3 - One mile upstream of Confluence with Valle
ley Creek
y Creek
3-116
-------
Alabama is on the Eastern fringe of the Mississippi Flyway System.
There is some overlapping of species from the Atlantic Flyway that
wander into the area.
The wood duck (Aix sponse) is the only "native" Alabama
species of waterfowl which breeds through the State in significant
numbers. Summer brood surveys show that about 50,000 young wood ducks
are produced annually in the State. Wood ducks were on the verge of
extinction in the early 1900's. Overharvesting, loss of habitat
through draining of the swamps and marshes and removal of trees that
provided nesting cavities had taken a heavy toll of the species. The
Game and Fish Division of the Alabama Department of Conservation and
Natural Resources has been instrumental in research and management
activities that have brought the wood duck from its low ebb to a sub-
stantial population.
In Jefferson County and the Black Warrior River Basin,
a great variety of habitats exists which is conducive to many species
of migratory birds. The major limiting factor is food; however,
waterfowl prefer agricultural fringe areas where food such as small
grains, corn, soybeans, and a variety of forage species (grasses) are
available. Migratory waterfowl are unable to find adequate food of
these kinds in Jefferson County for subsistance through the winter.
Adequate cover and water are available; however, waterfowl populations
are rather low. Songbirds find the area more to their liking. The
marshes, river, creeks, swamps, forest, and fringe areas provide
excellent wintering grounds for this group. Many species over winter
in the area or use it for a temporary stopover while migrating farther
southward.
Birds of prey typically follow waterfowl and songbirds
in their migration routes. Those species and individuals that prey
upon waterfowl are to be found in lesser numbers than those that prey
upon songbirds. As a result, birds of prey will be concentrated
according to their favorite prey.
Birds in the study area were included in the biological
survey by observation at all stations during sampling periods and
3-117
-------
during canoe travels down the streams. Those birds observed in the
area by AWARE, Inc. are shown in Appendix B-3 of the Technical Support
Document. In addition to field observations, library research has
produced a taxonomic list of birds of the Black Warrior River Basin
which is also included in Appendix B-3.
Amphibians, and Reptiles. Cursory observations by
AWARE, Inc. during the field survey recorded ten species of reptiles
and amphibians in the study area. These are the Eastern Cottonmouth,
Canebreak Rattle Snake, three water snakes, common snapping turtle,
alligator snapping turtle, Eastern Painted turtle, Alabama Map turtle,
and the Eastern Chicken turtle.
Mammals. The majority of the mammal data was compiled
from on-site observations. Relative indices of abundance were estab-
lished from actual sightings, droppings, tracks, den and nest sites,
conversations with local residents, and information from the Alabama
Department of Conservation. Stream banks and game trails were
examined for spoor and other indicators. Photographs were taken of
appropriate signs of wildlife in the study areas. Details are
included in the Technical Support Document concerning mammal abundance
indicators for beaver, raccoon, gray squirrel, opossum, striped skunk,
eastern cottontail, whitetail deer, muskrat, and mink.
3.1.10.1. Terrestrial Vegetation
The proposed plant site is not considered a biologi-
cally sensitive area. No unusual or rare species exist on the site.
No uniquely large trees will be affected. There is no official list
of rare or endangered plant species for Alabama, however, the
Department of Conservation is currently developing such a list. The
Forestry Commission has, however, become concerned with the status of
the ginseng plant. Due to high market values of the roots of this
plant, there is concern that individuals will seek to collect this
for market purposes.
3-118
-------
The Warrior River Basin and its tributary system con-
tain approximately 30 families of trees and woody shrubs. Some areas
along some of the streams are unusual in the diversity of vegetation.
A partial list of the dominant plant species occurring in the mixed
riparian zones is presented in Appendix B-6 of the Technical Support
Document.
Although there are marked differences in early sere
stages, later ones tend to become more alike, so that eventually con-
vergence occurs. Seres pass through several stages in this area,
therefore, the climax communities of all seres are much alike regard-
less of their origin.
Riparian wetlands and transition zones predominate
vegetation from on-site observations consisted primarily of:
Black Willow Salix nigra
American Sycamore Plantanus occidental is
Red Maple Acer rubrum
Box Elder Acer negundo
Ironwood Carpinus carolmiana
Yellow Poplar Liriodendron tulipifera
Sweet Gum Lignidambar styraciflua
Loblolly Pine Pinus taeda
American Beech Fagus grandifolia
Sassafras Sassafras alibidum
White Ash Fraxinum americana
American Elm Ulmus americana
Mountain Laurel Kalmia latifolia
River Cane Arnndinaria gigantea
Privet Ligustrum sinense
Honeysuckle Lonicera simpervirens
Elderberry Sambucus canadensis
Various forbs, grasses, and sedges
3.1.11. Land Use
3-119
-------
Existing. Jefferson County in its early years followed
the pattern of most new frontiers in development. That pattern is for
new settlers to locate in the river valleys where there are sources of
water for personal and industrial uses. Also, transportation routes
in the early years followed and used the rivers and river valleys.
Consequently, industrial areas were developed on sites that were topo-
graphically desirable, being level to only slightly rolling. Residen-
tial developments were then located surrounding the industrial areas.
As time went on, these developments continued in generally a diagonally
southwest-northeast pattern. This pattern primarily is in the Jones
and Opossum Valleys (Figure 3-24).
As the Birmingham area grew, there began outward, urban
residential expansion from Jones and Opossum Valleys. This expansion
crossed Red Mountain and has spread into Shades Valley. Continued
growth has occurred along the major transportation corridors into
Shelby County. Also, expansion has occurred in the northern part of
the county. These growth patterns have generally followed highways
U. S. 31 and Alabama highways 75 and 70 (Figure 3-35).
Opossum Valley has been and is the center for industrial
development in Jefferson County. There are also pressures for indus-
trial land use occurring in Shades Valley and Pinson Valley.
Commercial land use is basically located in the Central
Business District in downtown Birmingham. However, major shopping
centers have located in many of the suburbs. Additional strip develop-
ment commercial concerns have occurred along major arterial streets.
The downtown Birmingham area, due to its topography and
soil types, in reality is the most suitable area for agriculture in
Jefferson County. However, early farmers were forced out of these
more sutiable areas to make room for industrial, residential, and
commercial concerns. Agricultural enterprises are now located in the
northern and northwestern parts of the county.
Surface extraction of minerals is scattered throughout
the county, but primary mining is in the northern and western sections.
3-120
-------
U. S. Steel Facility
FIG. 3-35.
LAND ACCESSIBILITY MAP
SYMBOI
o
LEGEND
CATEGORY
INTERSTATE INTERCHANGE, RAIL-
ROAD OR PORT ACCESS
U.S. HIGHWAY ACCESS
STATE HIGHWAY ACCESS
COUNTY HIGHWAY ACCESS
NO ACCESS
t |
-------
3.1.11.1. Land Suitability Plan
Jefferson County is now faced with tremendous develop-
ment pressures. These pressures, similar to those in other urbanizing
areas of the country, are expected to continue at least through the
end of this century. Jefferson County has become more urbanized as
time has passed. This has created a special need for the most feasible
use of land for future development.
In order to proceed in a practical manner in this land
allocation, it is first necessary to inventory the land itself. Po-
tentials for development must consider the base physical characteris-
tics. The physical characteristics of the land to be considered are:
1. Topography
2. Climate
3. Slope
4. Flood-Prone Areas
5. Soils
6. Geology
7. Mineral Resources
Other important factors that have a bearing on land
suitability are:
1. Public Water Coverage
2. Public Sewage Coverage
3. Transportation Routes
4. Large Landholders
5. Existing Land Use
Based upon these characteristics, the Birmingham
Regional Planning Commission has developed a "Land Suitability Plan."
This plan is portrayed in Figure 3-36.
3.1.11.2. Large Landholders
Private corporations constitute the major landholders
within Jefferson County. Over one-third (36.2 percent) of the total
land area is owned by six private corporations. The largest portion
3-122
-------
r
LAND SUITABILITY PLAN
LEGEND
I I INDUSTRIAL
I | RESIDENTIAL
| | COMMERCIAL
[x-i-il PARKS
O TRANSPORTATION, COMMUNICATION
AND UTILITIES
|:::X:::| PUBLIC AND SEMI-PUBLIC
Pill AGRICULTURE
| | OPEN SPACE
yj
NJ
U. S. Steel Facility
FIG. 3-36.
-------
of this land is in the northern and western portions of the county
(Figure 3-37).
Zoning regulations, land use ordinances, and sub-
division regulations are all regulatory implements used by federal,
state, and local governments to determine land use patterns. Land
use policies direct and regulate future growth, provided these poli-
cies are enforced by appropriate jurisdictions.
Should part of these land holdings be released for
development, these will more than likely be released in very large
parcels, such as the Oxmoor Industrial Development by U. S. Steel.
When these large parcels are developed, they probably will be de-
veloped as large planned industrial or residential unit developments
or a combination of the two. Obviously, these forms will contribute
substantially to the continued growth of Jefferson County.
3.1.11.3. Residential Land
Residential acreage demands must be determined by
accurate assessment of many factors. Among these are:
1. The projected population
2. Size of households
3. Housing density
4. Existing housing
5. Traffic zones
There is some overlapping in suitability of residential
and industrial/commercial lands, however, residential land require-
ments are generally less stringent than those for industrial/commer-
cial. Residentially suitable areas in Jefferson County are
presented in Figure 3-38.
3.1.11.4. Agriculture Land
Existing land use, topography, soils, and transporta-
tion routes are important factors that affect agricultural land use
suitability. Only approximately 29,600 acres are in agriculture.
3-124
-------
LARGE LANDHOLDERS
LEGEND
II;,'iij U.S. STEEL
I I U.S. PIPE
( | REPUBLICSTEEL
ALABAMA BY-PRODUCTS CORPORATION
| | BELCHER LAND & TIMBER COMPANY
r~~1 MEAD CORPORATION
U. S. Steel Facility
FIG. 3-37.
-------
::::::::;;:' ••.'•TRUS.SVILLE
f\'.'-.-. .
U. S. Steel Facility
FIG. 3-38.
RESIDENTIAL LAND SUITABILITY
LEGEND
SYMBOL CLASSIFICATION
MOST SUITABLE
LEAST SUITABLE
-------
This represents 0.5 percent of total land area in the county.
Federal non-crop land accounts for 500 acres, crop land 14,900 acres,
and pasture 14,200 acres. Agriculture land suitability maps are
presented in Figure 3-39.
3.1.11.5. Extractive Land
The lands most suitable for extractive use are, of
course, those that are underlain by a high priority economic mineral
and not contiguous to existing incompatible land uses, such as
residential. Coal is the most important mineral mined in Jefferson
County from an economic priority standpoint.
Primary mineral resources and their locations are
shown in Figure 3-40.
Coal. The Warrior coal field in the northern and
western parts of the county, and the Cahaba coal
field, in the southeastern part near Shelby County,
are major coal resources.
Limestone. Widely distributed
Dolomite. Widely distributed
Chert. Widely distributed
Sand and Gravel. Scattered localities
Clay and Shale. Unlimited quantities
Iron Ore. Widely distributed
3.1.11.6. Recreational Land
The "Land Suitability Plan" formulated by the BRPC
distributed recreational acreage which considered existing service
areas and immediate demand as well as projected future needs. The
plan can only identify areas suitable for open space/recreation uses.
The type of recreational activity directly influences the amount and
kind of land needed. A large portion of the county is conducive to
open space/recreation (Figure 3-41).
3-127
-------
U. S. Steel Facility
FIG. 3-39.
AGRICULTURAL LAND SUITABILITY
I EGEND
SYMBOL CLASSIFICATION
K:-$J MOST SUITABLE
II MODERATELY SUITABI E
f I I EAST SUITABI E
-------
. S. Steel Facility
FIG. 3-40.
EXTRACTIVE LAND SUITABILITY
LEGEND
SYMBOL CLASSIFICATION
MOST SUITABLE
|"~1 MODERATELY SUITABLE
-------
PU. S. Steel Facility
FIG. 3-41.
OPEN SPACE LAND SUITABILITY
LEGEND
SYMBOL CLASSIFICATION
[ ] MOST SUITABLE
[ ] MODERATELY SUITABLE
LEAST SUITABLE
-------
3.1.11.7. Industrial Land
Industrial acreage requirements depend on the kinds of
manufacturing activities that characterize the economy. In a land
suitability plan, industrial land use should be the first distributed.
This use requires lands that meet the most stringent criteria. Also,
urban growth is better stimulated in distributing land use beginning
with industrial then residential, commercial, recreational, etc.
Geographic industrial and/or commercial land suitability is portrayed
in Figure 3-42.
3.1.11.8. Transportation Systems
The Jefferson County area land use plans and patterns
are enhanced by adequate transportation systems.
Railroads. Railroads serving the area are:
1. Alabama Great Southern Railroad
2. Gulf Mobile and Ohio Railroad
3. Louisville and Nashville Railroad
4. St. Louis-San Francisco Railroad
5. Southern Railway
6. The Seaboard Coast Line Railroad
7. Illinois Central Railway
8. Birmingham Southern Railroad
Both freight and passenger service are provided in the area.
Roads and Freeways. Major state and federal highway
systems adequately provide for tourist, commercial and industrial
traffic in the area. Interstate 65, U. S. 231, and U. S. 43 serve as
the north-south linkages. Interstate 59, U. S. 278, U. S. 78 and
U. S. 82 are the major east-west arteries.
Airports. The Birmingham Municipal Airport provides
the major air transportation services for both passenger and commercial
freight for the area. The airport is equipped to accommodate almost
every type of aircraft now in service. Future expansion of facilities
is expected.
3-131
-------
. S. Steel Facility
FIG. 3-42.
INDUSTRIAL AND/OR COMMERCIAL
LAND SUIT ABILITY
LEGEND
SYMBOL CLASSIFICATION
[ 1111'.IJ MOST SUITABLE
|.;.;.;:::] MODERATELY SUITABLE
| "| LEAST SUITABLE
-------
Water Routes. The Black Warrior-Tombigbee Waterway
provides great positive impact on land use plans and development in
the area. Port Birmingham provided a major terminal for raw materials
and cargo shipment flows in the area. The Waterway is a major factor
in commercial traffic.
3.1.12. Socio-Economic Conditions
3.1.12.1. Employment Analysis
History and Trends. A critical factor in the economic
health of an area is employment activity. Comparisons of employment,
between two given points in time, will indicate general economic
growth. Two related categories that will influence the Birmingham
region economically are:
1. National growth trends in employment
by sector, and
2. Growth trends in non-manufacturing activity.
Incentives to the economic growth of the region offered by the Birming-
ham area are: adequate utilities, shipping and transportation routes,
power and fuels, labor supply, and supportive and social services.
Certainly, there are situations in the region that are negative.
Recent labor disputes, limited sites, and decadent urban areas tend
to restrain growth. However, the overall environment is conducive to
positive growth.
It is expected that slight decreases will occur in
agriculture and mining. Construction, transportation and communica-
tions, and certain aspects of the financial sector will remain
relatively stable in percent of employment share, but will increase
slightly in overall numbers. Some absolute increases are expected to
occur in manufacturing, trade, service and government employment;
however, a precarious balance exists in these sectors. Any major
decline in expected expansion in any of these areas could result in
increased unemployment.
3-133
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3.1.12.2. The Regional Economy
Basic trends in economic activity and population growth
in the Birmingham area have been influenced by the region's historical
development and progress. The early years were influenced by the metal
processing industries. Therefore, the early economy and its attend-
ant life-styles have carried over into the present time, still sub-
stantially dependent upon steel production and its related activities.
The major foundation of Birmingham's economy is its
dependency on extractive industries and directly related activities.
Investments in production facilities have resulted in an increase in
the skilled and managerial labor force, however future growth will
depend more heavily upon the area's public and private institutions.
The public and private sectors will focus attention which will broaden
and diversify the economic base.
Birmingham's metals facilities have historically pro-
vided a significant portion of southern steel production. In 1920,
86 percent of southern steel production was produced in Birmingham.
In 1940, Birmingham produced 77 percent of southern steel. From 1940
to 1970, steel production in Birmingham has remained fairly stable,
however, total steel output in the United States has increased. This
has resulted in Birmingham's decrease in the percentage share produced
nationwide (see Table 3-27). Nationwide, steel capacity increased less
than 10 percent between 1960 and 1975.
Southeast Region and Birmingham Economic Growth. Other
influences on Birmingham's future growth are comparative growth factors
of other areas in the Southeast. Growth factors such as employment,
population, and income reflect that the Southeast is one of the fastest
growing regions in the nation, however, Birmingham's growth rate has
been quite low, comparatively. Birmingham reflected lower growth indi-
cations than any region in the Southeast and even ran behind the United
States average in population, manufacturing employment and personal
income for the 15-year period from 1960 to 1975 (see Table 3-28).
3-134
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TABLE 3-27
MINING AND AGRICULTURE EMPLOYMENT TRENDS
PERCENT OF
TOTAL U.S. EMPLOYMENT
10
9
8
7
CO
i
CO
en
6-7%
o
5
4
3
2
1
J-O70
5-6%
4-5%
••MH^H
3-4%
1960 1970 1980
SOURCE: BIRMINGHAM REGIONAL PLANNING COMMISSION
1990
2000
-------
TABLE 3-28
MANUFACTURING EMPLOYMENT TRENDS
to
I
CO
01
PERCENT OF
TOTAL U.S. EMPLOYMENT
30
25.3%
25
20
15
10
5
/0
23% 22-23%
n21-22°/
1960 1970 1980
SOURCE: BIRMINGHAM REGIONAL PLANNING COMMISSION
1990
2000
-------
Growth factors between 1970 and 1975 show that Birming-
ham is beginning to increase. This is a promising trend. In the mid-
sixties, the adverse racial situation and steel industry cut backs
retarded upward growth. Present trends reflect that Birmingham can
now participate more in regional and national growth patterns.
The economy of the Birmingham area appears healthier
than it was 15 or 20 years ago. Diversification is growing rapidly.
There has been a decline in manufacturing and primary metals employ-
ment and an increase in government and services employment (see
Tables 3-29 and 3-30). The decline in employment in metals produces
the adverse effect of lowering personal and per capita income.
3.1.12.3. Demographic and Economic Considerations
Analysis of Change. Population characteristics, popu-
lation structure and population estimations are prime indicators of
the economic health of a given region. The trends in population for
the Birmingham area reflect a steady continuous growth since the
1950's. There are, however, changes that have occurred within the
population.
In the fifties, Birmingham experienced a period of sig-
nificant growth in population. This was due to a number of reasons;
increased employment opportunities by the primary metals sector, rural
to urban migrations, northern cities out-migration, and increased
availability of welfare services and utilities.
In the sixties, however, Jefferson County experienced
a slower population growth. Several reasons are advanced for this
stability in employment in the primary metals sector; out-migration
of workers to northern cities, competition from other southern cities
(such as Atlanta), racial tension, moves to suburbs and antiquated
structure of the city.
The 1970's should show a period of continued dispersal
of urban populations to the suburbs, increased in-migration, decreasing
natural population rates and increased overall regional growth.
3-137
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TABLE 3-29
GOVERNMENT EMPLOYMENT TRENDS
Percent of
Total U.S. Employment
oo
i
oo
20 19%
18%
16.7%
15 15%
10
5
^^™~™
1960 1970 1980
Source: Birmingham Regional Planning Commission
1990
2000
-------
CO
PERCENT OF
TOTAL U.S. EMPLOYMENT
30
TABLE 3-30
SERVICES EMPLOYMENT TRENDS
1960 1970 1980
SOURCE: BIRMINGHAM REGIONAL PLANNING COMMISSION
25%
20%+
20%
20
17.2%+
15
10
5
I7.20/
fo
1990
2000
-------
The population for the Birmingham region shows a gradual
overall increase for the period 1960 through 1975. In 1960, the
population was 634,898. In 1975 it has increased to 649,500, a net
increase of almost 15,000. There was a large out-migration during
this period, however a substantial natural increase (births vs. deaths)
reflected an overall net increase.
3.1.13. Cultural (Archeological, Historical, Architectural)
The Alabama Historical Commission has developed a num-
ber of programs which are aimed toward preservation, including
surveys, planning, promotion, speaking engagements, and actual pre-
servation projects. These programs are carried out in cooperation
with federal agencies, local governmental and preservational groups,
and other state agencies whenever possible.
Survey. The first major objective of the Commission
was to inventory and catalogue all of Alabama's significant sites
and structures and thus to determine which merit preservation and the
order of restoration priorities. A preliminary listing of historic
properties has been compiled for each county. This list serves as
the basis for county-by-county in-depth surveys being made by staff
members and local volunteers. More than 3,000 historic structures
and sites have been located in the preliminary surveys and additional
properties are added on a continuing basis.
Among the types of properties being surveyed are ante-
bellum mansions, rustic structures such as log cabins, churches and
covered bridges, old public buildings such as courthouses, city halls,
railway depots, post offices, iron and stone bridges, and jails, and
historic commercial and industrial buildings. In short, anything
which is representative of a way of life and is at least 50 years old
is eligible to be placed on the survey listing.
National Register. Properties which the Commission
considers to be of lasting significance and worthy of preservation are
3-140
-------
nominated to the prestigious National Register of Historic Places
kept by the Office of Archaeology and Historic Preservation, U. S.
Department of the Interior. Once on the Register, these structures
and sites are eligible for federal restoration funds and are protected
from demolition by federally-financed projects, such as highway con-
struction or urban renewal.
There are now 151 properites listed on the National
Register and of these, 135 are individual nominations and 16 are his-
toric districts which protect a total of 671 structures. As of 1974,
there are 806 structures and sites included in the National Register
from Alabama. A detailed list of these structures and sites is pre-
sented in the Technical Support Document.
3.1.14. Environmentally Sensitive Areas
Generally, the riparian wetlands have been relatively
intolerant to man's activities in the upper reaches of the watersheds
in the study areas. In other words, areas close to Birmingham reflect
less diversity in both flora and fauna than those areas downstream
contiguous to Bankhead Reservoir.
These upper reaches are unable to assimilate the exces-
sive amounts of wastes received from the Birmingham industrial area.
Therefore, no unique sensitive areas exist in the upper stretches
adjacent to the streams.
No man-made sensitive areas--archeological, historical,
cultural or recreational sites—exist adjacent to the streams in the
study area that are influenced by stream pollution.
Essentially, three primary types of vegetative cover
exist in Jefferson County, Alabama. These are:
1. Marsh
2. Riparian Wetlands
3. Upland Forests
Figure 3-43 shows the general locations of these types.
3-141
-------
FIG. 3-43. EXISTING TYPES OF VEGETATIVE COVER
-------
Marsh Areas. The primary marsh area is located con-
tiguous to Bayview Lake. Generally, the upper portions of the lake
fringes are characterized by verdant growths of rushes, cattails,
sedges, marsh grasses and other aquatic plants, both submerged and
emergent. There are small scattered pockets of marshland in some of
the low-lying bottom lands. These are somewhat temporary in nature,
being characterized as marsh or swamp in periods of heavy rainfall or
river flooding.
Riparian Wetlands. Riparian wetlands as used here
denotes the gradually sloping stream banks adjacent to the Village and
Valley Creeks watersheds. These are characterized by loose sandy
soils. Heavy growths of river cane, honeysuckles, willows, and various
forbs and terrestrial grasses form the major vegetative cover types.
Certain portions of the watershed stream banks are hilly or composed
of limestone bluffs. These areas give themselves over to a climax
forest.
Climax Forest. By far the greater portion of these
watersheds are rolling uplands to steep hills or bluffs. Generally,
the upland forest type reaches from the ridges down to the stream
banks. There are certain areas where a certain species will dominate.
For example, in the areas where extensive lumbering occurs, pines are
the predominant species. The upland climax forest type consists
primarily of pines, oaks, hickories, beeches, poplars, and gums.
3.2. FUTURE ENVIRONMENT WITHOUT THE PROPOSED ACTION
3.2.1. Ambient Air Quality
3.2.1.1. Introduction
An air quality dispersion model was employed in the
prediction of ambient air quality conditions as a result of the pro-
posed action by the U. S. Steel Corporation. A detailed analysis has
been provided in the Technical Support Document to the Impact
3-143
-------
Statement. By predicting participate concentrations at monitoring
stations, it was found that a reduction of 63 percent would occur
as a result of the U. S. Steel modernization program. The results
are presented in Table 3-31. The 63 percent reduction is believed
to be of the correct order of magnitude; however, there may be limits
to and inadequacies in the model. Because of these limits to and
inadequacies in the model, the magnitude of the numbers presented in
Table 3-31 must be considered with caution. These inadequacies
include:
1. All the conditions were run assuming full
production rates were in effect.
2. Area sources are not adequately handled
by the AQDM.
3. The emission estimates incorporated into
the model are based on the latest EPA in-
formation and best data available; however,
only a portion of the data was obtained
from stack sampling analysis.
4. AQDM does not consider variations in terrain
which is a serious limitation considering
the valley/ridge nature of the Birmingham area.
5. Only emission sources which were under the
control of the U. S. Steel Corporation, which
emitted significant quantities of particulates
and were specifically altered as a result of
construction of the Q-BOP, coke battery, or
blast furnace, were incorporated into this
analysis.
6. The most significant source (up to 50 percent)
in the first two conditions was the fugitive
emissions from the open-hearth furnace in
Fairfield. The AQDM assumes complete dispersion
of particulates into the atmosphere, but this
is not the case since some sedimentation does
occur.
3-144
-------
TABLE 3-31
EXPECTED ARITHMETIC MEAN OF PARTICULATES
co
i
-£»
01
Expected Arithmetic Mean of Participates (Micrograms/cu. meter)
Station
Bessemer
Fairfield
West End
East Thomas
Birmingham
Downtown
NASN
Tarrant
Woodlawn
Mountain Brook
Huffman
Irondale
Grid Position (Km)
504.4-3695.5
507.9-3704.9
513.6-3705.5
514.0-3709.1
517.2-3712.4
517.3-3707.7
518.6-3707.0
521.5-3715.9
522.3-3710.7
524.1-3703.0
528.7-3717.9
527.2-3710.8
Jefferson County's Data
189-0966)
130-0971)
131-0972)
148-(1967)
130-0971)
131-0973)
246- (1966)
215-0971)
161-0971)
103-0972)
203- (1966)
140-0971)
144-0966)
113-0971)
53-0971)
58-(1973)
130-(1971)
Computer Model*
Condition #1 (pre-1972)
80
193
25
15
8
14
16
5
8
10
3
7
Computer Model
Condition #5
25
74
10
5
3
5
6
2
3
3
1
2
* Percent
Reductions
62
61
60
67
63
64
63
60
63
70
67
71
Avg. 66 percent
* Contribution from U. S. Steel Emission Sources Only
-------
The limitations described above could result in either
over or underprediction of total suspended particulate concentrations.
As an example, the model would tend to overpredict emission concen-
trations as a result of the assumption of full production rates and
the assumption that no sedimentation occurred. However, because only
U. S. Steel's emission sources were included in the modeling analysis,
underprediction of ambient air quality particulate concentrations would
occur. Recognizing these limitations of the model and the inability
to calibrate and verify the model during the progress of this investi-
gation, it was determined that the primary goal of the modeling
analysis would be to describe relative improvements in the ambient air
quality in the Birmingham area as a result of the action proposed by
the U. S. Steel Corporation.
Each of the five conditions described below was selected,
the emission rates developed, and the AQDM employed to project ambient
air quality conditions. At the completion of the computation, a rela-
tive improvement of conditions 2 through 5, when compared to condi-
tion 1, was developed to describe the net improvement in ambient air
quality as a result of the actions by the U. S. Steel Corporation.
This form of analysis permits the reasonable use of the predictive
tool as well as making assumptions with regard to the absolute magni-
tude of the particulate concentrations which cannot ba confirmed at
this time The conditions analyzed in this investigation were as
follows:
Condition 1. Condition 1 describes the emissions and
projects the ambient air quality total suspended particulate concen-
trations which occurred prior to 1972 from the primary production
facilities (coke, iron, and steel) at the Fairfield-Ensley complexes
of the U. S. Steel Corporation. The details of the emission rates
are described in Appendix A-2.1. The primary facilities included in
the analysis are Ensley and Fairfield blast furnaces, Ensley and
Fairfield open-hearth furnaces, and Fairfield coke batteries. The
emissions also include fugitive emissions from stockpile associated
with the above described facilities.
3-146
-------
Condition 2, Condition 2 is described in Appendix
A-2.5 as emissions from the primary production facilities (coke, iron,
and steel) at the Fairfield and Ensley complex if control devices had
been employed on pre-1972 operations rather than modernization of the
complex. Although admittedly a hypothetical condition, the analysis
contains all the same facilities described under Condition 1;
specifically, these facilities were Ensley and Fairfield blast fur-
naces, Ensley and Fairfield open-hearth furnaces, and Fairfield coke
batteries. This condition represents the future condition without
the modernization, at state implementation emission limits.
Condition 3. Condition 3 is intended to describe
existing conditions occurring in the U. S. Steel complex at state
implementation emission limits. It includes blast furnaces and coke
batteries at full production level plus the addition of two Q-BOP
furnaces which have been previously constructed and are presently in
operation at the Fairfield facilities.
Condition 4. Condition 4 describes interim operations
during the start-up of the proposed facilities. During this period,
it is anticipated that three blast furnaces will exist at Ensley Works,
four blast furnaces at Fairfield Works, and three Q-BOP's and five
coke batteries at Fairfield Works. The emission levels from each of
these sources are based on full production of facilities.
Condition 5. Condition 5 describes the final configu-
ration of facilities after the modernization program with the three
blast furnaces at Ensley Works shut down, a total of four coke
batteries in operation at Fairfield Works, plus the existing and
replacement Q-BOP's and the existing and new blast furnaces at
Fairfield Works.
The results of the analysis for each of these conditions
are presented in Figures 3-44 through 3-47. The figures depict the
percentage reduction of the U. S. Steel Corporation's contribution to
ambient TSP concentrations referred to as Condition 1. Additionally,
Figures 3-48 through 3-52 give the absolute magnitudes of the ambient
3-147
-------
U. S. STEEL FACILITY
3,710
3,709
3,708
3,707
3,706
3,705
3,704
3,703
3,702
3,701
513
FIG. 3-44. -PERCENT REDUCTION OF USSC CONTRIBUTION TO AMBIENT
PARTICULATE CONCENTRATIONS FOR CONDITION 2
% = (CONDITION 1 - CONDITION 2)/CONDITION 1 x 100
3-148
-------
U.S. STEEL FACILITY
3,711
3,710
3,708
3,707
3,706
3,705
3,704
3,703
3,702
3,701
511
512
513
FIG. 3-45. PERCENT REDUCTION OF USSC CONTRIBUTION TO AMBIENT
PARTICULATE CONCENTRATIONS FOR CONDITION 3
% = (CONDITION 1 - CONDITION 3)/CONDITION 1 x 100
3-149
-------
U.S. STEEL FACILITY
3,711
503
S04
FIG. 3-46. PERCENT REDUCTION OF USSC CONTRIBUTION TO AMBIENT
PARTICULATE CONCENTRATIONS FOR CONDITION 4
% = (CONDITION 1 - CONDITION 4)/CONDITION 1 x 100
3-150
-------
U. S. STEEL FACILITY
3,711
3,710
3,709
3,708
3,707
3,706
3,705
3,704
3,703
3,702
3,701
503
504
512
513
FIG. 3^7. PERCENT REDUCTION OF USSC CONTRIBUTION TO AMBIENT
PARTICULATE CONCENTRATIONS FOR CONDITION 5
% = (CONDITION 1 - CONDITION 5)/CONDITION 1 x 100
3-151
-------
U. S. STEEL FACILITY
3,711
3,710
3,709
3,708
FIG. 3-48 USSC CONTRIBUTION TO AMBIENT EXPECTED ARITHMETIC
MEAN OF PARTICIPATES FOR CONDITION 1
3-152
-------
U. S. STEEL FACILITY
3.711
3,710
3,709
3,708
3,707
3,706
3,705
3,704
3,703
3,702
3,701
503
504
FIG. 3-49. USSC CONTRIBUTION TO AMBIENT EXPECTED ARITHMETIC
MEAN OF PARTICULATES FOR CONDITION 2
3-153
-------
U.S. STEEL FACILITY
3,711
3,710
3,709
3,708
3,707
3,706
3,705
3,704
3,703
3,702
3,701
503
504
FIG. 3-50 USSC CONTRIBUTION TO AMBIENT EXPECTED ARITHMETIC
MEAN OF PARTICULATES FOR CONDITION 3
3-154
-------
U.S. STEEL FACILITY
3,711
3,710
3,709
3,701
3,707
3,706
3,705
3,704
3,703
3,702
503
504
505
507
508
509
510
511
512
513
FIG 3-51 USSC CONTRIBUTION TO AMBIENT EXPECTED ARITHMETIC
MEAN OF PARTICULATES FOR CONDITION 4
3-155
-------
U. S. STEEL FACILITY
FIG. 3-52. USSC CONTRIBUTION TO AMBIENT EXPECTED ARITHMETIC
MEAN OF PARTICULATES FOR CONDITION 5
3-156
-------
TSP concentrations. These figures should be approached with caution
because of the limitations and inadequacies in the model.
3.2.1.2. Future Conditions Without the Proposed New Sources
Of the five conditions analyzed during the ambient air
quality investigations, Condition 2 represents future conditions
without the proposed new source. Based on discussions in the alterna-
tives chapter of this document, it appears that the Condition 2
situation would not have been economically feasible. An analysis of
Condition 2 which describes the ambient air quality resulting from
pre-1972 equipment complying with the State Implementation Plan
emission limitations indicates that the ambient air quality concen-
trations in Jefferson County will exceed those that will occur as
a result of the proposed action (Condition 5), which is total
modernization.
Figure 3-45 presents reduction of U. S. Steel's contri-
bution to ambient TSP concentrations for Condition 2. Condition 2
represents the existing ambient air quality for the pre-1972 sources
controlled with best available control technology. Condition 1,
pre-1972 conditioning, was used as the standard condition in the cal-
culation of the percent reductions. Inspection of this figure identi-
fies a significant reduction in total suspended particulates as a
result of employing best available control technology on existing
facilities. Percent reduction calculations were also performed for
Conditions 3, 4, and 5. The results are presented in Figures 3-46,
3-47, and 3-48, respectively. Further discussion of Condition 5
appears later in this document. Other pollutant emissions (S02>
hydrocarbons, CO, NOY) are not anticipated to change significantly
A
as a result of this action. The Environmental Protection Agency has
determined that the increase in hydrocarbon emissions from the pre-
heater on the new coke oven battery will be subject to the offset
policy requirements presented in Section 129 of the 1977 New Clean
Air Act Amendments.
3-157
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3.2.2. Water Quality
3.2.2.1. Future Conditions Without the Proposed Facilities
For the purpose of this discussion, it has been assumed
that only the blast furnace is considered as a new source and, there-
fore the wastes from that source will be addressed with regard to
their influence on environmental impact. Based on the analysis pre-
sented herein, it does not appear that small alterations of any
dischargers to these streams will cause a significant improvement, or
degradation of the existing water quality. However, it is antici-
pated, based on its present design, that the discharge from the
Valley Creek STP will double, resulting in a degradation of the
existing water quality. It should be emphasized that not only
point source, but non-point source discharges, which are substan-
tially more difficult to control, contribute to the poor water
quality conditions presently existing in Opossum and Valley Creeks.
Village Creek would exist in a condition similar to
that presently occurring without the proposed action. It should be
emphasized, however, that substantial reductions in organic loads as
a result of the final construction and operation of the new municipal
waste treatment facilities on Village Creek will reduce the organic
loads to the system and will improve water quality conditions to some
extent. Nevertheless, accurate projections of these improvements
would be difficult considering the existing state of the water quality
conditions of Village Creek, and furthermore, considering upstream
contaminants which may be caused by point or non-point source discharges,
the final water quality conditions may not be improved greatly.
3-158
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3.2.3. Biology
3.2.3.1. Future Without the Proposed Action
Previous sections have pointed out the significant
variation in physical stream characteristics and susceptibility of
Village, Valley and Opossum Creek to the extreme flow and temperature
variations. These variations can be directly attributed to land use
practices and wastewater discharges associated with the headwaters of
each of the aforementioned streams. Recently Frazier (1972) has pointed
out that velocity is a dominant physical factor affecting stream life.
Most stream dwelling species are adapted to and require particular flow
velocities. Tolerance ranges are rather narrow and often will vary
with different stages of the life cycle. Behavioral influences directly
related to current velocities include spawning, egg development,
juvenile growth, adult life, and migratory habits. Also velocity may
indirectly determine food and habitat availability through its influence
on invertebrate life, turbidity, erosion and sedimentation. Generally
high stream velocities associated with flood flow conditions have adverse
effects on stream biota (Darnell, 1976). The data developed by Elwood
and Waters (1969) indicate that severe flooding can have a devastating
effect on the young of the year class fishes and significantly reduce
the density of older fishes. Studies conducted in California by Seegrist
and Gard (1972) indicate that flooding can change the species composition
of a stream dramatically and that these effects can persist for several
years. Extreme low flow conditions can also greatly affect the stability
from aquatic community structure. Discontinuance flow reduces the stream
habitat to a series of isolated pools which subsequently become stagnant
thus exposing the surviving fishes and invertebrates to a greater preda-
tion by both aquatic and terrestial organisms (Larimore, 1963). Unstable
or severely alternating stream flow characteristics create an environment
that few aquatic species can tolerate. In such incidences extreme velo-
cities occur under natural conditions; populations existing in such
3-159
-------
habitats are characterized by repeated invasion and subsequent demise
(Darnell, 1976). The addition of other environmental factors, i.e.,
the introduction of toxic substances into streams subject to extreme
variation in velocities would be expected to accelerate the break-down
of a stable aquatic community structure.
Streams subject to extreme flow variations are in
most cases subject to extreme temperature fluctuations. This is
especially true for those streams that are impacted by construction
activities such as channelization as well as those streams that receive
significant concentrations of runoff from impervious substances associated
with industrial, commercial and high density residential land uses. The
upper reaches of Opossum, Village and Valley Creeks have been shown
to fall within this category. The magnitude of thermal insult does not
have to be of a degree to directly kill aquatic organisms in order to
endanger any species within the aquatic community. Damage to the aquatic
community structure can occur well within the zone of tolerance, since
temperature may act as a catalyst, a depressant, an activator, a restrictor,
a stimulator and a controller of biological metabolism (U. S. Department
of the Interior, 1967). Temperature has been shown to significantly affect
metabolism, respiration, behavior, distribution and migratory habits,
feeding rates, growth and reproduction, as well as the susceptibility of
fish to parasites and diseases (De Silva, 1969). Temperature has also
been shown to enhance the effects of other toxic agents within the aquatic
environment. The summary of combined and synergistic effects of toxic
materials on fish by De Silva (1969) and more recently by Middlebrooks
(1973) leads to two general conclusions: toxicity frequently increases
with increased temperature and organisms subjected to toxic materials are
less tolerant of temperature extremes.
Based on the biological, chemical and physical information
of Opossum, Valley and Village Creeks, even without the proposed action
none of these streams will recover with any degree of rapidity. To bring
all of the aforementioned factors into focus a Recovery Index and an
3-160
-------
Inertia Index proposed by Cairns and Dickson (1975) and personal communi-
cation with Dickson (1977) have been utilized. The Recovery Index contains
the following considerations:
1. Existence of nearby epicenters for providing
organisms to reinvade a damaged system.
(From the biological--fish, invertebrates
and periphyton--and physical evaluations of
the three systems studies, the existence of
nearby epicenters is rated as poor.)
2. Transportability or mobility of dissemules--
the dissemules might be spores, eggs, larvae,
flying adults which might lay eggs, or other
stages in the life history of an organism
which permits it either voluntarily or involun-
tarily to move to a new area. (From the fact
that no fish and only a few invertebrates were
found in Opossum at the upstream reference, the
transportability rating for Opossum is poor.
Using the same biological indicators the rating
for Valley and Village is moderate.)
3. Condition of the habitat following pollutional
stress. (Physical habitats—riffles, pools,
shelves, etc.---in Village and Valley Creeks are
good and without pollutional loads should allow
for excellent diversity development. For this
reason both creeks are given a habitat rating
of good. Opossum Creek has very little habitat
diversity due to a tar-like substrate and is
given a rating of poor.)
4. Presence of residual toxicants following pollu-
tional stress. (Based upon sediment analysis
3-161
-------
for heavy metals and organics all streams are
rated with large amounts of residual toxicants.)
5. Chemical-physical environmental quality after
pollutional stress. (Village and Valley Creeks
are given a rating of moderate for chemical -
physical environmental quality. This is based
on the fact that physical substratum has not
been significantly altered. Opossum on the other
hand is rated as being in severe disequilibrium.)
6. Management or organizational capabilities for
immediate and direct control of damaged area.
(All creeks are rated with some management or
organizational capabilities due to the existing
208 studies in Jefferson County.)
In a classification of less than 55 to greater than 400,
Opossum has a rating of 2, Valley and Village have values of 48. None
of the streams have a good chance of making a rapid recovery in an environ-
ment without the proposed action.
Inertia has been defined by the developers of the index
as the ability of an aquatic community or ecosystem to resist displace-
ment of disequilibrium in regards to either structure or function, i.e.,
a stream with a high Inertia Index has a high degree of inertia and will
not change from its present state without a great deal of effort. In
contrast a stream with poor environmental inertia will alter itself from
its present situation with slight alterations. The Inertia Index includes
the following considerations:
1. Indigenous organisms accustomed to highly
variable environmental conditions.
Based upon collections of fish, periphyton, and benthic macroinvertebrates
the following ratings have been assigned: Opossum had no fish, only
3-162
-------
tolerant invertebrates and only a few algal species and is rated as good
since those organisms found are able to withstand wide ranges of stress;
Valley and Opossum are rated as moderate because a greater diversity of
all organisms was observed.
2. System has high structural and functional redun-
dancy .
Classification of all 3 streams is moderate in regard to structural
and functional redundancy, because each system is neither complex
(mature) nor one with absence of fractionation of activities. These
streams rather fall somewhere between these two extremes.
3. Stream order, flow dependability, turbulent
diffusivity, and flushing capacity.
Stream order, flow dependability, turbulent diffusity and flushing
capacity are not considered dependable in any of the three systems
in the light of carrying away toxicity. For this reason all streams
are rated poor.
4. Hard, well-buffered water antagonistic to
toxic substances.
The water of all 3 systems is hard (<250 hardness as CaCO- and well-
buffered) (Alkalinity 50-90). As a result, the general effect is one
of antagonism to toxic parameters observed. Rating for all streams is
good.
5. System close to a major ecological transitional
threshold (e.g., from a cold to a warm water
fishery).
None of the streams are close to a major ecological transitional thres-
hold. Opossum experiences periodic thermal fluctuations, but they are
unpredictable and inconsistent. Rating for all streams is with a
substantial margin of safety.
6. Presence of a drainage basin management group
with a water quality monitoring program.
All streams were given a weak rating. This is reflective of the extended
period of time which will be required to improve these streams.
3-163
-------
In a classification of less than 55 to greater than 400,
Opossum has a rating of 108, Valley and Village have values of 72. This
index shows that all three streams have a moderate degree of inertia,
i.e., a moderate ability to resist their present disequilibrium. This
indicates that if all of the present perturbations were removed, the
streams would recover. This statement must be evaluated in light of the
Recovery Index previously discussed which indicated that recovery would
not be rapid. This is not a contradiction but shows only that the
tendency to return to a normal (unstressed) situation exists. However,
due to residual toxins, etc. this will not occur without a large degree
of environmental change.
Based on the above information, the future of Opossum,
Valley, and Village Creeks will continue to be a stressed situation.
The presence of high concentrations of toxicants in the sediments will
persist for long periods of time without the construction of the new
blast furnace. Also, water quality will continue to be degraded due to
non-point discharge, extreme temperature and flow variations, and the
general misuse by the public through solid waste disposals.
3.2.4. Socio-Economic Conditions
3.2.4.1. Future Environment Without the New Source
To simulate economic impacts to the region a 50 percent
decline in regional steel production is assumed (Birmingham Regional
Planning Commission). A total 1980 steel and iron products value is
estimated at $738,469,000, therefore, a 50 percent reduction would
reflect an output decline of $369,235,000. This would associate with
a decline of 11,234 employees and a payroll loss of $127,854,000 based
on an annual salary of $11,381 per employee. In terms of disposable
personal income, $102,411,000 is available for spending ($95,242,000
for personal consumption expenditures; $7,169,000 for housing). Total
projected decreases are thus:
3-164
-------
(1973) Personal Consumption Related $102,411,000
Decreased Steel Production 369.235,000
(1973) TOTAL DECREASE $471,646,000
It can be assumed that a decline in regional steel pro-
duction would cause other sectors in the overall regional economy to
contract. This assumption establishes criteria against which alterna-
tives can be evaluated. These changes are listed in Table 3-32. A
regional income multiplier of 1.96 is established when the total produc-
tive output reduction is divided by the value added decrease. In other
words, each dollar loss resulting from base realignment results in an
additional loss of 96 cents in the regional economy.
Employment changes in other sectors will result from this
simulated change to the economy. These are reflected in Table 3-33.
Direct employment losses would be 11,234, therefore, the additional
13,104 job losses reflect a regional employment multiplier of 2.16.
That is, each direct job loss results in an additional 1.16 job losses.
3-165
-------
TABLE 3-32
IMPACT ANALYSIS (IN MILLIONS OF DOLLARS)
BRPC STEEL SIMULATION, 1980
1.01
1.02
1.03
1.04
2.04
2.05
2.06
3.01
3.05
3.07
3.09
3.10
4.01
4.02
4.03
4.04
4.05
4.06
4.07
4.08
5.01
5.02
5.03
5.04
5.05
5.06
5.07
5.08
5.09
5.10
5.11
5.12
5.13
5.14
5.15
6.01
6.02
6.03
6.04
Livestk+Livestk Products
Field + Orchard Crops
Forestry + Fishery Prods
Agri , Forst + Fish Serve
Coal Mining
Crude Petrol + Nat Gas
Stone + Clay Mining
Food + Kindred Products
Fabrics, Yarns + Threads
Tire Cord+Misc Text Gds
Apparel Frm Purchsd Matr
Misc Fabricated Text Prd
Sawmills + Planing Mills
Veneer + Plywood
Lmbr+Wood Prd Ex Contnrs
Wooden Containers
Household Furniture
Othr Furn + Fixtures
Pulp + Papr Prd Ex Contnrs
Paperbrd Containers+Boxe
Petrol Refng + Reltd Prd
Paving Mix+Asphalt Prd
Industrl Ihorg+Org Chem
Fertilizers
Agri Chem Ex Fertlzrs
Misc Chem Prd
Plast Mtrls+Resin+Syn Ru
Org Manmade Fibers
Drugs
Cleaning Preparations
Toilet Preparations
Paints + Allied Prd
Tires + Innertubes
Othr Rubber Prd
Manifac Plastics Prd
Glass + Glass Prd
Cement+Lime+Gypsum Prd
Clay+Cement Prd+Refactrs
Othr Nonmet Mineral Prd
TOTAL OUTPUT
REDUCTION
1.636
0.458
0.150
0.434
6.203
0.727
1.130
17.191
1.155
0.013
3.530
0.264
0.354
0.305
0.905
0.054
0.643
0.060
1.104
0.619
3.448
0.322
4.446
0.025
0.019
1.301
0.053
0.038
0.100
0.164
0.133
0.360
0.154
0.079
0.176
0.007
0.462
5.085
0.238
TOTAL V.A.
REDUCTION
0.624
0.348
0.091
0.235
4.232
0.547
0.824
5.526
0.478
0.005
1.779
0.118
0.150
0.116
0.447
0.022
0.329
0.034
0.517
0.265
0.665
0.151
2.615
0.008
0.009
0.643
0.025
0.023
0.076
0.091
0.093
0.169
0.079
0.044
0.098
0.004
0.279
2.764
0.132
3-166
-------
TABLE 3-32 (Cont'd)
IMPACT ANALYSIS (IN MILLIONS OF DOLLARS)
BRPC STEEL SIMULATION, 1980
(continued)
7.01
7.02
7.03
7.04
8.01
8.02
8.03
8004
8.05
8.06
8.07
9.02
9.03
10.03
10.05
10.06
10.07
10.08
11.01
11.02
11.04
11.05
12.01
12.02
12.03
12.05
12.06
12.07
13.01
13.02
13.03
14.01
14.02
14.03
14.04
14.05
15.03
16.01
16.02
Primary Iron + Steel
Primary Copper
Primary Aluminum
Othr Prim Nonferrous Met
Metal Cans
Metal Barrel s,Drum+Pai Is
Met Sanit+Plumbing Prd
Nonelec Heating Equip
Fab Structural Metal Prd
Screw Mach Prd+Stamping
Othr Fab Metal Prd
Gen Indus Mach+Equip
Machine Shop Prd
Mining Machinery
Mtrl-Hndlng Mach Ex True
Indust Trucks + Tractors
Metal Working Machinery
Specl Indstry Machinery
Motor Vehicles + Parts
Aircraft + Parts
Locomivs+Rail+St Cars
Cycles, Trailers, etc.
Elec Measuring Instrumts
Elec Motors + Generators
Industrl Controls, etc.
Light Fixt+Wiring Device
Electrnc Compnts+Access
Misc Electrical Machinry
Serve Industry Machinery
Household Appliances
Radio, TV+Commun Equip
Scientific Instrmnts,etc
Med,Surgcl , Dental Instr
Watches, Clocks + Parts
Optical+Opthalmic Goods
Photo Equip + Supplies
Office Supplies
Ordnance + Accessories
Othr Misc Prd
TOTAL OUTPUT
REDUCTION
401.980
0.587
0.766
2.153
0.084
0.059
0.031
0.103
0.358
2.519
6.241
3.278
2.692
0.063
0.309
0.003
0.172
0.483
1.923
0.087
0.027
0.012
0.001
0.012
0.526
0.306
0.007
0.008
0.041
0.044
0.011
0.022
0.037
0.002
0.023
0.006
1.171
0.041
2.131
TOTAL V.A.
REDUCTION
184.714
0.159
0.277
0.699
0.035
0.023
0.015
0.051
0.174
1.234
3.395
1.797
1.867
0.031
0.179
0.002
0.111
0.274
0.534
0.043
0.010
0.005
0.001
0.007
0.301
0.166
0.004
0.005
0.019
0.022
Oo006
0.013
0.023
0.001
0.014
0.004
-0.000
0.024
1.194
3-167
-------
TABLE 3-vk (Conf d)
IMPACT ANALYSIS (IN MILLIONS OF DOLLARS)
BRPC STEEL SIMULATION, 1980
(continued)
17,01
17.02
17.03
17.04
17.05
17.07
18.01
18.02
18o03
18.04
19.01
19.05
20.01
20.02
20.03
20.04
20c05
20.06
21.01
21.02
21.03
21.04
21.05
21.06
21.07
21.08
22.01
Railroads+Relatd Serves
Local+Highway Passngr TR
Motor Freight+Warehouse
Water Transportation
Air Transport
Transportation Services
Tel ecommuni cati on
Electric Power
Gas
Water + Sanitary Service
New Const. Nonf arm Res id
Maintenance+Repair Const
Wholesale+Retail Trade
Finance + Insurance
Real Estate + Rental
Advertising
Othr Bls+Prof Services
Bus Travel ,Enter+Gifts
Printing + Publishing
Radio + TV Broadcasting
Hotels + Lodging Places
Persnl+Repar Serv.Ex Car
Automobile Repair+Servc
Amusements
Medical + Health Service
Educat Servc+Nonprof Org
Post Office
Total
TOTAL OUTPUT
REDUCTION
8.062
1.122
11.921
0.469
0.301
0.053
6.541
100892
6.493
0.446
7.169
8o811
36.531
18.292
13.244
4.096
12.749
3.491
2.429
0.002
0.938
3.886
3.104
1.117
5.139
6.691
1.155
657.009
TOTAL V.A.
REDUCTION
5.459
0.710
6.762
0.237
0.177
0,038
50390
8.069
2.457
0.263
20954
4.806
27.358
9.390
11.328
3.256
8.085
0.000
1.638
0.001
0.561
2.595
1.726
0.583
3.805
4.074
0.887
334.699
3-168
-------
TABLE 3-33
IMPACT ANALYSIS, BRPC STEEL SIMULATION, 1980
1.01
1.02
1.03
1.04
2.04
2.05
2.06
3.01
3.05
3.07
3.09
3.10
4.01
4.02
4.03
4.04
4.05
4.06
4.07
4.08
5.01
5.02
5.03
5.04
5.05
5.06
5.07
5.08
5.09
5.10
5.11
5.12
5.13
5.14
5.15
6.01
6.02
6.03
6.04
Livestk+Livestk Products
Field + Orchard Crops
Forestry + Fishery Prods
Agri , Forst + Fish Serve
Coal Mining
Crude Petrol + Nat Gas
Stone + Clay Mining
Food + Kindred Products
Fabrics, Yarns + Threads
Tire Cord+Misc Text Gds
Apparel Frm Purchsd Matr
Misc Fabricated Text Prd
Sawmills + Planing Mills
Veneer + Plywood
Lmbr+Wood Prd Ex Contnrs
Wooden Containers
Household Furniture
Othr Furn + Fixtures
Pulp+Papr Prd Ex Contnrs
Paperbrd Containers+Boxe
Petrol Refng + Reltd Prd
Paving Mix+Asphalt Prd
Industrl Inorg+Org Chem
Fertilizers
Agri Chem Ex Fertlzrs
Misc Chem Prd
Plast Mtrls+Resin+Syn RU
Org Manmade Fibers
Drugs
Cleaning Preparations
Toilet Preparations
Paints + Allied Prd
Tires + Innertubes
Othr Rubber Prd
Manufac Plastics Prd
Glass + Glass Prd
Cement+Lime+Gypsum Prd
Clay+Cement Prd+Refactrs
Othr Nonmet Mineral Prd
3-169
EMPLOYMENT
REDUCTION
99
28
3
26
266
10
43
211
46
1
142
11
22
10
37
4
40
2
29
18
12
4
75
1
1
35
1
1
2
2
2
7
4
4
9
0
10
146
12
-------
TABLE 3-33 (Cont'd)
IMPACT ANALYSIS, BRPC STEEL SIMULATION, 1980
(continued) EMPLOYMENT
REDUCTION
7.01
7.02
7.03
7.04
8.01
8.02
8.03
8.04
8.05
8.06
8.07
9.02
9.03
10.03
10.05
10.06
10.07
10c08
11.01
11.02
11.04
11.05
12.01
12.02
12.03
12.05
12.06
12.07
13.01
13.02
13.03
14.01
14.02
14.03
14.04
14.05
15.03
16.01
16.02
17.01
17,02
17.03
Primary Iron + Steel
Primary Copper
Primary Aluminum
Othr Prim Nonferrous Met
Metal Cans
Metal Barrel s,Drum+Pai Is
Met Sanit+Plumbing Prd
Nonelec Heating Equip
Fab Structural Metal Prd
Screw Mach Pro+Stamping
Othr Fab Metal Prd
Gen Indus Mach+Equip
Machine Shop Prd
Mining Machinery
Mtrl-Hndlng Mach Ex True
Indust Trucks + Tractors
Metal Working Machinery
Specl Indstry Machinery
Motor Vehicles + Parts
Aircraft + Parts
Locomtvs+Rail+St Cars
Cycles, Trailers, etc.
Elec Measuring Instrumts
Elec Motors + Generators
Industrl Controls, etc
Light Fixt+Wiring Device
Electrnc Compnts+Access
Misc Electrical Machinry
Serve Industry Machinery
Household Appliances
RadiOjTV+Commun Equip
Scientific Instrmnts,etc
Med.Surgcl , Dental Instr
Watches, Clocks + Parts
Optical+Opthalmic Goods
Photo Equip + Supplies
Office Supplies
Ordnance + Accessories
Othr Misc Prd
Railroads+Relatd Serves
Local+Highway Passngr Tr
Motor Freight+Wa rehouse
3-170
13,261
11
26
74
2
2
1
3
13
129
312
102
231
3
8
0
6
17
26
2
1
2
0
0
22
12
0
0
1
2
0
1
2
0
1
0
100
1
95
278
37
603
-------
TABLE 3-33 (Cont'd)
IMPACT ANALYSIS, BRPC STEEL SIMULATION, 1980
(continued) EMPLOYMENT
REDUCTION
17004 Water Transportation 14
17.05 Air Transport 15
17.07 Transportation Services 5
18.01 Telecommunication 317
18.02 Electric Power 184
18.03 Gas 126
18.04 Water + Sanitary Service 4
19.01 New Const.Nonfarm Resid 183
19005 Maintenance+Repair Const 110
20001 Wholesale+Retail Trade 3,120
20.02 Finance + Insurance 683
20.03 Real Estate + Rental 150
20.04 Advertising 17
20.05 Othr Bus+Prof Services 809
20.06 Bus Travel,Enter+Gifts 185
21.01 Printing + Publishing 150
21.02 Radio + TV Broadcasting 5
21.03 Hotels + Lodging Places 81
21.04 Persnl+ Repar Serv. Ex Car 173
21.05 Automobile Repair+Servc 95
21.06 Amusements 68
21o07 Medical + Health Service 577
21.08 Educat Servc+Nonprof Org 398
22.01 Post Office 105
Total 24,338
3-171
-------
4. DETAILED DESCRIPTION OF THE PROPOSED PROJECT
-------
CHAPTER 4
DETAILED DESCRIPTION OF THE PROPOSED PROJECT
4.1. PHYSICAL FACILITIES
4.1.1. Construction
The new blast furnace will take a minimum of 29 months
to construct with a possible manpower peaking period around the
twentieth month. Estimated peaking daily manpower requirement will
be approximately 1,200 men during construction. The Birmingham
SMSA will provide the major percentage of this work force except for
certain specialty subcontractors.
Blast furnace No. 8 will be characteristic of the
larger capacity, higher top pressure facilities being constructed by
the industry during this decade. The use of beneficiated fuels has
increased output as well as assisted control of the process from
environmental considerations. The three products of operation—molten
iron, slag, and blast furnace gas--are all of value and will be
utilized.
4.1.1.1. Location
Blast Furnace. Blast furnace No. 8 will be located
immediately north of existing blast furnace No. 7 at Fairfield
operations. Fairfield Works is an integrated steelmaking facility
located within Opossum Valley and southwest of the City of Fairfield,
Alabama. Fairfield operations cover approximately 5,000 acres. The
blast furnace complex area plan (as shown in Figures 4-1 and 4-2)
will occupy 13.15 acres.
Materials Storage. The storage layout is shown in
Figure 4-1. The materials will be in a stockhouse area, 1,100 feet
north of the new blast furnace. Supply of materials to the blast
furnace will be by means of hoppers and conveyor belts.
4-1
-------
Waste Treatment Facilities. The waste treatment
facilities are shown on Figure 4-2, and are located approximately
600 feet southwest of the blast furnace.
Slag Pits. Slag will be dumped into two slag pits
immediately north of the blast furnace proper for cooling (see
Figure 4-1). The slag pits will be used alternately until emptied
and conveyed to Exum Landfill (see Figure 4-10).
Service Facilities. The location of the service
facilities will be immediately north of facilities for blast furnace
Nos. 7, 6, and 5, which run north to south. This will allow existing
transportation facilities — railroad lines, roads, utility lines,
etc.--to be easily adapted to the new facility.
4.1.1.2. Methods
Organization. This type of construction requires many
specialty contractors. Accordingly, U. S. Steel Corporation will
manage the activities of its contractors.
Scheduling. Clearing and grubbing of 13.15 acres
of land will be followed by foundation and drainage activities.
Foundations will be engineered and vary with the equipment and
structure requirements. Caissons will be excavated down to supporting
rock for heavy structures. The bedrock is limestone with anticipated
sinkholes and other discontinuities. In the event such disconti-
nuities are encountered, spread footings will be used for major
structures. The structural contractor will then follow, erecting the
furnace, superstructure, stoves, supporting facilities, etc. The
mechanical, piping, and electrical work will be started as construction
permits.
4.1.1.3. Requirements
Equipment. The major equipment items to be used on this
project are as follows:
4-2
-------
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MATERIAL HANDLING SYSTEM
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Foundations — Four drill rigs for caissons, one backhoe,
2 1/2-cubic yard capacity bulldozer, 2 1/2-cubic yard capacity front-
end loader, 60-ton capacity crawler crane, 50-ton capacity truck crane,
offsite concrete batch plant, dump trucks of various sizes, roller
compaction equipment, concrete delivery trucks of various capacities,
and miscellaneous light trucks.
Structural--Four crawler cranes of various sizes up to
150 tons, two tower derricks of 150-ton capacity, two mobile truck
cranes up to 65-ton capacity, straddle truck, and numerous trucks of
various capacities.
Electrical and Piping—Various trucks, small cranes,
welding machines by all contractors.
Energy—All fuels for the internal combustion equipment
will be furnished by contractors from local sources. Electrical power
for lighting and small tools will be supplied from existing plant
sources. The remainder of special electric power requirements is
anticipated to be furnished by contractors with their own generating
facilities.
Materials--It is estimated that the following major
materials will be used in this project: 44,000 cu yd of reinforced
concrete and 16,000 tons of structural steel. Eighty-five percent of
this material is expected to be delivered by rail. Potable water is
to come from existing plant sources.
Work Force—It is anticipated that the peaking force
required for this project will be approximately 1,200 workmen.
Safety—Construction will proceed under stringent safety
procedures, either those of OSHA, or U. S. Steel's safety programs,
whichever is more stringent. Accident records will be kept by the
individual contractors. Any other records will be maintained by the
Plant Safety Department.
Sanitary--Facilities for this project are to be portable
chemical toilets as approved by the local health offices.
4-5
-------
4.2. OPERATION
4.2.1. Resultant Changes
4.2.1.1. Process
The new blast furnace will require a different charge
than is given the other blast furnaces. Blast furnace No. 8 will require
iron ore pellets, sinter, coke and limestone. With start-up of No. 8,
remaining furnaces 5, 6, and 7 will also receive a more refined material
charge than they are presently receiving. Improved performance and
reliability should result. A detailed net raw material demand list for
Fairfield Works before and after break-in of the No. 8 blast furnace is
presented in Table 4-1.
4.2.1.2. Energy Balance
An energy balance for the existing iron-making facilities
at Fairfield Works, based on rates for the year 1976, is provided in
Figure 4-3. Inspection of this figure reveals that a total of 16.57
MMBTU was required for each ton of iron produced. Implementation of
blast furnace No. 8 and phasing out of 1, 2, and 3, will result in the
energy requirements depicted in Figure 4-4. Analysis of this figure
reveals that a total of 14.43 MMBTU will be required per ton of iron
produced, a savings of 2.14 MMBTU per ton of iron produced.
4.2.1.3. Water Requirements
Water required for the blast furnace will be supplied
from the Birmingham municipal water supply system and the Birmingham
Industrial Water Board. No treatment is required of the water before
entering the water systems associated with the blast furnace. The
amount and sources of this increased water demand are outlined in
Table 4-2.
4-6
-------
TABLE 4-1
ANTICIPATED RAW MATERIAL DLMAND CHANGES
WITH BLAST FURNACE HO. 8
Material
Produced Total
or Required FCE No.l FCE No. 2 FCE No. 3 Ensley FCE No. 5 FCE No. 6
Iron Ore Required
Crude 478,000 478,000 477,000 1,433,000
Coarse 65,000 65,000 66,000 196,000 296.000 306,000
Sinter (Fine) 143,000 143,000 143,000 429,000 610,000 632,000
Pellets
Coke Required 217,000 217,000 217,000 651,000 343,000 355,000
Limestone 37,000 36,000 36,000 109,000 55,000 57.000
Dolomite 16,000 17,000 16,000 49,000
Total Stone
Blast Furnace
Falrfleld 5,6,7
Falrfleld 8
Ensley 1,2,3
Sinter Plant
Sinter Required
Hot Metal Produced
Total Total
FCE No. 7 Falrfield Blast FCES
-- 1,443,000
402,000 1,004,000 1,200,000
829,000 2,071.000 2,500,000
__
466,000 1,164.000 1,815.000
75.000 187.000 296,000
49,000
Before No. 8
Completed
1,433,000
1,200,000
2,500,000
0
5,133.000
1,815.000
296,000
449,000
745,000
187,000
0
158,000
400,000
745,000
2,500,000
2,900,000
After No. 8
Total Completed
FCE No. 5 FCE No. 6 FCE No. 7 FCE No. 8 Blast FCE 'ln9Yean"S/
0
145,000 195,000 260,000 — 600,000 600,000
335,000 449,000 599,000 1,117,0002,500.0002.500,000
171,000 229,000 305,000 1,675,000 2,380,000 2,380,000
236,000 316,000 435,000 963,0001,950,0001,950,000
28,000 38,000 54,000 134,000 254,000 318,000
395,000
713,000
120,000
134,000
0
459,000
~7T3,000
2,500,000
3,500,000
-------
TABLE 4-2
ADDITIONAL INDUSTRIAL WATER REQUIREMENTS9
NO. 8 BLAST FURNACE, FAIRFIELD WORKS
Normal
User gpm 9Pd
Blast Furnace
Make-up to Gas
Cleaning System 800 1,152,000
Strainer
Backwash 0 0
Strainer
Backwash 0 0
Cooling Tower
Make-up 320 460,800
Running Blast
Furnace Gas
Seals 300 432,000
1,420 2,044,800
Boiler House
Boiler Feed-
water Make-up 1,150 1,656,000
Cool ing Tower
Make-up 600 864,000
3,170 4,564,800
Peak
gpm gpd
1,100 1,584,000
500 720,000
300 432,000
320 460,800
300 432,000
2,520 3,628,800
2,800b 1,800,000°
660 950,400
5,980b 6,379,200°
aCity of Birmingham Industrial Water Board
Short Duration Peak
cDay Peak
4-8
-------
B.F. GAS TO STOVES
BLAST FURNACE GAS
46,274 MMBTU/DAY
vo
I RON, SLAB & LOSS
(NO ENERGY VALUE ASSIGNED)
BLAST FURNACES
NOS. 1.2. 3. 5.6. &7
PRODUCTION RATE:
6188 NT/DAY (1976)
COAL DERIVATIVES
89,107 MMBTU/DAY
NATURAL GAS
557 MMBTU/DAY
FUEL OIL
124 MMBTU/DAY
ELECTRICITY
371 MMBTU/DAY
STEAM
12,376 MMBTU/DAY
TOTAL: 102,535 MMBTU/DAY (16.57 MMBTU/TON)
ENERGY BALANCE
FIG. 4-3. IRONMAKING - FAIRFIELD WORKS
-------
B. F. GAS TO STOVES
BLAST FURNACE GAS
55,072 MMBTU/DAY
I
o
I RON, SLAG, & LOSS
(NO ENERGY VALUE ASSIGNED)
19,704 MMBTU/DAY
BLAST FURNACES
NOS. 5, 6, 7 & 8
PRODUCTION RATE:
NOS. 5, 6, & 7 FCES.
4640 NT/DAY
NO. 8 FCE-4949 NT/DAY
TOTAL IRON-9589 NT/DAY
COAL DERIVATIVES
117,544 MMBTU/DAY
NATURAL GAS
863 MMBTU/DAY
FUEL OIL
192 MMBTU/DAY
ELECTRICITY
575 MMBTU/DAY
STEAM
19,178 MMBTU/DAY
TOTAL: 138,352 MMBTU/DAY (14.43 MMBTU/TON)
ENERGY BALANCE
FIG. 4-4. IRONMAKING - FAIRFIELD WORKS
-------
4.2.1.3. Empl oyment
Manpower changes in operations at Ensley and at
Fairfield will result from the break-in and operation of blast
furnace No. 8, as well as from the subsequent idling of Ensley
blast furnaces 1, 2, and 3. The base period before the break-in
will have three operating blast furnaces each at Fairfield and at
Ensley. The break-in period will have four operating furnaces at
Fairfield and three at Ensley. This period will require an incremental
increase of 259 employees at Fairfield Works. Subsequently, three
Ensley furnaces will be idled, causing a reduction in work force with
each furnace idling. Idling of the three furnaces will reduce the
operating work force by 45, then 68, and 168, sequentially. The net
reduction in Fairfield Works caused by modernization of the blast
furnace operations will then be 22 positions at the blast furnace.
4.2.2. Process Description
A blast furnace is a circular shell of steel about
130 ft high, which is lined with heat resistant fire brick. The
new blast furnace will use a different top charging procedure than
the existing Fairfield blast furnaces. It will have a greater
capacity, require a more refined material burden, and operate at a
higher internal pressure.
4.2.2.1. Material Handling
Materials for smelting are stored in the stockhouse.
These materials are loaded onto the charging conveyor from another
conveyor system which is loaded from the silos in the stockhouse.
The conveyor belt traveling to the furnace top pours its contents
into a receiving hopper.
4-11
-------
4.2.2.2. Charging the Furnace
Once the burden material is weighed, the material is
dumped onto a 60-in. collector belt, and taken at a rate of 342 fpm
to the furnace top by the main charging belt. At the top of the
furnace, the material is charged through a series of hoppers and
their associated seal valves onto a revolving chute which discharges
the burden into the furnace.
The top of the furnace is designed to operate from 0
to 30 psig top pressure. The system, Figure 4-5, contains a twin
hopper arrangement. Each hopper can be pressurized to 30 psig.
The key features of the furnace top are two lockhoppers
equipped with flap valves, material flow control valves, a single
central discharge into the furnace, a rotating chute which is adjustable
in slope from outside the furnace and the design for replacement of
any major component in 16 hours.
Burden materials are charged into the furnace through
its top by alternately opening and closing the seal valves above and
below each lockhopper. To accomplish this and to prevent the escape
of gas to the atmosphere, it is necessary that each lockhopper be
alternately pressurized and depressurized. Pressurization of each
lockhoppar is accomplished with nitrogen. This eliminates emissions
from the top.
Nitrogen required to pressurize the two lockhoppers is
produced at the air separation plant. This nitrogen is discharged to
the atmosphere when a hopper is depressurized.
As the batch of material is discharged, additional
nitrogen can be forced into the lockhoppers to replace the volume of
the materials emptied. Then, when the lockhopper is depressurized to
receive the next batch, principally nitrogen is emitted.
The rotating chute can be used to charge raw material
to any portion of the furnace throat area, including what used to be
"the shadow of the bell." Spiral charging will be used.
4-12
-------
Feed Chute
Lock
Hoppers
Furnace Top
Working Platform
\
Furnace
Throat
FIG.4-5.TWIN HOPPER SYSTEM OF CHARGING FOR
BLAST FURNACE NUMBER 8
4-13
-------
Typically, the revolving chute will rotate at 8 rpm,
driven by a 600/1,800-rpm motor. The relation of lockhopper size
and flow control gate opening is such that a discharge time of 90
sec is obtained and material is distributed into the furnace during
the corresponding 12 revolutions of the chute.
The spiral layers of coke, ore, and limestone placed
in the furnace in accurately measured quantities will insure that
iron of the desired chemical analysis will be produced. Charging,
or filling, the furnace is a continuous process, more materials being
added as those within the furnace melt and flow into the hearth, or
bottom.
A gas analyzing probe capable of extending to and
receiving gas samples from the center of the furnace or any of nine
other positions back to the wall will aid in determining maximum gas
utilization and burden distribution.
4.2.2.3. Hot Air Supply
Adjacent to the blast furnace will be three cylindrical
shells with dome-shaped tops. These will be the hot blast stoves.
The function of these stoves is to furnish extremely hot air to the
furnace to aid combustion of the coke. Within the hot blast stove
is a labyrinth of fire bricks called checkers. Gas from the blast
furnaces is burned in the combustion chamber of the stoves until the
bricks in the stove dome have been heated to a temperature of 2300°F.
Then the gas is cut off and air is blown through the stove, where it
absorbs heat from the checkers, and then into the bottom of the blast
furnace through openings called tuyeres. This continues until the
temperature of the checkers has been reduced to a point where the
desired hot blast temperature can no longer be delivered, then the
cycle is repeated. The stoves are operated alternately, one stove
furnishing a supply of hot air to the furnace while the others are
being heated. Heated air, at the rate of 210,000 cu ft of air per min,
will be blown into the blast furnace.
4-14
-------
4.2.2.4. Furnace Operation
The coke burns continuously, and its burning will be
greatly intensified by the heated air from the stove, blown in at
temperatures of 2100°F. The iron will sink gradually toward the
bottom of the furnace as the material beneath it melts away. The
heat greatly increases toward the bottom, where air makes contact
with the coke. The iron and limestone melt and trickle through the
flaming coke to the hearth, which is a cylindrical receptacle at the
base of the furnace.
The silica and certain other impurities in the melted
iron ore are absorbed by the molten limestone. This forms a slag
which is lighter than the molten iron and floats on the pool of liquid
metal. Every several hours a hole known as the "iron notch" is opened
in the hearth and the hot iron is allowed to flow out and down a
ceramic-lined trough. From the trough it flows into a sand-lined
runner, and from the runner into an insulated container referred to
as a "submarine" ladle. This drainage process is called "casting."
The flux and impurities are withdrawn in the form of
slag. These materials are separated from the iron by the casting
operation and diverted to the slag pits for cooling and subsequent
removal to a slag dump.
Nearly all of the iron produced at Fairfield Works is
used in the making of steel. Iron for this purpose is transferred
to the Q-BOP department where it is poured into huge cauldrons, or
hot metal mixers. There it is held in a molten state until needed
for charging into the Q-BOP furnaces. A portion of the hot iron is
used at the foundry to produce ingot molds. Some of the iron may be
moved to the pig casting machine at the ladle house where it is poured
from a ladle into two parallel, endless chains of pig molds. As the
molds move slowly upward and outward, the metal hardens into solid
blocks of "pigs." The "pigs" are cooled by water sprays, and
discharged into railroad cars.
4-15
-------
4.2.3. Design Summary
1. 32-ft diameter
2. 26 tuyeres, 2 compartment tuyeres (separate nose
cooling)
3. 30 psi high top pressure (maximum)
4. 77,520 cu ft working volume
5. Ratio working volume to sq ft of hearth is 96.4
6. Three stoves (total heating surface 1,993,600 sq ft)
7. 2100°F hot blast—Bloom stove burners
8. Mohr-Raco hot blast valves with automatic stove
changing controls
9. 210,000 cfm @ 60 psi wind max
10. One Ingersoll-Rand axial turbo blower
11. Two 900-psi steam pressure boilers (Combustion
Engineers' type)
12. Two iron notches (with provisions to remove trough)
13. Two 75-ton casthouse cranes (one 15-ton cinder
running crane)
14. One cinder notch
15. Two slag pits
16. Bailey-Wurth mud guns--Woodings low profile iron
notch drills
17. 5,000 tons per day (6,000 tons peak hot metal)
capacity
18. Six 250-ton submarine-type hot metal cars
19. 1,100 Ib/NTHM coke equivalent
20. 150 Ib/NTHM flux
21. Liquid fuel injection (No. 6 fuel oil)
22. Burden mix--60 percent pellets, 40 percent sinter
23. Pellets, sinter and coke to be screened
24. Conveyor charged furnace (60 in. belt to top speed
342 fpm)
4-16
-------
25. Cutler hammer charging control system (two directors
for furnace operation linked to Honeywell 4400
computer at the Q-BOP for monitoring furnace operation)
26. Stockhouse capacity (coke, 13.5 hr; sinter, 22.5 hr;
pellets, 29.8 hr; miscellaneous material, 30.0 hr)
27- Stockhouse has three coke, two sinter, two pellet,
four miscellaneous and two fines monolithic concrete
silos
28. Koppers-Wurth-type top "no bells" (nitrogen purge),
one 30-ton crane for servicing top
29. BAUMCO gas cleaning system with closed water system
(Venturi type without septum valve)--both contact and
non-contact water systems are recycled
30. Channel cool externally bosh and hearth
31. Underhearth is water cooled
4.2.4. Operational Parameters
Raw Materials Required
Coke 950,000 tons/yr
Sinter 1,125,000 tons/yr
Pellets 1,700,000 tons/yr
Flux (Limestone) 130,000 tons/yr
Products
Iron 1,825,000 tons/yr
Slag 600 Ib/ton hot metal
Blast Furnace Gas 110 x 109 ACF
4.3. WASTE GENERATION
4.3.1. Gas Cleaning
As the air strikes the burning coke, the fuel gives off
hot carbon monoxide gas which rises through the furnace, reacting on
4-17
-------
the layers of ore and removing much of the oxygen. The gas thus formed
is highly combustible and is suitable for use as fuel. It is collected
at the top of the furnace and is forced out through pipes called
"uptakes."
After cleaning, part of the gas is piped to the hot blast
stoves to continue the heating process, maintaining a continuous cycle
of heat from stove to blast furnace back to stove. The remainder of the
gas is burned in steam boilers to produce power for the blowers which
force air into the furnace. This gas is also used to turn generators,
producing electrical current that assists operation of some of Fairfield's
mills.
The maximum expected volume of gas produced by No. 8
blast furnace is 300,000 standard cu ft per min (scfm). This gas will
contain approximately six grains of dust per cu ft. On this basis, the
total quantity of dust leaving the top of the furnace is 188 tons per
day.
The generated blast furnace gas will be taken off the top
of the furnace through four large uptakes which connect to form one
downcomer to the dustcatcher. Gas will enter the top of the dustcatcher
and travel down a cone in the center of the tank. As the gas passes
through the cone, it will be decelerated upon entering the bottom part
of the tank. The heavier dust particles will maintain their velocity
and will be driven to the bottom of the dustcatcher as the gas exits
and is piped to the Venturi scrubbers.
With an efficiency of approximately 33 1/3 percent, some
62 tons of dust are removed from the gas and collected in the bottom of
the dustcatcher for periodic removal. Removal of dust from the dust-
catcher is accomplished by opening a system of valves to permit discharge
through a pug mill. Available water and/or steam is injected into the
pug mill to prevent dusting when discharged into a truck. This material
will then be delivered by truck to the sinter plant for recycling.
The gas, now containing approximately four grains per
cu ft, will pass from the dustcatcher to adjustable-throat Venturi
4-18
-------
scrubbers, having a minimum efficiency of 99.87 percent for final
cleaning. Here the velocity of the gas is significantly increased by
passing through a throat restriction in which water sprays are located.
The high velocity gas atomizes the water which entrains the dust particles,
thus removing the dust particles from the gas stream. The maximum dust
content of the cleaned gas is now 0.005 grains per cu ft.
The blast furnace gas at this point will have been so
thoroughly cleaned that it can be reused directly in the stoves of No. 8.
Only part of the gas is used in the stoves, the remainder being piped
to the boilerhouse. The system will maintain a constant gas back
pressure of 85 in. FLO for the No. 8 blast furnace stoves and release
the balance, a pressure of 20 in. H?0 to the boilerhouse. Any excess
gas will be burned in a stack at the boiler-turbo-blower building.
The separator-cooler functions as two separate systems.
The gas and dirty water enter the tank. The dirty water immediately
separates and is gravity fed to the classifier and then to the
thickeners. The gas goes through a spin vane where it exits to the
upper portion of the tank. The gas will be cooled to a maximum 100°F.
The slurry mixture of dust and water is collected for
passage into the recirculated, enclosed waste water treatment system.
The water treatment schematic for blast furnace No. 8 is presented in
Figure 4-6. The slurry flows to a spiral classifier which removes
some of the larger solids and silt. This material is recycled to the
furnace through the sinter plant, as is dust from the dustcatcher.
The slurry flow is then normally equally split to one
of two 80-ft diameter thickeners. Thickeners are circular reinforced
concrete tanks. Dirty water enters at the center of the thickeners
and clarifier effluent leaves over a continuous weir which follows
the tank circumference. Rotating arms carry a series of rakes set
at an angle such that the solids are settled and gently pushed toward
the center of the thickener. Thickener underflow is pumped to one of
two vacuum filters which filter the sludge and produce a filter cake.
This material is also recycled by sending it through the sinter plant.
4-19
-------
HOT BLAST FURNACE GAS
SPIRAL
CLASSIFIER
HOT BLAST FURNACE GAS
(ENTRAINED DUST)
A
$
SOLIDS
(TO SINTER PLANT)
SLURRY
WATER
INFLUENT
/COOLED,CLEANED\
' BLAST FURNACE I BO'
EFFLUENT
WATER
SLUDGE
FILTER
/FURNACE \ "
/5000 TONS\
(IRON /DAY }
1 1 3
z
a: a:
u. H
K *
3s
^
IS
INDUSTRIAL „
MAKEUP
WATER '
/
1
c
r1
t
DUST
270
GPM
270
GPM
iif, .!££,
II II
,(V
/
1,
HOT WELL || COLD WELL
I
STRAINER
BACKWASH"^
TO GAS
/
1
1
tf
\ S /
MAKEUP
(AS REQUIREDll
1 1 1
1 1
SLAG PIT SUMP
CLEANING AND ;
COOLING WATER
'
-S
SLUDGE
^X—^X^ ^ (TO SINTER PL
k. * SLUDGE
/ 120 GPM 120 GPM 120 GPM
H( Hi W
C\ \
\ /COOL
1 \J TOW
J
1 1
t
| . .. _ ||in«rtrtrtv-vr- t
HOT WELL || COLD WELL
n
— 7030 GPM
TO STAG PITS
FURNACE SYSTEM SLOWDOWN AND GAS CLEANING SYSTEM MAKE-UP
CLEANING SYSTEM
FIG.4-6.WATER TREATMENT FLOW DIAGRAM FOR NUMBER 8 BLAST FURNACE
-------
Cationic polymer addition at a concentration of 5 ppm
and anionic polymer feed of approximately one ppm concentration will
assist in producing a satisfactory effluent by acting as a coagulant.
The effluent water, still at an elevated temperature,
is discharged into the hot well. The flow then passes through one of
three cooling towers which achieves the desired temperature reduction.
The cooled effluent water will now be of such a nature
that it can be successfully reintroduced to the gas cleaning and
cooling equipment. Prior to entering the scrubber, a portion will be
diverted from the system to serve as make-up for the slag pit sump.
Slowdown will be utilized to quench the blast furnace
slag. A major portion of this water evaporates in quenching with the
remainder filtering through the slag for collection and recycle in the
slag pit quench system. Slowdown from the gas cleaning system is
expected to be as much as 0.65 mgd.
4.3.2. Casthouse Emissions
Based on information provided by the U. S. Steel
Corporation, no basic iron casthouses in the United States have air
emission controls. No casthouse emission controls are planned for
the new blast furnace at Fairfield Works.
4.3.3. Cooling
Due to the very high temperatures obtained in operating
the blast furnace, a large amount of cooling water is required. This
is recirculated through the independent furnace cooling system.
Encircling the furnace are water troughs into which
water supplying the numerous cooling circuits is discharged as visible
streams. Water flows from these troughs into a hot well. The water
is then pumped to one of two evaporative cooling towers where the desired
temperature reduction is achieved. Water from these cooling towers is
4-21
-------
collected in a cold well. All required make-up water for both waste
treatment and furnace cooling water systems may effectively be added
at this point. Slowdown from cooling will be employed as make-up to
the gas cleaning water system. This system blowdown will also be
accomplished prior to and in conjunction with strainer operation. The
water will then be reintroduced into the numerous cooling circuits
encompassing the furnace shell. Blowdown will go first to other
treatment facilities for cooling and then to the final effluent control
pond before eventual discharge to Little Creek, which enters Opossum
Creek.
The furnace stack will be cooled by circulating water
through stack plates which are imbedded in the brickwork of the furnace.
There are 26 rows of stack plates offering cooling up to 11 ft, 6 in.
beneath the stockline. The bosh and hearth will have external channel
coolers. In the area of the two iron notches, outside jackets and
internal staves will provide the cooling. External channel coolers also
will be used at the tuyeres level around the 26 water-cooled tuyeres
and corresponding tuyere coolers. Under-hearth cooling will be accom-
plished by collecting water from the stack system and gravity feeding
it through twenty, 3-in. stainless steel pipes imbedded in the bottom
course of the carbon block hearth. A cinder notch will be available at
the north side of the hearth if it is needed. For normal operations the
cinder notch will be covered.
The water pumped from the furnace col dwell sump will be
used in the stack plates. Stove valves, tuyere noses, and tuyere
cooler water from the stove valves and tuyere noses is pumped back to
the bosh channels and tuyere jackets before it goes to the hotwell sump.
Stack cooling system discharge will be collected and run through the
upper hearth, lower hearth, and underhearth cooling which discharges
back to the hotwell sump. Because of the large volume of water pumped
through this system, the water is expected to pick up about 20°F of
temperature in the entire cycle. Industrial make-up water will be
automatically added to the furnace col dwell sump as required.
4-22
-------
4.3.4. Slippages or Service Requirements
On infrequent occasions a large mass of burden material
within the furnace will descent rapidly, creating a sudden increase in
internal furnace pressure. To prevent damage to furnace top equipment,
bleeder valves are positioned near the junction of the four uptakes and
the downcomer and are located 280 ft above grade. These valves are
safety valves for emergency use only and are designed to automatically
and sequentially open at varying pressures to relieve excessive furnace
pressure by discharging furnace gas to the atmosphere (see Figure 4-7).
The time interval during which these valves are open is usually of short
duration. The slips that will occur in the new blast furnace will be
greatly reduced in frequency of occurrence. Slip frequency should occur
on a monthly recurrence.
4.3.5. Material Handling
The burden to be charged into No. 8 blast furnace includes
iron-bearing material, coke, and flux material. Iron-bearing material
will consist of iron ore pellets and sinter. Flux material will include
gravel, dolomite, and limestone.
All burden materials will be delivered to the furnace
complex by railroad car and transferred to the stockhouse storage silos
by conveyor systems. Coke will be transmitted directly from the coke
battery to the stockhouse silos by conveyors.
Pellets, coke, sinter, and flux will be withdrawn from
the stockhouse silos by vibrating pan feeders and placed on belt conveyors,
Pellets, coke, and sinter will be screened as the material comes from the
respective belt conveyors and deposited into weight hoppers. The weight
hoppers will discharge directly onto another conveyor. Coke will be
screened to remove minus 1/8-in material. Minus 1/4-in material will
be removed from the pellets and sinter. Conveyors will transfer these
materials to storage silos. The flow diagram for this facility is shown
in Figure 4-8.
4-23
-------
Explosion Clean Gas
Relief Valves Bleeder Valve
Stove
Heating Stack
Coke
Pellets
Sinter
-£>
rv>
Clean Gas
To Stoves
Clean Gas
To Steel Plant
Scrubber
Cooler
Slag
Iron
Mini
Scrubber
FIG. 4-7 GAS CLEANING SYSTEM FOR BLAST FURNACE
NUMBER 8
-------
(8) FEEDERS
36" X 7'-o"e> 6°
240 . .TPH
2-SD. VIB. SCREENS
8 X 14 212 TPH C» 20'
(2^ VIB. FEEDERS
60 X 9-0' 1° 2O°
2060 JPH
FN0.8
BLAST
"URNACE
P-3
I
PELLETS
41500 FT3
14.9 HRS
3000 TONS
^-i >*PF-4
36' BELT <» 240 FPM 860 TPH
__«. __
L L
36" BELT ^240 FPW 860 TPH
P-2
BFCE-2
€0 BELT*
342 FPM
1765 TPH
-PHG-2
(2) Via FEEDERS
60"X 9'-0"®20°
1670 TPH
-2 S.D. VIB. SCREENS
8x14 . 20O TPH 162 FPM 240 TPH
FOR CONTINUATION OF
CONV. SEE DWG. J- 132923
ALL FLOW RATES SHOWN ARE MAX. CAPACITY
REF.
FLOW DIAGRAM DWG.J-I3292I
J-132923
<&\ FEEDERS
36" X 7'-0> 10°
340 . TPH
S-3
i
SINTER
39000 FT3
11.3 MRS
2260 TONS
36 BELT «*> 240 FPM 700 TPH
2£' BELT rt> 240 FPM 700 TFH
S-2
BFCE-1
60 BELT rs> 342 FPM
3590 TPH
CB-I
i' BELT * JOS FPM 65
1 4
TPH
(12) FEEDERS
36' X 7-0"
125 TPH
C-3
COKE
340OO FT3
4.5 HRS
600 TONS
2 S.D VIE
8*|4 254 TPHS22
(2) VIB. FEEDERS
60 X 9-0' «> 20°
670 TPH
2
COKE
34000 FT3
4.5 HRS
6OO TONS
7
.F-5
•-7
48 BELT r31 294 FPM 480 JPH
-8
4B" BELT «* 294 FPM 460 TPH
C-2
2
PELLETS
41500 FT3
14.9 MRS
3000 TONS
L L
2
SINTER
390OO FT3
11.3 HRS
2260 TON'S
3
COKE
340OOFT3
4.5 HRS
6OO TONS
7 T
i , .i!^ _ __>—(EMERGENCY)
-iJ-0
141-VIB FEEDERS
36M2-0'e 10°
250 TPH L,D,G
380 TPH M.O.,
121 VIB. FEEDERS
42' X 8-0'«" 10°
500'TPH L,D,G
750 TPH M.O.
W ^
M-2
MHG-I
T^IHF-H
MHG-2
MHF -2
36' BELT « 294 FPM B60 TPH
CD-VIB. FEEDER
60X9-00 20°
1670 TPH LDG
2225 TPH MJO.
j ®!SS:r-
9fU
MlT
RELEASED FOR
CONSTRUCTION ^
.. J3.:-357-:^4o .M^£
AL BfLf *« •*> _ **Tt ~ -
ON ORIGINAL
r r
• J J 3
5 ( 7 I CM
FIG. 4-8. FLOW DIAGRAM FOR MATERIAL FEED TO BLAST FURNACE NO. 8
IP
7 !i?-a--:'vi5 i-.-^- I
M.M
FIG. 4-8
BLAST FURNACE NO. 8
FAIRFIELD WORKS
Design Engineering
[U$S) United States Steel Corporation
Pittsburgh, Pennsylvania
[.tit
J-132922
4-27
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A dust collection system will be utilized to collect dust
that is generated when pellets, coke, and sinter are screened. The
system consists of dry collection baghouse units in the stockhouse which
are connected by ducts to hoods positioned over each screen. The pro-
duction rates for each of the two pellet, coke, and sinter screens in
the stockhouse are approximately 272, 254, and 200 tons per hr,
respectively, of screened material. Exhaust air is provided by fans
which are positioned downstream of the baghouses. These units have an
estimated efficiency of 99.9 percent. The collection units in the stock-
house are capable of handling an estimated 25,000 standard cu ft of dust
laden air per minute. Cleaned exhausted air from the collection units
will be discharged to atmosphere. Dust accumulated in the units will be
deposited in the storage silos along with the materials removed by the
screens for disposal by railroad car. This dust supression technique
will be utilized during railroad car loading.
There will be six separate baghouses with separate fans,
one at each exhaust point. These baghouses have design emission rates
of 428 Ib/hr, corresponding design exit concentrations of .005 gr/scfd
and design removal efficiencies of 99.9 percent. The fines collected
by the baghouses will be discharged onto a covered conveyor system to
covered silos. A wetting agent is sprayed on the dust to control it.
The wetted dust is sent to the sinter plant for agglomeration and sub-
sequent charging to the blast furnace. Figures 4-8 and 4-9 provide
schematic depictions of the material handling and charging areas.
The dust suppression system also employs a solution of
water and a wetting agent to produce a fog-type spray through the nozzles
to envelop and contain dust which may be generated during railroad car
loading. Application of the liquid spray is controlled by electrical
Interlocks and switches to activate sprays at specific locations only
when equipment at that location is operating.
4-26
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4.3.6. Boilers
Steam boilers power the blowers which force air into
the furnace and also turn the generators which produce the electrical
current required by many other facilities at the Fairfield plant.
These boilers normally burn generated blast furnace gas. A secondary
fuel supply that enriches the mix is coke oven gas. Beyond these two
supplies, natural gas is the third fuel to be fired if the other two
enriching sources are unavailable.
Failure of supply of the two secondary sources of fuel
(coke oven gas and natural gas) causes the automatic firing of a fuel
oil supply to the boilers. Particulate emissions in the event that
fuel oil will be burned will be 0.1 lb/1,000 BTU's of oil fired.
Maximum oil that could be fired per boiler is 32,645 Ib/hr (603,930,000
BTU/hr). The boilers are 425,000 Ibs steam capacity with 300,000 Ibs
produced by blast furnace gas and 125,000 Ibs by secondary fuel.
The S02 would be 1.08 lb/1,000 BTU if only oil fired.
The NO would be 0.3 lb/1,000 BTU if only oil fired. However, the
/\
blending of fuels will reduce this emission rate.
The lean blast furnace gas burned by the stoves is
enriched with natural gas before being fired. The boilers will use
natural gas stabilizing burners instead of enriching the blast furnace
gas before firing.
4.3.7. Blast Furnace Gas Emission Summary
Raw Gas
50 Ib dust/ton iron
125 tons/day dust (173.6 Ib/min)
Moisture - .004 Ib H20/cu ft
Temperature - 350°F-500°F
Pressure - 4 to 30 psig
4-27
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SINTER
SCREENS
PELLET
SCREENS
i r
I, ^f I » I ^#
1
I ROTARY LOCKS
HZ)
COKE SCREENS
FIG.4-9. SCHEMATIC DEPICTION OF MATERIALS HANDLING
FOR BLAST FURNACE NO. 8
-------
Dustcatcher
37.5 ton/day (52.1 Ib/nrin) or 30 percent
of total dust removed
Gas Entering Scrubber
Moisture - .004 Ib H20/cu ft
Temperature - 350°F-500°F
Pressure - 4 to 30 psig
87.5 tons/day dust (121.5 Ib/min), 3 to 4
grains/scf
Flow - 149,000 to 297,000 scfm
Gas Composition - 26 percent CO, 14.4 percent
1.6 percent H2, 58 percent N2
Clean Gas to Plant Gas Main
Moisture - 2.35 grains/scf
Dust Loading - .005 grains/scf (maximum)
Temperature - 100°F
Pressure - 20 in. HO in plant, main and 85 in.
H20 in blast furnace No. 8
4.3.8. Uastewater Treatment System Summary
Slurry Water (gas vessel to spiral classifier)
Dust Content (solids) - 2,180 ppm
Sp. Gravity (solids) - 3.5 to 4.5
Flow - 6,600 gpm
Temperature - 140°F (maximum)
Discharge from Spiral Classifier
1.0 ton/day solids
Slurry HpQ (influent to thickeners)
3,300 gpm normal (per thickener)
6,600 gpm maximum to one 80 ft thickener
4-29
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In - 2,180 ppm suspended solids
Out - 50 ppm (long-term average) normal
Cationic Polymer Feed - 5 ppm
Anionic Polymer Feed - 1 ppm
Sludge (thickener underflow) to Vacuum Filters
Solids - 35 to 50 percent by weight
Specific gravity (solids) - 3.5 to 4.5
Vacuum Filter Discharge
Solids - 75 percent (minimum) by weight,
86.6 tons/day
Through Cooling Towers
Evaporation - 120 gpm (each)
Influent Temperature - 140 F (maximum)
Effluent Temperature - 90 F (maximum)
B1owdown (intermittent to plant treatment including
final effluent pond)
Flow - 430 gpm, 125 gal/ton iron
Long-Term Average Concentrations - Suspended Solids*
50 ppm; Cyanide (total), 15 ppm; Phenol, 1.0 ppm;
Ammonia (as NFL), 62 ppm
4.3.9. Furnace Cooling System Summary
Flow - 13,700 gpm
Through Cooling Towers (2)
Evaporation - 270 gpm (each)
Influent Temperature - 125°F (maximum)
Effluent Temperature - 100°F (maximum)
B1owdown
Flow - 800 gpm (5 percent) to waste treatment
make-up, gas cleaning, etc.
4-30
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4.3.10. Water Discharges
Blast Furance No. 8. Blast furnace No. 8 will require
an additional 4.6 mgd of water at Fairfield (see Table 4-2). Based
on experience with the other operating blast furnaces at Fairfield,
the effluent stream generated by the facility will be less than 1 mgd
to the existing waste stream from the blast furnace area going to the
final effluent control pond. The remaining water is lost through
evaporation during cooling operations associated with the blast
furnace.
4.3.11. Solid Waste Management and Disposal
The solid waste disposal methods utilized by U. S. Steel
at the Fairfield Works do not impact the environment to any appreciable
extent. It is expected that the new facilities will function in a
manner that solid waste disposal will not have an adverse effect on the
ecosystems of the area. Present waste management practices are
expected to continue at the new facilities. Basically, solid waste
disposal practices are as follows:
Oil - Waste oil is a mixture of Bunker C (3,000 gal/yr)
and diesel fuel (6,000 gal/yr). Waste oil is either
reused in combination with slag to construct traffic
arteries and roads within the confines of U. S. Steel
property or it is transported to waste oil reclaim
operations.
Filter Cake - This residue is disposed of in a landfill,
the Exum Dump, the location of which is depicted in
Figure 4-10. The three primary sources of filter
cake are:
1. Coke Plant Lime/Bio Mass - This produces
approximately 3,300 dry tons annually.
4-31
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Q-BOP FILTER CAKES
COKE PLANT AND TIN MILL
FILTER CAKES
WJ >? •IfW'lWry ? I M^^rV^r^^^O^' f/ / 1
V
'/ ^mm^m^.^ : ;w!mifc//J?™\l ^^^^^%^\
FIG. 4-10. LOCATION OF U. S. STEEL FACILITIES - LAND FILL SITES
4-32
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2. Tin Mill Treatment Plant - Approximately
15,800 tons annually.
3. Q-BOP - Sludge and filter cake residue of
15,200 tons annually.
Part of the filter cake is recycled by sending it
through the sinter plant.
Sludge - There are four sources of sludge and the
disposition is as follows:
1. Sintering - Stock.
2. Blast Furnace - Recycled as sinter.
3. Rolling - Recycled as stock/sinter.
4. Pickling - Landfill on property.
Dust - From limestone is recycled; from transport
systems is recycled; from scrubber is settled,
thickened and transferred to a landfill; from
blast furnace is transported to the sinter plant
for recycling; from Q-BOP to stock.
Scale - From rolling mills is transported to the sinter
plant for recycling. It is recycled in the blast
furnace.
Slag - An independent contractor removes part of the
slag then processes it to remove iron. He then
sells it to another contractor who, in turn, resells
it for highway construction. It is used on property
for roadways.
Construction Rubble and Debris - Hauled to a USSC
dump site on USSC property.
Trash - Transported by USSC to a landfill on Oxmoor
Road operated by Jefferson County. Officials of
the Jefferson County, Alabama, Public Health
4-33
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Department indicate there is, to their knowledge,
no dumping of industrial wastes on any of the
public landfill" sites.
A detailed listing of the types of residuals, their
compositions, and ultimate disposal site locations is presented in
Appendix F to the TSD.
4-34
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5. IMPACTS OF THE PROPOSED ACTION
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CHAPTER 5
IMPACTS OF THE PROPOSED PROJECT
5.1. AIR QUALITY
5.1.1. Future Conditions with the Proposed Action—Total
Suspended Participates (TSP)
The results of the ambient air quality modeling
analysis in comparing conditions occurring in the Birmingham area
in 1972 (Condition 1) and those which will occur as a result of the
proposed action (Condition 5) are presented in Figure 5-1. Figure
5-1 depicts the percent reduction of the U. S. Steel Corporation's
contribution to the ambient TSP concentrations as a result of the
proposed new facilities (Condition 5, referenced to Condition 1).
The analyses reveal a maximum reduction of 90 percent in TSP
concentrations corresponding with the installation of the proposed
new facilities and it is apparent that a substantial overall
reduction in TSP concentrations will occur with the installation of
the proposed new facilities. Figures 5-2 and 5-3 show the absolute
magnitudes of the concentrations predicted by the model for Condition 1
and Condition 5, respectively. These figures indicate the area of
impact around U. S. Steel's facilities subject to inaccuracies due
to limitations in the model which have been discussed previously.
Based on these analyses, it is concluded that installation of the
proposed new facilities will have a positive impact with regard to
its influence on the air quality of the surrounding community and
should contribute to improve general environmental conditions. A
reduction in U. S. Steel emissions and concomitant improvement 1n air
quality would result from application of best technology to both new
and existing sources, including the construction of the proposed new
blast furnace (Condition 5).
5-1
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U. S. STEEL FACILITY
3,711
3,701
3,709
3,708
3,707
3,706
3,705
3,704
3,703
3,702
503
FIG. 5-1. PERCENT REDUCTION OF USSC CONTRIBUTION TO AMBIENT
PARTICULATE CONCENTRATIONS FOR CONDITION 5
% = (CONDITION 1 - CONDITION 5)/CONDITION 1 x 100
5-2
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U. S. STEEL FACILITY
3,711
3,710
3,709
3,708
3,707
3,706
3,705
3,704
3,703
3,702
3,701
503
FIG. 5-2. USSC CONTRIBUTION TO AMBIENT EXPECTED ARITHMETIC
MEAN OF PARTICIPATES FOR CONDITION 1
5-3
-------
U. S. STEEL FACILITY
3,711
3,710
3,709
3,708
3,707
3,706
3,705
3,704
3,703
3,702
3,701
510
511
512
513
FIG. 5-3 USSC CONTRIBUTION TO AMBIENT EXPECTED ARITHMETIC
MEAN OF PARTICULATES FOR CONDITION 5
5-4
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5.1.2. Future Conditions with the Proposed Action—Other
Pollutants
No attempt was made to model pollutants other than
TSP from air quality considerations. However, based on past and
projected emission rates for sulfur dioxide (802) and analysis of
the proposed process modifications and replacement facilities» it
is anticipated that ambient S02 and hydrocarbon concentrations will
not increase as a result of the proposed action. Figures 5-4 and
5-5 present S02 and particulate emission rates provided by U. S. Steel.
Actual particulate emission rates used in the modeling differed from
those depicted in these figures. Inspection of Figures 5-4 and 5-5
reveals a reduction in SCL emission rates from coking facilities,
compared to 1973. Neither the coking capacity nor the source of
coal will change during future operations compared to conditions
in the past. The U. S. Steel Corporation is presently in compli-
ance with appropriate emission regulations concerning SO,,.
As part of the March 31, 1978, settlement agrement with
the Alabama Air Pollution Control Commission, the State of Alabama,
the Jefferson County Board of Health, the United States of America,
and the Administrator of the EPA, U. S. Steel Corporation must submit
a hydrocarbon offset to the Jefferson County Department of Health for
the preheater and related coke battery facilities. This hydrocarbon
offset will be available for review by the public at the Jefferson
County Health Department prior to the start-up of the preheater. There
will not be a substantial environmental impact as a result of the proposed
action from the standpoint of pollutants other than total suspended
particulates, providing the hydrocarbon emissions can be reduced to an
acceptable level.
5.2. SOCIO-ECONOMIC CONSIDERATIONS
5.2.1. Future Environment with the Proposed Action
The extractive industry and its attendant activities
comprise the major foundation of the economy of Birmingham and
5-5
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en
i
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T V J
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QC=]
CD
Ml R 1 L II
U \
so2
POINT LOCATION TON/YEAR
A STACK 808
B STACK 819
C STACK 1,112
D STACK 1,131
E STACK 1,619
F STACK 849
G BAT NO. 3
.H BAT NO. 4
1 BAT NO. 5
J BAT NO. 6
K BAT NO. 7
L BAT NO. 8
.
7^__
f
1 i IOC 1 1 0 1
OP
°E on
II K I BO 1
EMISSIONS -1973
PARTICIPATE
TON/YEAR POINT LOCATION
ISO
- 1 —
S
II 10
HUN
HUM G IOA
SO2 PARTICULATE
TON/YEAR TON/YEAR
72 M BAT NO. 9 429
73 N QUENCH TOWER 249
100 0 QUENCH TOWER 223
101 P QUENCH TOWER 105
145 Q QUENCH TOWER 314
76 R QUENCH TOWER 419
408 S COAL UNLOADING 630
414 T COAL STORAGE 336
562 U COKE STORAGE 6
571 V CONVEYOR 33
441 COAL
377 CONVEYING 134
COKE
CONVEYING 4
6,338 6,222
FIG. 5-4. SO2 AND PARTICULATE EMISSIONS - 1973
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en
so2
POINT LOCATION TON/YEAR
EMISSIONS
PARTICULATE
TON/YEAR
1978(Proj.)
POINT LOCATION TON/YEAR
PARTICULATE
TON/YEAR
A STACK
B PREHEATER
C STACK
D STACK
E STACK
F BAT NO. 2
G BAT NO. 5
H BAT NO. 6
I BAT NO. 9
J QUENCH TOWER
K QUENCH TOWER
L QUENCH TOWER
M QUENCH TOWER
1,987
424
1,112
1,131
849
94
24
56
57
43
43
101
103
77
97
34
35
26
N
O
P
Q
R
S
T
U
V
W
X
COAL
CONVEYING
COKE
CONVEYING
COAL STORAGE
COAL UNLOADING
COKE STORAGE
PULVERIZER
SILOS
PULVERIZER
MIXER
TRANSFER BIN
PULVERIZER
CONVEYOR
BAT NO. 2
5,503
157
587
4
30
13
12
3
3
10
4
1
189
1,868
FIG. 5-5 S02 AND PARTICULATE EMISSIONS-1978 (PROJECTED)
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Jefferson County, Alabama. This economy is substantially dependent
upon steel production and related activities.
Projections of future growth for the Birmingham area
by local and state planners rely heavily on assuming continuing growth
of the iron and steel industry.
U. S. Steel is the primary influence in Birmingham's
metal facilities. Due to the fact that in 1975 the U. S.'s share
of world steel production was only 16.3 percent, an additional
35 million tons are needed by 1980. In order to maintain its exist-
ing production, U. S. Steel proposes construction of a new blast
furnace. This will enable certain antiquated facilities to be
phased out. An estimated increase of 600,000 tons per year of
steel will be produced at the new facilities.
To assess impact to the economy, certain estimates
must be made. An estimate of regional output of iron and steel pro-
ducts for 1980 dollar-wise is $738,469,000 (Birmingham Regional
Planning Commission Batelle-Columbus Laboratories, 1976).
Other estimates of types of direct changes to con-
sider are assumption of:
1. A decrease in the regional output of iron and
steel products.
2. A decrease in personal consumption spending as
a result of decreased payrolls.
At the present time, the economy of the Birmingham
area is healthier than at any previous time. To continue this trend,
proper balances must occur in employment diversification. Any major
decline in expected expansion in any of these areas could result in
higher rates of unemployment. The only adverse impact would be a
reduction of 22 employees assuming installation of blast furnace
No. 8. This is an insignificant effect on the overall economy. Details
concerning this evaluation can be found in the Technical Support
Document.
5-8
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5.3. WATER QUALITY
5.3.1. Future Conditions with the Proposed Action
In considering the future conditions with the proposed
action, the waste discharges contributed to receiving streams will be
shifted with regard to U. S. Steel's facilities. The present discharges
on Village Creek will be reduced substantially and some increase in dis-
charges to Valley Creek through Opossum Creek will occur. The proposed
action will reduce U. S. Steel Corporation discharge to Village Creek as
follows: 13.0 Ib/day of cyanides; 1.8 Ib/day of phenols; 103 Ib/day of
ammonia; and 1,668 Ib/day of suspended solids. The future conditions on
Opossum and Valley Creeks with construction of the new blast furnace will
result in increased loadings as follows: suspended solids increase 52 lb/
day; cyanides increase 1.3 Ib/day; phenols increase 2.77 Ib/day; and
ammonia increases 52 Ib/day (based on BATEA effluent limitations; see
Chapter 6).
The impact on Village Creek of the proposed action
will be to reduce the. contributions of pollutants from the U. S. Steel
facility. As discussed for Valley Creek, a measurable alteration
of the environment probably will not occur as a result of the proposed
action. Similar comments apply to an improvement in water quality
conditions as a result of reduction in waste load discharges by
U. S. Steel to Village Creek. Considering the large quantities
of contaminants entering Village Creek as a result of other point
and non-point sources, the final accurate prediction of improved
water quality conditions must be questioned. Nevertheless, it is
appropriate to indicate that some improvement to the backwaters
of Bayview Lake will accompany the improvement in the reduction of
waste load discharges to Village Creek from municipal facilities
as well as U. S. Steel Corporation. The resulting improvement below
Bayview Lake is dependent on the lake recovery which may not occur
(for an extended period of time) even if all contaminants cease to
be discharged to this reservoir.
5-9
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An indication of the impact of the new blast furnace
on the water quality in Valley Creek at BAT levels of treatment
can be obtained from a water quality model of Valley Creek. According
to the model predictions the blast furnace will decrease the dis-
solved oxygen in the river at the critical point by approximately
0.12 mg/1, increase the ammonia nitrogen concentration by approxi-
mately 0.1 mg/1, increase the phenol concentration by 0.012 mg/1
and increase the cyanide concentration by 0.001 mg/1 at the 10-year
seven-day low flow condition.
It must be kept in mind that these predictions are
made based on the assumption that all biological decay rates will
remain constant and that changes in the nature and level of waste
loads to the river have no effect on the kinetics of the biological
processes taking place in the river. However, significant changes
in the nature and amount of the waste being discharged to Valley
Creek will take place. The discharge of materials known to be
inhibitory to biochemical oxidation will be substantially reduced
from the U. S. Steel discharge and there will also be a substantial
reduction in the amount of oxygen demanding material. At the same
time, it is expected that the discharge from the Valley Creek Sewage
Treatment Plant will approximately double in volume and that the
concentration of oxygen demanding material in the waste will also
increase as the plant is brought up to its designed capacity. In
light of the radical changes that are expected in the wastes dis-
charged to Valley Creek it can be anticipated that there will be
chances in the biological kinetics affecting the water quality of
Valley Creek. Exactly what this effect will be, however, cannot be
determined with present technology.
5.4. BIOLOGY
5.4.1. Future Conditions with the Proposed Action
As stated in Section 5.3., adoption of the proposed
action will increase loadings of suspended solids, cyanides, phenols,
5-10
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and ammonia to Opossum and Valley Creeks. A decrease in the loadings
of these substances to Village Creek will also accompany adoption
of the proposed action. Overall impacts on water qualtiy will be
a net reduction of 8.9 MGD of wastewater, 1,616 Ib/day of total
suspended solids, 51 Ib/day of ammonia-nitrogen, 11.7 Ib/day of
cyanides and a net increase of 0.97 Ib/day of phenols discharged
to the tributaries of Bankhead Reservoir.
In the following analysis, the impacts of the proposed
action on the future environment are evaluated from the standpoint of
the Recovery Index methodology introduced in Chapter 3.
1. Existence of nearby epicenters for providing
organisms to reinvade a damaged system. (The
existence of nearby epicenters was given a rating
of poor for all of the streams affected. Adop-
tion of the proposed action will not alter this
rating.)
2. Transportability or mobility of dissemules—
the dissemules might be spores, eggs, larvae,
flying adults which might lay eggs, or other
stages in the life history of an organism
which permits it either voluntarily or
involuntarily to move to a new area.
(No fish and only a few invertebrates were
found in Opossum Creek at the upstream
reference station. Therefore transport-
ability or mobility of dissemules was
rated as poor for Opossum and the proposed
action would not alter this rating. While
U. S. Steel Corporation's discharges to
Village Creek will be reduced, no signifi-
cant alteration of transportability or
mobility is anticipated and Village retains
a rating of moderate. Similarly, while
Valley Creek will receive increases in
5-11
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loadings of solids, cyanide, phenols, and
ammonia, in-stream levels of these components
are not anticipated to change significantly.
Consequently, Valley Creek will retain a mod-
erate transportability and mobility of disse-
mules.)
3. Condition of the habitat following pollutional
stress. (Adoption of the proposed action will
not alter the physical habitats and the rating
for Opossum remains at poor and that of Valley
and Village at good.)
4. Presence of residual toxicants following pol-
lutional stress. (Sediment analyses for heavy
metals and organics indicate that all stream
sediments contain large amounts of residual
toxicants.)
5. Chemical-physical environmental quality after
pollutional stress. (Village and Valley Creeks
were given a moderate rating for chemical -
physical environmental quality. This is based
on the fact that physical substratum has not
been significantly altered. Opossum, on the
other hand, is rated as being in severe dis-
equilibrium.)
6. Management or organizational capabilities for
immediate and direct control of damaged area.
(All creeks are given a rating corresponding
to some management or organizational capabilities
due to the existing 208 studies in Jefferson
County.)
As a result of the above analysis, none of the streams
have the potential for rapid recovery. This is the case with or
without the new source. A similar analysis was performed using
the Inertia Index and yielded results identical to those obtained
without the proposed action.
5-12
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6. DISCUSSION OF ALTERNATIVES
-------
CHAPTER 6
DISCUSSION OF ALTERNATIVES
6.1. BUILD OR NO-BUILD
From the turn of the century until the early years of
this decade, all of the steel which was produced at what is now
Fairfield Works was produced by the open hearth process. Nine fur-
naces were built at Ensley, and later twelve furnaces were built at
Fairfield. Four of the Ensley furnaces were permanently shut down
in 1962. As production rates increased through improved technology,
environmental concerns heightened. The emissions from these furnaces
became a matter of great concern to the public and to U. S. Steel.
Due to obsolescence, it was quite clear that the years
of the Ensley open hearths were limited. The solution to the emission
problem at the remaining furnaces at Ensley had to be replacement
facilities or a permanent discontinuance of operations as the cost of
control equipment could not be justified in view of their limited
remaining life.
At Fairfield, a decision was made in 1971 to install
precipitators on the 12 open hearth furnaces, but the advent of a new
steelmaking technology—the Q-BOP furnace—brought about the decision
to replace the 12 Fairfield furnaces with a two-furnace Q-BOP facility,
which provided control of steelmaking emissions at Fairfield.
A decision on shutting down the Ensley open hearths
without replacing the capacity was separately addressed. If the Ensley
open hearths were to be shut down without replacement, it would result
in a 25 percent loss in steelmaking capability, the future of this
plant would have been uncertain, and the effect on the community would
have been severe. It is indisputable that a loss in steelmaking
capability would not complement and respond to the well documented
economic growth in the steel market in the South. Studies portrayed
6-1
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the opportunities available to U. S. Steel in maintaining its steelmaking
capability in the market area served by the Southern Steel Division,
and U. S. Steel moved forward with plans for new facilities to permit
continued production of raw steel required for operation with Ensley's
open hearths shutdown. This assured the future of Fairfield Works as a
major steel-producing facility, a matter of great significance to
Birmingham, to Alabama, and to the South. This decision on the part of
U. S. Steel Corporation would make Fairfield Works a modern, competitive
steelmaking operation.
6.2. CAPACITY ALTERNATIVES
Various alternatives were studied to maintain raw steel
production at Fairfield Works, occasioned by shutting down the Ensley
open hearth furnaces. At least nine separate plans were evaluated as
shown in Table 6-1.
During the third quarter of 1973, a recommendation
evolved from these studies which specified that the best approach to
meet existing conditions would be to displace Ensley open hearth opera-
tions with two 150-ton electric furnaces. It had been determined that
air quality control devices on these five old open hearth furnaces
could not be justified, and that production capacity should be replaced
by modern steelmaking facilities, with effective emission control equip-
ment to achieve compliance. Facility replacement was selected in
preference to emission control equipment on existing furnaces, because
to equip the Ensley open hearths with the necessary equipment to meet
air pollution emission standards would require significant capital
expenditures while being utilitarian for only a few years.
Electric furnaces which were contemplated would have had
a capability of about 600,000 annual tons and the total raw steel
requirement of the plant would have been met by increasing the Q-BOP
output. At this time, it was estimated the Q-BOP capability could be
6-2
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TABLE 6-1
ALTERNATIVES FOR PRODUCING STEEL
FAIRFIELD WORKS
en
CO
Alternate
Project
Steel
Production
Q-BOP Shop
Alt. Furnaces
1
Roof Burners
& Precipi-
tators at
Ens ley.
2,700,000
560,000
2
Roof Burners
& Precipi-
tators at
Ens ley.
2,700,000
635,000
3
Two 150-Ton
Electric
Furnaces at
Ensley with
In-Line
Scrap Aisle.
Added Teem-
ing at Q-BOP
Shop.
2,930,000
570,000
4
Two 150-Ton
Electric
Furnaces at
Ensley with
Parallel
Scrap Aisle.
Added Teem-
ing at Q-BOP
Shop.
2,930,000
570,000
5
One 200-Ton
Electric
Furnace at
Q-BOP Shop
with
Parallel
Teeming
Aisle &
Added Mixer.
3,100,000
400,000
6
Additional
Teemi ng
Aisle at
Q-BOP Shop
with In-
creased
Production
on Two
Q-BOP
Furnaces.
3,500,000
--
7
Three 150-
Ton Electric
Furnaces at
Ensley with
In-Line
Scrap Aisles.
2,700,000
800,000
8
Three 150-
Ton Electric
Furnaces at
Ensley with
Parallel
Scrap Aisles.
2,700,000
800,000
9
Third Q-BOP
Furnace
with
Additional
TeenTiiiy
Facilities.
3,500,000
—
Total
(Annual Tons) 3,260,000 3,335,000 3,500,000 3,500,000 3,500,000
3,500,000
3,500,000 3,500,000 3,500,000
-------
increased with additional teeming facilities and provisions of
additional hot metal through better burdening practices.
At the time of development, the electric furnace
proposal was considered more desirable than adding a third Q-BOP
furnace for several reasons:
1. Shorter construction time.
2. Better balance of iron and scrap.
3. Minimum interference with production.
4. Additional iron-making facilities would not be
required.
Later, the electric furnace plan for Ensley was also
updated and reevaluated against the alternative possibility of a third
Q-BOP furnace at Fairfield. Several factors were considered:
1. The required expenditure for electric furnace
facilities has increased to significantly more
than that required for additional Q-BOP facilities
at Fairfield.
2. An expanded Q-BOP operation at Fairfield would
provide additional steel scrap, which is a valuable
commodity in the steelmaking operation.
3. It appeared that additional funds might be available
for investment in iron-producing facilities required
to support the Q-BOP expansion. This alternative
was considered since the Ensley blast furnaces were
obsolete and emitted relatively large quantities of
pollutants as compared to a new facility.
In October, 1974, after the start-up of the Q-BOP furnaces,
a new plan was finalized which would displace both blast furnace and
open hearth operations at Ensley. This proposal included a third Q-BOP
furnace, teeming facilities, new soaking pits, and a new blast furnace
at Fairfield.
The new facilities will permit continued production
with adequate raw steel support required for operation with Ensley1s
open hearth shutdown.
6-4
-------
6.3. PROCESS ALTERNATIVES
The blast furnace is the only available process for
producing molten iron, the principal feed stock for a Q-BOP furnace.
Therefore, no process alternatives were investigated.
6.4. SITE LOCATION
6.4.1. Criteria for the Site Selection
The new source, No. 8 blast furnace, is a support
facility for steelmaking operations at Fairfield Works, replacing three
existing blast furnaces at Ensley. Its site location can be explained
easily and categorically with respect to locating it at another south-
eastern location, another location some place else in the country, or
at a Greenfield site:
1. A blast furnace produces molten iron at an elevated
temperature, and this hot liquid iron must be
transported in insulated ladles to maintain its
temperature, with a minimum transport time between
where it is produced and where it is consumed. The
reality of this physical situation dictates that the
iron-making facility be conterminous with the
steelmaking operation. For this reason, No. 8 blast
furnace must be built contiguous with existing iron-
making facilities at Fairfield Works.
2. Additionally, Fairfield Works is in the heart of the
major southeastern city market for the consumption
of steel products. Southeastern city market concen-
trations are depicted in Figure 6-1. From an
economic view, it would be irrational to contemplate
relocation of this steelmaking complex to a site
remote from the distribution center of its saleable
products, as it is now presently situated.
6-5
-------
CTl
I
CT>
FIG. 6-1. SOUTHEASTERN CITY MARKET AREAS
-------
In assessing suitable land for industrial development,
certain criteria must be met. Among the requirements considered by
U. S. Steel Corporation were:
1. Slope and Topography - The Birmingham Regional
Planning Commission, in their land use plans,
recommends a level to slightly rolling topography
with less than 10 percent slope for industrial
development land.
2. Flood Prone Areas - These areas must not be located
within the industrial complex as they would con-
tribute to ground and surface water pollution.
Well drained areas are desired.
3. Geology and Soils - Well drained sites that do hold
water for long periods are most suitable.
4. Public Water - Coverage is necessary adjacent to the
considered location.
5. Public Sewer - Coverage is necessary in the imme-
diate vicinity.
6. Transportation Routes - Convenient transportation
routes to and from a considered location for any
industrial development are a must. Minimum disrup-
tion to present transportation systems is desirable.
The present transportation system is used as follows:
Incoming Raw Materials. Imported iron ore and pellets
from foreign sources are unloaded at the USSC ore terminal or at Alabama
State Dock at Mobile. These are transported by barge up the Warrior/
Tombigbee River to Birmingham Port on the Locust Fork of the Warrior
River. These materials are then transported by Birmingham Southern
Railroad to Elliot Yard at Fairfield.
Dolomite is mined by open-pit quarrying at Dononah
Quarry. Chunk dolomite is transported to the blast furnaces by rail.
Crushed dolomite is carried by semi-trailers.
6-7
-------
Coal is mined in the Warrior Coal Field and is also
procured from other sources. Coal is barged to Birmingham Port and
offloaded to facilities for washing. It is then transported by rail
to the coke plant site.
Transportation of raw materials is by waterways and
railroads that traverse the more sparsely populated parts of the
region. This results in a less adverse impact to the environment than
if another site were chosen which might necessitate routes that would
contribute to an already overburdened transportation system. There-
fore, the planned location is the most feasible from transportation
considerations.
Raw Materials Handling. Emphasis is on making a clean
separation of the coarse and fine material, and at the same time main-
taining a high volume operation. With the start up of blast furnace
No. 8, there will be a reduction in demand for iron ore and an increase
in pellet ore use. Ore pellets are taken directly to the blast furnace
area from pellet stockpiles for charging to the furnace. Individual
pellet surfaces are very impervious to leaching in open-air stockpiles.
Burnt lime is required for the Q-BOP. The burnt lime
process from dolomite leaves a calcium oxide residue. The residue is
pumped into trucks and transported to a pressurized vessel at the
Fairfield plant. Emissions can only occur by passage through the
Q-BOP's, exiting the stack, or by accidental spillage from loading
activities at the quarry. None of these contingencies constitutes
major emissions.
Shipping Finished Products. There are adequate
transportation systems contiguous to the proposed plant site. Seven
major railroads serve the Birmingham area. Two of these--Louisville
& Nashville and Birmingham Southern Railroads--are adjacent to the
U. S. Steel facilities.
6-8
-------
Port Birmingham is a major terminal for cargo shipments.
The Black Warrior/Tombigbee Waterway is an important factor in commercial
traffic. This system provides a useful transportation system for
shipping.
Easy access from the planned site location to major
highway systems is available. Interchanges to Interstate Highway 65
and 59 are nearby.
6.4.2. Determination
U. S. Steel Corporation already owns land that meets
the requirements as outlined above, plus other criteria for a suitable
plant location. For these many reasons, minimum adverse impact to the
environment would be experienced as a result of selection of the pro-
posed site. In summary, the Fairfield site was selected as the best
alternative to maintain steel production for the Southeastern market.
The new blast furnace is to be located on the same base-
line and north of existing blast furnaces at Fairfield Works. These
existing furnaces are numbered 5, 6, and 7, from south to north. By
situating the new furnace here, it will be sequentially numbered and
known as "No. 8 blast furnace."
Because the existing coking operation lies close by, this
is the most advantageous location for a new furnace from the standpoint
of handling coke, which is one of the principal feedstocks for a
blast furnace. Also, this is the only area contiguous to the existing
blast furnace operation where there is available land for constructing
a new furnace and its auxiliaries. For this reason, no other local
sites were seriously evaluated.
6.5. WASTEWATER TREATMENT
The No. 8 blast furnace, as a new source, is required
to meet New Source Performance Standards (NSPS) identified as Best
6-9
-------
Available Demonstrated Control Technology (BADCT). The NSPS identified
for a blast furnace are the same as Best Available Technology Economi-
cally Available (BATEA) and, consequently, the BADCT and BATEA effluent
limitations are identical. All of the Phase I guidelines for the iron
and steel industrial category, including all guidelines pertaining to
a blast furnace, have been remanded by the courts. Therefore, the
effluent limitations appropriate to BADCT for a blast furnace could
change.
The U. S. Steel Corporation proposes to comply with the
New Source Performance Standards by installing the equivalent of BATEA
technology (Best Available Technology Economically Available consists
of "Best Practicable Technology Currently Available" (BPTCA) plus
treatment of cooling tower blowdown via alkaline chlorination, pressure
filtration, carbon adsorption, and pH neutralization. BPTCA has been
identified as polymer addition to thicken solids collected in gas clean-
ing operations and vacuum filtration of the thickened sludge. Emphasis
has also been placed on water reuse utilizing cooling towers.). BPTCA
and BATEA effluent limitations are presented in Tables 6-2 and 6-3,
respectively.
A methodology for wastewater treatment, utilizing modifi-
cation and optimization of processes and existing treatment facilities,
has been selected by the U. S. Steel Corporation in accordance with the
assumption that the NPDES permit for Fairfield Works will be revised
to include the existing allocations, plus the BADCT allocations for a
new blast furnace. The following information communicated by the
U. S. Steel Corporation concerns this proposed wastewater treatment
methodology:
6-10
-------
TABLE 6-2
BPTCA EFFLUENT LIMITATIONS—BLAST FURNACE
(FE) SUBCATEGORY
Parameter
Suspended Solids
Total Cyanide
Phenols
Ammonia (as NHj
PH
BPTCA Limitation*
lbs/1,000 Ibs
0.0260
0.0078
0.0021
0.0651
6.0 - 9.0
mg/1
50.
15.
4.
125.
* Referenced to flow of 125 gal/ton of Fe produced.
6-11
-------
TABLE 6-3
BATEA EFFLUENT LIMITATIONS—BLAST FURNACE
(FE) SUBCATEGORY
Parameter
Suspended Solids
CyanideA
Phenols
Ammonia
Sulfide
Fluoride
PH
BATEA Limitation*
lbs/1,000 Ibs
0.0052
0.00013
0.00026
0.0052
0.00016
0.0104
6.0 - 9.0
mg/1
10.
0.25
0.5
10.
0.3
20.
* Referenced to flow of 125 gal/ton of Fe produced.
6-12
-------
1. No. 8 blast furnace has been designed
to prevent ingress of any tramp or
otherwise uncontrolled addition of
water to the gas cleaning and cooling
recycle system. As such, it will be
the "tightest" such system built with-
in USSC to date.
2. Process water from No. 8 furnace recycle
system will be used as make-up for slag
recycle systems. This is, in effect, a
blow down for the No. 8 blast furnace
gas cleaning system.
3. Only clean coke is produced at Fairfield
Works. Clean coke is used to describe
coke that is quenched in a closed recycle
system using service water to make up
evaporation losses. Clean coke contains
an absolute minimum of phenol, cyanide
and ammonia, and its use results in a
minimum addition of these chemicals to
the blast furnace water system.
4. Based on the burden and the furnace design,
the coke rate on No. 8 blast furnace will
be significantly lower than the industry
average thereby further limiting the
phenol, cyanide, and ammonia present in
No. 8 blast furnace effluent. This is
due to basic design as well as the quality
of the prepared burden.
5. No. 8 blast furnace blowdown receives
additional treatment together with other
plant effluent in a final polishing pond
prior to discharge.
6. It is expected that operating and treat-
ment improvements in other areas of the
plant will continue to be experienced,
thereby further reducing the level of
suspended solids, phenol, cyanide, and
ammonia in the plant discharge.
6-13
-------
Other wastewater treatment processes potentially applicable
to specific constituents identified in effluents from a blast furnace, e.g.,
ammonia, cyanide, heavy metals, and phenols, are discussed in Appendix E of
the TSD. These technologies, however, are either undemonstrated or unecono-
mic from the standpoint of treatment of an actual blast furnace effluent.
6.6 AIR EMISSION CONTROL ALTERNATIVES
This section discusses the alternatives to emission control
technologies selected by U. S. Steel for implementation to control emissions
from Blast Furnace No. 8, No. 2 Coke Battery and the third Q-BOP and includes
all proven emission control metholodogies for the emission points discussed.
6.6.1. Coke Battery
As part of the construction of the new coke battery,
storage bins for coal will be provided which will serve all existing
batteries as well as the new coke battery at the Fairfield complex.
Coal storage outside of the bins will be kept to a minimum. Antici-
pated emissions from the coal storage bins will be treated employing
baghouses. Other techniques which could be employed include scrubbers
or electrostatic precipitators. However, based on specific emission
characteristics, energy requirements and equivalency in emission
control alternatives, baghouses will be employed.
The alternative to the bin storage is ground storage
which has a potential for emission of significantly greater quantities
of coal dust and permits the coal to be wetted, resulting in additional
energy requirements to dry the coal prior to coking. Reduced moisture
addition was also considered in the selection of baghouses as opposed
to wet scrubber systems for the removal of emissions.
Coal is then transferred to pulverizers which must be
employed in order to reduce the coal size prior to coking. No alter-
native exists for the pulverizer and although other particulate
removal controls exist for the air emissions, such as wet scrubbers,
cyclones and precipitators, the baghouse will be employed because of
equivalency for removing particulates, and prevention of additional
6-14
-------
moisture being added to the pulverized coal. After pulverization the
coal is blended. All emissions are controlled by baghouses for the
same reasons given for the storage silos and pulverizers. Transfer
points along the coal conditioning train described above are all con-
trolled employing baghouses. Other alternatives to this process would
be uncovered conveyor belts and lack of emission control.
After blending, the coal is transferred to the silo which
services a new coke battery which also has emission control devices to
prevent particulate emissions during the discharge of coal into the
silo. For similar reasons as described earlier, i.e., energy requirements
for electrostatic precipitators as well as maintenance, and problems of
wetting the recovered coal, baghouses are employed in the suppression of
emissions from the silo. The coal is transferred from this silo to the
secondary pulverizers whose emissions are also controlled by the same
baghouses. From the silo the pulverized coal is transferred to the pre-
heater which assures dryness of the coal and therefore most efficient
discharge of powdered dried coal into the coking ovens.
Techniques which could be employed in the removal of
emissions from the pre-heater include electrostatic precipitators, bag-
houses, and scrubbers. During design of the coal processing system,
engineering decisions dictated that the wet scrubbers be employed
because the electrostatic precipitators were being evaluated at other
U. S. Steel installations and the scrubber is equivalent technology to
the baghouse. Alternatives to the pre-heater are direct discharge of
coal into the coke ovens bypassing the pre-heater system. Such a scheme
would result in additional emissions from the coke batteries because of
a requirement for leveling the coal immediately after being ejected into
the coke oven. The leveling procedure requires opening of the coke oven
thus permitting emissions. Leveling is not normally required if the
pulverized coal is dried and pre-heated. Coal flows much like a liquid
under these conditions. The pre-heated, pulverized coal naturally levels
itself thus preventing the need for a leveling process.
6-15
-------
The pulverized coal is transferred from the pre-heater
to enclosed bins on the top of the coke battery. From these bins the
coal is transferred to pre-metering bins. The emissions from all bins
are controlled by wet scrubbers. Wet scrubbers were selected by equiva-
lent technology. Both precipitators and baghouses could have been employed
at this point in the emission control process. The coal is then trans-
ferred from the pre-metering bins to the charging device which places the
coal in the coke oven. Three alternatives are available for charging.
These are:
1. Conveyor charging
2. Pipeline charging
3. Hot Larry car
After investigation of these three techniques, it was
determined that the most efficient method of charging coal, based on
engineering decisions within the U. S. Steel Corporation, was the
selection of a hot Larry car. The hot Larry car was determined to be
equivalent technology with regard to emission control as well as process
operation. The one designed and proposed for employment in the new coke
battery at Fairfield is the result of the third generation design with
U. S. Steel Corporation.
Mud sealing will be employed to prevent top side leaks
during coking which is standard procedure and does not have an identi-
fiable alternative.
The new coke battery has been provided with two collecting
mains for the coke oven gases being released during the coking process.
One main is adequate to conduct all coke oven gases during any phase of the
coking operation to the by-product recovery system. Nevertheless, for
added security, two mains have been provided which should insure reliable
exhaustion of coke oven gases.
Emissions from coke oven doors can be controlled by two
alternatives:
1. Providing hoods above the doors in an attempt to
capture emission gases, which are then diverted
to some form of emission control device. Such a
6-16
-------
technique is frequently ineffective, especially
under windy conditions, because the releases from
the door are not readily captured within the ducts.
2. Extensive and careful design of seals around the
doors to prevent emissions. This alternative was
selected by the U. S. Steel Corporation.
Removal of coke from the coke battery can be accomplished
by using various techniques. It can be accomplished by merely pushing the
coke into an open car which is rapidly transferred to the quench tower to
reduce the coke temperature and thus prevent its consumption. This tech-
nique has been modified to include a hood above the car which captures
the gases, which can then be ducted to some form of emission control
device. Neither of these techniques was selected by U. S. Steel because
the open car obviously permits excessive emissions. The open car plus
the hood arrangement requires extreme care to insure that the safety of
personnel working in the vicinity of the coke ovens is not jeopardized.
A more effective technique than either of these includes
utilization of a single spot car and an associated emission control or
gas cleaning car. At the present time, the only established emission
control technique used on a gas cleaning car is wet scrubbing. This not
only removes particulates, but also some hydrocarbon emissions by condensing
the gases. Future technology may permit the use of baghouses instead of
wet scrubber systems. Nevertheless, at this point the state of the art
requires that wet scrubber systems be employed. A modification of this
technique which was not selected by U. S. Steel for this coke battery
would position the gas cleaning facilities at a fixed location and employ
a vacuum system after moving the spot car to the oven which is ready to be
pushed. This technique would be comparable to the spot car and gas cleaning
car which is employed by U. S. Steel Corporation.
After the coke has been discharged to the spot loading car,
it is transferred to quench towers for cooling. Quench towers may be either
direct or offset. U. S. Steel Corporation has selected 90 degree off-set
towers which aid in particulate removal and baffles which serve as partial
demisters. Dry quench towers may be employed, but at the present time,
6-17
-------
difficulties with regard to maintenance and economy, as well as power
requirements preclude their use on this coke battery. After quenching,
the coke is screened and crushed. Emissions from this operation are
controlled employing a baghouse instead of a precipitator or scrubber.
It is preferable to reduce the moisture content of the coke as much
as possible prior to its being added to the blast furnace and each of
these controlled technologies are approximately equivalent. Therefore,
baghouses were selected. At the end of this operation, the coke is
transferred to the blast furnace silo. Covered conveyor belts are
employed for this operation. An alternative transfer mechanism would
be to place the coke directly in railroad cars.
6.6.2. Emission Control Alternatives for the New Blast Furnace
Coke, pellets and sinter, as well as quantities of other
materials are transferred to the blast furnace by conveyor belts and
stored in silos. Screening occurs prior to injection of properly sized
materials to the blast furnace and produces emissions which are controlled.
Wet scrubber systems, precipitators or baghouses could be employed.
Scrubbers were not selected because of the addition of moisture which
would require dewatering facilities and additional energy requirements.
Baghouses were selected because they were equivalent technology to other
particulate emission control techniques. The material captured by the
baghouse and fines from a screening operation were all transferred to
a silo. A transfer from the silo to the transportation vehicle is also
controlled using water sprays for dust suppression. The properly sized
material is transferred from the silos to the collection belt which is
a final process prior to injection into the blast furnace. Belts handling
sinter pellets and coke receive emission control through the same baghouse
previously described for the screening operation. Therefore, alternatives
described under that technique apply here as well.
6-18
-------
6.6.3. Alternative Emission Control for the Q-BQP Furnace
The main exhaust hood from the Q-BOP furnace will be con-
trolled employing a wet scrubber system and a flare. The alternatives
for emission control of the main exhaust hood would be evaporative cooling
followed by either a baghouse or a precipitator. The scrubber system is
equivalent emission control and precludes the need for the evaporative
cooling system prior to other controls, i.e., either baghouse or precipi-
tator. Flare control is the only effective procedure for the conversion
of carbon monoxide. During the period of time in which the Q-BOP is
turned down, a 30 ft wide by 3 ft deep hood with continuous exhaust
through a bag collector recovers a majority of the emissions. Either
scrubbers or precipitators might be employed. However, considering
this additional water usage and power requirements, bag collectors were
determined to be most effective. Hot metal transfer processes also are
exhausted through the same baghouse.
6-19
-------
7. MITIGATIVE MEASURES
-------
CHAPTER 7
MEASURES TO MITIGATE ADVERSE ENVIRONMENTAL IMPACTS
7.1. CONSTRUCTION IMPACTS
Temporary adverse impacts to air and water quality
will result from construction of the new No. 8 Blast Furnace.
Clearing, grubbing, and earthmoving can result in
the creation of a local dust problem. Truck traffic, which is anti-
cipated to involve 15 percent of the materials required for construc-
tion, will generate additional dust. Roads were watered to mitigate
impacts resulting from dust generation. Due to a policy of road
paving, slagging, or oiling, and the remoteness of the construction
site from any public area, the possibility of dust problems off-site
is seen as minimal.
Dams were built to control drilling mud runoff. Storm-
water drainage from the construction site will be handled by the
plant-wide drainage system. It will be concentrated by pre-existing
equipment and given primary treatment to minimize the effect on
Opossum Creek.
7.2. OPERATIONAL IMPACTS
7.2.1. Air Quality
The following summary presents those emission control
devices and process improvements which will be implemented to mitigate
adverse impacts to air quality as a result of operation of Blast
Furnace No. 8. These emission controls and process improvements are
discussed in detail in Chapters 3 and 4 and alternative controls for
air emissions are discussed in Chapter 6.
7-1
-------
No. 8 Blast Furnace
1. Material handling - Six separate baghouses with
separate fans.
2. Unloading and transferring - Liquid type dust
suppression system.
3. Clean gas flare stack - With twin burner heads
to control pressure in blast furnace gas
distribution main.
4. Dustcatcher, reverse flow type - Large particles
drop out due to sudden change in direction and
decreased velocity.
5. Venturi scrubbers - For cleaning and cooling blast
furnace gas.
6. Seal valves above and below top hopper - Two
hoppers used alternately and pressurized with
nitrogen.
In addition, the following emission controls and process
improvements will be implemented to mitigate adverse impacts to air
quality as a result of operation of the third Q-BOP and the No. 2
Coke Battery:
Third Q BOP
1. Drop-out doors - Large particles are allowed to
drop out of gas cleaning system.
2. Venturi scrubbers - Gas cleaning and cooling.
3. Flare stack - To burn CO in gas before releasing
to atmosphere.
4. Furnace enclosure - To capture emissions during
blow.
5. Secondary hood - To capture emissions during
turndown, charging, etc.
7-2
-------
6. Charging doors - Equipped with air seals and water
seals to prevent dust escape.
7. South mixer - Fume control system.
No. 2 Coke Battery
1. Coke and coal preparation - The following units
are equipped with baghouses:
Three 10,000 - ton silos
Pulverizer building
Mixer
100-ton bin
Secondary pulverizer
Coke transfer station
Belts A26A and A26B
2. Wet scrubber - Premetering bin.
3. Quench tower and baffle system.
4. Venturi scrubbers - Preheaters, clean exhaust
gas.
5. Pushing controls - One spot quench car with
venturi.
6. Improved charging cars.
7. Improved doors.
In general, the entire modernization program, including
the construction of No. 8 Blast Furnace, the third Q-BOP, and Coke
Battery No. 2, constitutes the replacement of existing facilities
having high air emissions in an attempt to mitigate adverse air
impacts.
7.2.2. Water Quality
Adverse impacts to water quality as a result of operation
of Blast Furnace No. 8 will be mitigated by the implementation of a
7-3
-------
wastewater management system which utilizes modification and optimization
of processes and existing treatment facilities and is discussed in Chapter
6. Also, the shutting down of facilities at Ensley Works will mitigate
adverse impacts to the water quality of Village Creek.
7-4
-------
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-------
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California," Transactions of American Fisheries Society 101 (3): 478-482
(1972).
Sharda, C. P., and L. Namwannan, "Viscose Rayon Factory Wastes and Their
Treatment," Techno!. Sindri 3 58-60 (1966); Water Poll. Abstr. 41 No. 1698
(1968).
13
-------
Shimoiizaka, J., "Recovery of Xanthate from Cadmium Xanthate," Nippon
Kogyo Kaishi (Japan) 88. 539-543 (1972).
Shink, C. A., "Plating Wastes: A Simplified Approach to Treatment,"
Plating 55 1302-1305 (1968).
Sievers, J. F., and C. J. Novotny, "Recovery of Mixed Rinse Water by Means
of Ion Exchange," Plating 42, 482-485 (1971).
Skidmore, J. F-, "Toxicity of Zinc Compounds to Aquatic Animals, with
Special Reference to Fish." Quarterly Rev. of Biology. 39^227 (1964).
Smith, 0. M., "The Detection of Poison in Public Water Supplies," Water
Works Eng. 97_, 1293 (1944).
Southgate, B. A., F. T. K. Pentelow and R. Bassindale, "An Investigation
into the Causes of Death of Salmon and Sea Trout Smolts in the Estuary
of the River Tees," Biochem, J. 26 273-284 (1932).
Southgate, B. A., F. T. K. Pentelow and R. Bassindale, "The Toxicity to
Trout of Potassium Cyanide and p-Cresol in Water Containing Different
Concentrations of Dissolved Oxygen. Biochem, J. 27 983-985 (1933).
Spehar, R., "Cadmium and Zinc Toxicity to Jordanella floridae," M. S.
Tehsis, University of Minnesota, Duluth (1974).
State of the Art; Review mi Product Recovery, Water Pollution Control
Research" Series, 1707 ODJW 11/69, (Washington, D.C.: U. S. Dept. of the
Interior, 1969).
Stokinger, H. E., and R. L. Woodward, "Toxicologic Methods For Establishing
Drinking Water Standards," J. Amer. Water Works Association 50 (4), 85
(1958). ~
Stone, E. H. F., "Treatment of Non-Ferrous Metal Process Waste at Kynoch
Works, Birmingham, England," Proc. 22nd Ind. Waste Conf. 848-865 (1967).
Stone, E. H. F., "Treatment of Non-Ferrous Metal Process Wastes," Metal
Finish. J. 18 (212), 280-290, (1972).
Stoner, L. B., "Waste Treatment Facilities for Jones and Laughlin Steel
Corporation, Hennepin Works," Proc. 26th Ind. Waste Conf. 26 761-765
(1971). —
Stumm, W., and J. J. Morgan Aquatic Chemistry, (New York: Wiley-Interscience,
1970).
Sumner, F. B., and P. Doudoroff, "Some Experiments on Temperature Acclimati-
zation and Respiratory Metabolism in Fishes," Biol. Bull. (Woods Hole,
Mass.) 74 403-429 (1938).
14
-------
Tallmange, J. A., "Nonferrous Metals," In Chemical Technology. Vol. 2.
Industrial Waste Water Control. C. Fred Gurham, Ed. TTiew York: Academic
Press, inc., 19657!
Teer, E. H., and L. V. Russell, "Heavy Metals Removal from Wood Preserving
Wastewater," Presented at 27th Ind. Waste Conf., Purdue University, 1972.
Thompson, J., and V. J. Miller, "Role of Ion Exchange in Treatment of Metal
Finishing Wastes," Plating 58 809-812 (1971).
Trussell, R. P., "The Percent Unionized Ammonia in Aqueous Ammonia Solutions
at Different pH Levels and Temperatures," J. Fish. Res. Bd. Canada 29_
1505-1506.
U. S. Department of the Interior, Temperature and Aquatic Life, Federal
Water Pollution Control Administration, Laboratory Investigations, Series
No. 6 (1967).
USEPA Aji Investigation of Techniques for Removal of_ Cyanide from Electro-
plating Wastes. NT IS PB208 210, (197l7T~
USEPA Development Document for Effluent Limitations Guidelines and New
Source Performance Standards for the Steel Making Segment of the Iron
and Steel Manufacturing Print Source Category (June, 1974).
USEPA, Methods for Chemical Analysis of_ Water and Wastes. Cincinnati,
Ohio (1974T:
U.S. Geological Survey, Atlas Series II, "Drainage Areas for Jefferson
County, Alabama" (1977).
U.S. Weather Bureau, "Rainfall Intensity-Duration-Frequency Curves,"
Tech. Paper 25 (1955).
Volco Brass and Copper Co. Brass Wire Mill Process Changes and Waste
Abatement, Recovery and Reuse^ Water Pollution Control Research Series
#12010 DFP, (Washington, D. C.: U.S. Environmental Protection Agency,
1971).
Wang, L. K., R. P. Leonard, J. G. Michalouic and D. W. Goupil, "Flue
Treatment-Pick A Way," Water Waste Eng. 10 (9), 20-24 (1973).
Warnick, S. L., and H. L. Bell, "The Acute Toxicity of Some Heavy Metals to
Different Species of Aquatic Insects," Jour. Water Poll. Control Fed. 41_
(Part 1) 280 (1969).
15
-------
Weber, C. I., "Biological Field and Laboratory Methods for Measuring
the Quality of Surface Waters and Effluents," U. S. EPA, Cincinnati,
Ohio (1971).
Weiner, R. F., "Acute Problems in Effluent Treatment," Plating 54
1354-1356 (1967).
Welch, A., "Potassium Permanganate in Water Treatment," ih Water Works
Assoc. 55 734-741 (1963).
Werner, H. W., "Treatment of Metal Finishing Wastes by Robertshaw Controls
Company," presented at 27th Ind. Waste Conf., Purdue University, 1972.
Willey, B. F., and H. Jennings, "Iron and Manganese Removal with Potassium
Permanganate," J. Amer. Water Works Assoc. 55 729-734 (1963).
Wilmoth, R. C., and R. D. Hill, "Neutralization of High Ferric Iron Acid
Mine Drainage," U. S. EPA Report 14010 ETV 8/70 (1970).
Wuhrmann, K., and H. Woker, "Beitrage zur Toxicologie der Fische. II.
Experimentelle Untersuchungen liber die Ammoniak - und Blausaurevergiftung."
[Contributions to fish toxicology. II. Experimental investigations of
ammonia and hydrocyanic acid poisoning.] Schwiez. Z. Hydro!. 11 210-244
(1948).
Wuhrmann, K., and H. Woker "Beitrage zur toxicologie der Fische. VIII. Uber
die Giftwirkungen von Ammoniak - und Zyanidlosungen mit verschiedener
Sauerstoffspannung und Temperatur auf Fishe. [Contributions to fish
toxicology. VIII. Concerning the toxicity to fishes of ammonia and cyanide
solutions with varying oxygen tension and temperature.] Schweiz. Z. Hydro!.
]_5 235-260 (1953).
Wuhrmann, K., and H. Woker "Influence of Temperature and Oxygen Tension on
the Toxcity of Poisons to Fish," Int. Ver. Theor. Angew. Limnol., Verh. 1_2
795-801 (1955).
Wurm, H. J., "The Treatment of Phenolic Wastes," Proc. 23rd Purdue Ind. Waste
Conf. 23 1054-1073 (1968).
Wurtz, C. B., "Zinc Effects on Freshwater Mollusks," Nautilus, 76:53 (1962).
Wynn, C. S., B. S. Kirk and R. McNabney, "Pilot Plant for Tertiary Treatment
of Wastewater with Ozone," EPA/R2-73-149 (1973).
Zievers, J. F-, and C. J. Novotny, "Recovery of Mixed Rinse Water by Ion
Exchange," Plating 58 482-485 (1971).
16
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APPENDIX A
U. S. ENVIRONMENTAL PROTECTION AGENCY LETTER,
APRIL 15, 1976, to U. S. STEEL CORPORATION
-------
APPENDIX A
UNITED STATES ENVIRONMENTAL PROTECTION AGENCY
KI,I«» REGION IV
1421 pi:Acn'ri?t t: ST.. N. n.
ATLANTA. GUOHGIA 30309 4AEW:W11C
APR 1 5 197G
CERTIFIED MAIL
RETURN RECEIPT REQUESTED
Mr. James L. Hamilton, III
United States Stcol Corporation
COO Grant Street
Pittsburgh, Pennsylvania 15230
Dear Mr. Hamilton:
As a result of various meetings and discussions with my staff I
have made the following determinations relative to the discharge to the
navigable waters of the United States from your Fairfield, Alabajna plant
expansion:
BLAST FURNACr.
1. Construction of this facility was not in progress as of
February 19, 1974,
2. This facility falls within the Iron ajid Steel industrial
category.
3. New Source Performance Standards for this industrial category
were proposed in the Federal Register on February 19, 197-1.
4. There is a New Source Performance Standard within this category
which can reasonably be considered applicable to the facility.
S. The expansion is of sufficient magnitude that it can reasonably
be expected to have sufficient flexibility to achieve the applicable
New Source Performance Standards.
JCP^UL-Sf these determination^ I have concluded that because
this expansion lias the f lexibilTt'^to rrciTrev^"appl'rcab'J.c"^e\r Source
Performance Standards and construction of it did not begin prior to the
New Source Performance Standards proposal date, .the_qxiian.d.e.d_p.Q;:.tJ,QJL..Q£
tJJP s^_facil3.ty.,js _a_ ne\v^squrce._ Therefore, in accordance with Section
5li(c)(I)" of "the "Federal Water Pollution Control Act, as amended (33 USC
1311), 1 have ruled that issuance of an NPD1-S permit to this facility
is subject to all provisions of the National Environmental Policy Act
of 1969 "(83 Stat. 852) .
APK19197G
'I- CONTROL
-------
QBOP UNIT AND COKT. OVI-HS
1. Construction of this facility was not in progress as of
February 19, 1974.
2. This facility falls within the Iron and Steel industrial
category.
3. New Source Performance Standards for this industrial category
were proposed in the Federal Register on February 19, 1974.
4. There is a New Source Performance Standard within this category
which can reasonably be considered applicable to this facility.
5. This expansion is not of sufficient magnitude that it can
reasonably be expected to have sufficient flexibility to achieve the
applicable New Source Performance Standards.
As_a_ result of these deter mi nations^ I h'ave, concluded that .because,,
_xibil,JJ'y..3'.pi ^achieve, applicable ..Now.. Source
iKled .p..PXt.i.on.._of_.th\s. f Jicility ..is../*?).
Therefore, in accordance, with Section 5Jl(c)(l) of
the Federa h'atcr Pollution Control Act, as amended (33 USC loll), 1
have ruled that issuance of an NPDHS permit to this facility is not
subject to any provisions of the National Environmental Policy Act of
1969 (83 Stat. 852).
The
request and two copies thereof must be submitted to the Regional Hearing
Clerk, Environmental Protection Agency, 1421 Peachtrce Street, N.H.,
Atlanta, Georgia 30309. The submission of the request will be within
the time period if mailed by Certified Mail before the 20th day. The
request must:
1. State the name and address of the person making' such request;
2. Include an agreement by the. requestor to be subject to
examination and cross-examination and to make any employee or consultant
of such requestor or other person represented by the requestor available
for examination and cross-examination at the expense of such requestor
or such other person upon the request of the Presiding Officer, on his
own motion, or on the motion of any party;
3. State with particularity the reasons for the request; and
4. State with part.icular.ity the issues proposed to be considered
nt the hearing.
-------
Additional information on adjudicator/ hearings and legal decisions
is found at Title 40, Code of Federal Regulations, Section 125.36, 39,
Federal RcM'.ister 27081.
If you have further questions concerning this mattci*, please
contact Mr. William 11. Cloward of our Water Enforcement Branch at
40/1/520-20]?.
Sincerely yours,
Jack H. Ravan
Regional Administrator
cc: Mr. James W. Karr
Alabama IVIC
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APPENDIX B
DRAFT NPDES PERMIT
U. S. STEEL CORPORATION
FAIRFIELD, ALABAMA
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Pcrn.ii No. AL 0003646
Application No. AL 076 OYM 3 000610
AUTHORIZATION TO DISCHARGE UNDER THE
NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM
1. In compliance with the provisions of the Federal Water Pollution Control Act, as amended,
(33 U.S.C. 1251 et. seq; the "Act"),
United States Steel Corporation
is authorized to discharge from a facility located at
United States Steel Corporation
Fairfield District Works
P. 0. Box 599
Fairfield, Alabama 35064
to receiving waters named
Discharge Serial Nos. 002 thru 009 enter Village Creek
Discharge Serial Nos. 010 thru 027 enter Opossum Creek
Discharge Serial No. 029 enters Valley Creek
in accordance with effluent limitations, monitoring requirements and other conditions set forth
in Parts I, II, and III hereof.
2. This permit shall become effective on
3. This permit and the authorization to discharge shall expire at midnight,
4. Signed this day of
Regional Administrator
EPA Form 3320-4 (10-73)
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Pape 2 of 16
Permit No. AL 0003646
MONITORING AND REPORTING
5. Representative Sampling
Samples and measurements taken as required herein shall be representative of the volume
and nature of the monitored discharge.
g f Reporting
Monitoring results obtained during the previous month shall be summari.pr1 for
each month and reported on a Discharge Monitoring Report Form (EPA No. 3320-1),
postmarked no later than the 28th day of the month following the completed reporting
period..The first report is due on f . Duplicate signed copies of
these, and all other reports required nerem, shall be submitted to the Regional
Administrator and the State at the following addresses:
U.S. ENVIRONMENTAL PROTECTION AGENCY
RUGiGH IV
WATE3 EHFOHOi^-lT STANCH
345 COUKTL^D STREET, Nc
ATLANTA, GEORGIA 30308
AL Water Improve. Comm.
State Ofc Bldg.
Montgomery, AL 36130
' • Definitions
a. The "daily average" discharge means the total discharge by weight during a calehdar
month divided by the number of days in the month that the production or
commercial facility was operating. Where less than daily sampling is required by this
permit, the daily average discharge shall be determined by the summation of all the
measured daily discharges by weight divided by the number of days during the
calendar month when the measurements were made.
b. The "daily maximum" discharge means the total discharge by weight during any
calendar day.
8. Test Procedures
Test procedures for the analysis of pollutants shall conform to regulations published
pursuant to Section 304(g) of the Act, under which such procedures may be required.
9. Recording of Results
For each measurement or sample taken pursuant to the requirements of this permit, the
permittee shall record the following information:
a. The exact place, date, and time of sampling;
b. The dates the analyses were performed;
c. The person(s) who performed the analyses;
B-2
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Pjp.- 3 oi 16
Pcrmil No. AL 0003646
d. The analytical techniques or methods used; and
e. The results of all required analyses.
10. Additional Monitoring by Permittee
If the permittee monitors any pollutant at the location(s) designated heroin more
frequently than required by this permit, using approved analytical methods as specified
above, the results of such monitoring shall be included in the calculation and reporting of
the values required in the Discharge Monitoring Report Form (EPA Xo. 3320-1). Such
increased frequency shall also be indicated.
11. Records Retention
All records and information resulting from the monitoring activities required by this
permit including all records of analyses performed and calibration and maintenance of
instrumentation and recordings from continuous monitorl*^ instrumentation shall be
retained for a minimum of three (3) years, or longer if requested by the Regional
Administrator or the State water pollution control agency.
B-3
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Page 4 of 16
PermitNo. AL 0003646
MANAGEMENT REQUIREMENTS
12. Change in Discharge
All discharges authorized herein shall be consistent with the terms and conditions of this
permit. The discharge of any pollutant identified in this permit more frequently than or
at a level in excess of that authorized shall constitute a violation of the permit.
Any anticipated or detected new or different discharges of pollutants
must be reported to the Regional Administrator. Following such report,
the permit may be modified to specify and limit any pollutants not
previously limited.
13 ^Noncompliance Notification
If, for any reason, the permittee does not comply with or will be unable to comply with
any daily maximum effluent limitation specified in this permit, the permittee shall
provide the Regional Administrator and the State with the following information, in
writing, within five (5) days of becoming aware of such condition:
a. A description of the discharge and cause of noncompliance; and
b. The period of noncompliance, including exact dates and times: or, if not corrected,
the anticipated time the noncompliance is expected to continue, and steps being
taken to reduce, eliminate and prevent recurrence of the noncomplying discharge.
14. Facilities Operation
The permittee shall at all times maintain in good working order and operate at optimum ef-
ficiency all treatment or control facilities or systems installed or used by the permittee
to achieve compliance with the terms and conditions of this permit.
15. Adverse Impact
The permittee shall take all reasonable steps to minimize any adverse impact to navigable
waters resulting from noncompliance with any effluent limitations specified in this
permit, including such accelerated or additional monitoring as necessary to determine the
nature and impact of the noncomplying discharge.
161 Bypassing
Any diversion from or bypass of facilities necessary to maintain compliance with the
terms and conditions of this permit is prohibited, except (i) where unavoidable to prevent
loss of life or severe property damage, or (ii) where excessive storm drainage or runoff
would damage any facilities necessary for compliance with the effluent limitations and
prohibitions of this permit. The permittee shall promptly notify the Regional
Administrator and the State in writing of each such diversion or bypass.
B-4
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Page 5 of 16
Permit No. AL OQ03646
17. Removed Substances
Solids, sludges, filter backwash, or other pollutants removed in the course of treatment or
control of wastewaters shall be disposed of in a manner such as to prevent any pollutant
from such materials from entering navigable waters.
18. Power Failures
In order to maintain compliance with the effluent limitations and prohibitions of this
permit, the permittee shall either:
a. In accordance with the Schedule of Compliance contained in Part I, provide an
alternative power source sufficient to operate the wastewater control facilities;
or, if such alternative power source is not in existence, and no date for its implementation
appears in Part I,
b. Halt, reduce or otherwise control production and/or all discharges upon the
reduction, loss, or failure of the primary source of power to the wastewater control
facilities.
RESPONSIBILITIES
19. Right of Entry
The permittee shall allow the head of the State water pollution control agency, the
Regional Administrator, and/or their authorized representatives, upon the presentation of
credentials:
a. To enter upon the permittee's premises where an effluent source is located or in
which any records are required to be kept under the terms and conditions of this
permit; and
b. At reasonable times to have access to and copy any records required to be kept under
the terms and conditions of this permit; to inspect any monitoring equipment or
monitoring method required in this permit; and to sample any discharge of pollutants.
20. Transfer of Ownership or Control
In the event of any change in control or ownership of facilities from which the authorized
discharges emanate, the permittee shall notify the succeeding owner or controller of the
existence of this permit by letter, a copy of which shall be forwarded to the Regional
Administrator and the State water pollution control agency.
21. Availability of Reports
Except for data determined to be confidential under Section 308 of the Act, all reports
prepared in accordance with the terms of this permit shall be available for public
B-5
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Page 6 of 16
Permit No. AL 0003646
inspection at the offices of the State water pollution control agency and the Regional
Administrator. As required by the Act, effluent data shall not be considered confidential.
Knowingly making any false statement on any such report may result in the imposition of
criminal penalties as provided for in Section 309 of the Act.
22. Permit Modification
After notice and opportunity for a hearing, this permit may be modified, suspended, or
revoked in whole or in part during its term for cause including, but not limited to, the
following:
a. Violation of any terms or conditions of this permit;
b. Obtaining this permit by misrepresentation or failure to disclose fully all relevant
facts; or
c. A change in any condition that requires either a temporary or permanent reduction or
elimination of the authorized discharge.
23. Toxic Pollu tan ts
If a toxic effluent standard or prohibition (including any schedule
of compliance specified in such effluent standard or prohibition)
is established under Section 307(A) of the Act for a toxic pollutant
which is present in the discharge and such standard or prohibition
is more stringent than any limitation for such pollutant in the
permit, and the Agency seeks to revise or modify the permit in
accordance with the toxic effluent standard or prohibition, the
permittee shall have notice and opportunity for hearing, with right
of appeal, on the method of application of the toxic standard or
prohibition if such application requires the use of discretion,
judgement, or calculation by the permitting Agency. This provision
is subject to the attached agreement.
24. L'ivil and Criminal Liability
Except as provided in permit conditions on "Bypassing" (Part II, A-5) and "Power
Failures" (Part II, A-7), nothing in this permit shall be construed to relieve the permittee
from civil or criminal penalties for noncompliance. This provision is subject to
the attached agreement.
25<,Oi7 and Hazardous Substance Liability
Nothing in this permit shall be construed to preclude the institution of any legal action or
relieve the permittee from any responsibilities, liabilities, or penalties to which the
permittee is or may bo subject under Section 311 of the Act.
26.S(ofc Laws
Nothing in this permit shall be construed to preclude the institution of any legal action or
relieve the permittee from any responsibilities, liabilities, or penalties established pursuant
to any applicable State law or regulation under authority preserved by Section 510 of the
Act.
B-6
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Page 7 of 16
Permit No. AL 0003646
27. Property Rights
The issuance of this permit does not convey any property rights in either real or personal
property, or any exclusive privileges, nor does it authorize any injury to private property
or any invasion of personal rights.
2B9.Severability
The provisions of this permit are severable, and if any provision of this permit, or the
application of any provision of this permit to any circumstance, is held invalid, the
application of such provision to other circumstances, and the remainder of this permit,
shall not be affected thereby.
29. Other Requirements
This permit shall be subject to an agreement between United States
Steel Corporation and the U. S. Environmental Protection Agency
attached hereto.
a. The "daily average" concentration means the arithmetic average
(weighted by flow value) of all the daily determinations of concen-
tration made during a calendar month. Daily determinations of concen-
tration made using a composite sample shall be the concentration of
the composite sample. When grab samples are used, the daily determina-
tion of concentration shall be the arithmetic average (weighted by
flow value) of all the samples collected during that calendar day.
b. The "daily maximum" concentration means the daily determination
of concentration for any calendar day.
c. "Weighted by flow value" means the summation of each sample concen-
tration times its respective flow in convenient units divided by the
total flow.
d. For the purpose of this permit, a calendar day is defined as any
consecutive 24-hour period.
e. For discharge serial numbers 010-027 from the Fairfield Works, all
e.ffluent limitations, except temperature, pH and dissolved oxygen, shall
based upon "net daily loadings or concentrations," which are defined as
net difference between the product of inlet volume times inlet concentra
times a volume-to-weight conversion factor of 8.34, and the product of
discharge volume times discharge concentration times the same 8.34 facto
or the net difference between inlet and outlet concentrations.
B-7
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30. EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS
1. During the period beginning on the effective date of this permit and lasting through the term of this permit,
the permittee is authorized to discharge from outfall(s) serial number(s) 002 ; Blast Furnace (Ensley Works)
CO
oo
Such discharges shall be limited and monitored by the permittee as specified below:
Effluent Characteristic
Discharge Limitations
Monitoring Requirements
kg/day (Ibs/day)
Daily Avg Daily Max
Flow—m3/Day (MGD)
Temperature, °C(°F)
Ammonia-Nitrogen
*Cyanide
Phenols
TSS
214(472)
6.8(15)
643(1417)
20.9(46)
Other Units (Specify)
Daily Avg Daily Max
35(95)
41 mg/1
67 mg/1
Measurement
Frequency
Once/Week
Once/Week
Once/Week
Once/Week
Once/Week
Once/Week
Sample
Type
Instantaneous
Grab
Composite
Composite
Composite
Composite
*This limit shall become effective on January 1, 1982. An interim effluent limitation of 46 Kg/day(100 Ib/day)
daily maximun shall be effective from the effective date of the permit thru December 31, 197P,, anr" an interim
final effluent limitation of 23 Kg/day(50 Ib/day) daily maximum shall be effective from January 1, 1979,
thru December 31, 1981.
The pH shall not be less than 6.0 standard units nor greater than 9.
once/week with a grab sample.
standard units and shall be monitored
There shall be no discharge of floating solids or visible foam in other than trace amounts.
Samples taken in compliance with the monitoring requirements specified above shall be taken at the following location(s):
nearest accessible point after final treatment but prior to actual discharge or mixing with the
receiving waters.
»
o
o
o
o
u>
ON
-------
CD
I
vo
During the period beginning on the effective date of this permit and lasting through the term of this permit,
the permittee is authorized to discharge from outfall(s) serial number(s) 003-009 ; Ensley Mills
Such discharges shall be limited and monitored by the permittee as specified below:
Effluent Characteristic
Flow—m3/Day (MGD)
Temperature °C(°F)
TSS
Oil & Grease
Iron
Zinc
Discharge Limitations
Monitoring Requirements
Daily Avg
/day) Other Units (Specify)
Daily Max
__
— _
—
__
—
Daily Avg
—
50 mg/1
18 rag/1
5 mg/1
1 mg/1
Daily Max
35(95)
100 mg/1 *
30 mg/1 *
10 rag/1 *
• *O * -~ .
2 me/1 *
Measurement
Frequency
Once/Week
Once/Week
Once/Week
Once/Week
Once/Week
Once/Week
Sample
Type
Instantaneous
Grab
Composite
Grab
Composite
Composite
The pH shall not be less than 6.0 standard units nor greater than 9.0 standard units and shall be monitored
once/week with a grab sample.
There shall be no discharge of floating solids or visible foam in other than trace amounts.
Samples taken in compliance with the monitoring requirements specified above shall be taken at the following location(s):
nearest accessible point after final treatment but prior to actual discharge or mixing with the
receiving waters.
*
8-
o
*Concentration discharge limitations are combined flow weighted averages.
-------
3.
GO
I
During the period beginning on the effective date of this permit and lasting through June 30, 1977,
the permittee is authorized to discharge from outfall(s) serial number(s) 010-027 , Fairf ield Works.
Such discharges shall be limited and monitored by the permittee as specified below:
Effluent Characteristic
Discharge Limitations
kg/day (lbs/da"y) Other Units (Specify)
Monitoring Requirements
Daily Avg
Flow-m3/Day (MGD)
Temperature °C(°F)
Ammonia-Nitrogen
Cyanide
Phenols
TSS
Oil & Grease
T.D. Iron
COD
Total Chromium
Total Zinc
Tin
Fluoride
1800(4000)
291(640)
136(300)
5761(12690)
4.5(10)
41(90)
70(155)
202(446)
Daily Max
789(1740)
23(50)
15.8(35)
3510(7300)
631(1391)
272(600)
9568(21074)
13.5(30)
74(163)
140(310)
320(705)
Daily Avg
Daily Max
35(95)
Measurement
Frequency
Continuous
Continuous
Once/Week
Once/Week
Once/Week
Once/Week
Once/Week
Once/Week
Once/Week
Once/Week
Once/Week
Once/Week
Once/Week
Sample
Type
Recorder
Recorder
24-Hour Composite
24-Hour Composite
24-Hour Composite
24-Hour Composite
Grab
24-Hour Composite
24-Hour Composite
24-Hour Composite
24-Hour Composite
24-Hour Composite
24-Hour Composite
The pH shall not be less than 6.0 standard units nor greater than 9.0 standard units and shall be monitored
once/week with a grab sample.
There shall be no discharge of floating solids or visible foam in other than trace amounts.
Samples taken in compliance with the monitoring requirements specified above shall be taken at the facility
already established and defined as the Opossum Creek Monitoring Station.
A weekly average D.O. concentration of 5.0 mg/1 shall be maintained in the discharge. This parameter
shall be monitored five times per week using a grab sample. After a oeriod of one vear the monitoring
frequency may be modified based upon an evaluation of the data.
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Proposed Modification
CO
During the period beginning July 1, 1977, and lasting through the term of the permit,
the permittee is authorized to discharge from outfall(s) serial number(s) 010-027; Fairfield Works.
Such discharges shall be limited and monitored by the permittee as specified below:
Effluent Characteristic
Discharge Limitations
Other Units (Specify)
Daily Max
35(95)
Flow-m3/Day (MGD)
Temperature °C(°F)
Ammonia-Nitrogen
Cyanide
Phenols
TSS
Total Zinc
Oil & Grease
T. D. Iron
COD
Total Chromium
Tin
Fluoride
kg/day
Daily Avg
—
—
—
—
—
1930(4255)
16.3(36)
354(780)
136(300)
5761(12690)
4.5(10)
70(155)
323(713)
(Ibs/day)
Daily Max
—
—
860(1896)
24.5(54)
19.5(43)
3828(8440)
32.7(72)
744(1641)
272(600)
9568(21074)
13.5(30)
140(310)
577(1271)
Othei
Daily A
—
—
—
—
—
—
—
—
—
—
—
—
—
Monitoring Requirements
Measurement
Frequency
Continuous
Continuous
Once/Week
Once/Week
Once/Week
Once/Week
Once/Week
Once/Week
Once/Week
Once/Week
Once/Week
Once/Week
Once/Week
Sample
Type
Recorder
Recorder
24-Hour Composite
24-Hour Composite
24-Hour Composite
24-Hour Composite
24-Hour Composite
Grab
24-Hour Composite
24-Hour Composite
24-Hour Composite
24-Hour Composite
24-Hour Composite
The pH shall not be less than 6.0 standard units nor greater than 9.0 standard units and shall be
monitored once/week with grab samples.
There shall be no discharge of floating solids or visible foam in other than trace amounts.
Samples taken in compliance with the monitoring requirements specified above shall be taken
at the facility already established and defined as the Opossum Creek Monitoring Station.
A weekly average D.O. concentration of 5.0 mg/1 and a daily minimum of 4.0 mg/1 shall be
maintained in the .discharge. This parameter shall be monitored five times per week using
a grab sample. After a period of one year, the monitoring frequency may be modified based
upon an evaluation of the data.
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5. During the period beginning on the effective date of this permit and lasting through the term of this permit,
the permittee is authorized to discharge from outfall(s) serial number(s) 029A and 029{Sinteri-ig Plant).
Such discharges shall be limited and monitored by the permittee as specified below:
Effluent Characteristic
Discharge Limitations
kg/day (lbs/da"y) Other Units (Specify)
Daily Avg Daily Max Daily Avg Daily Max
DSN 029A - Sanitary Wastewaters: (Effective July 1, 1977)
Flow—m3/Day (MGD) — — — —
Fecal Coliform -- — 200/lOOml 400/lOOml
BOD — — 30 me/1 45 tWl
Monitoring Requirements
Measurement
Frequency
Once/Month
Once/llonth
On r.e /Month
Sample
Type
Instantaneous
Grab
Tomoosite
oo
ro
DSN 029 * Process and Sanitary:
Flow-m /Day(MGD)
Temperature °C(°F)
TSS
Oil & Grease
40 mg/1
10 mg/1
35(95)
60 mg/1
20 mg/1
Once /Week
Once/Week
Once/Week
Once/Week
Ins tantaneous
Grab
24-Hour Composite
Grab
The pH shall not be less than 6»0 standard units nor greater than 9.5 standard units and shall be monitored at
029 once/week with grab samples. This requirement will become effective on July 1, 1977.
There shall be no discharge of floating solids or visible foam in other than trace amounts.
Samples taken in compliance with the monitoring requirements specified above shall be taken at the following location(s):
nearest accessible point after final treatment but prior to actual discharge or mixing with the
receiving waters.
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CO
I
B.
The following limits shall be used to determine compliance with discharge numbers 010-027 during
periods of rainfall or rainfall drainage. In the event the discharge of any wastewater from
discharges 010-027 exceeds the parameters set out on pages 11 thru 16 of 21 by reason of rainfall
or rainfall drainage, the Company must show compliance with this oermit by proving that the performance
values so esta'Slishe'4 in th4 a section are bcin^ met at "ac^* SMC** treatment system.A
Effluent Characteristic
Tin Mill
Flow-m3/Day (MOD)
Oil & Grease
TSS
COD
Conductivity, ymhos
pH, std. units
Coke Works
Flow-m3/Day(MGD)
COD
Phenols
Cyanide
Ammonia-Nitrogen
pH, std. units
Discharge Limitations
kg/day (Ibs/day) Other Units (Specify)
Monitoring Requirements
Daily Avg
Daily Max
(Gross)
197(435)
978(2157)
4385(9658)
1761(3879)
2.3(5)
19
Daily .Min. Daily Max
Measurement
Frequency
6.0
2539
10.0
9.0
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
AA
Sample
Type
Instantaneous
Grab
24-Hour Composite
24-Hour Composite
Grab
Grab
Instantaneous
24-Hour Composite
24-Hour Composite
24-Hour Comoosite
24-Hour Composite
Grab
5 $
3 °
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*Rainy days will be determined by rainfall that is greater than or equal to 0.1".
**0n sampled days affected by rainfall or rainfall drainage.
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6. Continued
Effluent Characteristic
CO
I
Discharge Limitations
kg/day (Ibs/day) Other Units (Specify)
Monitoring Requirements
Daily Avg
C.
Wire Mill
TSS
Conductivity, ymhos
pH, std. units
Daily Max
(Gross)
86(189)
Daily Min. Daily Max
6.0
D.I. From effective date of this permit until July 1, 1977,
Q-BOP's (2)
Flow-m3/Day(MGD)
TSS — 204(4.49)
Conductivity, umhos — — —
pH, std. units — — 6.0
2068
12.0
745
9.0
D.2. From July 1, 1977, untilthe expiration date of this permit,
Q-BOP's (3)
Flow-m3/Day(MGD)
TSS — 306(674)
Conductivity, pmhos — — — 745
pH, std. units — — 6.0 9.0
Measurement
Frequency
**
AA
AA
**
**
AA
AA
AA
AA
AA
AA
AA
Sample
Type
Instantaneous
24-Hour Composite
Grab
Grab
Instantaneous
24-Hour Composite
Grab
Grab
Instantaneous
24-Hour Composite
Grab 3 |
Grab £
**0n sampled days affepted by rainfall or rainfall drainage.
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6. Continued
Proposed Modification
Effluent Characteristic
CO
en
Discharge Limitations
kg/day (Ibs/day) Other Units (Specify)
Monitoring Requirements
Daily Avg
(Gross)
E. 1. Blast Furnaces (No. 5, 6, & 7)
Flow-m3/Day(MGD)
TSS
pH, std. units —
Daily Max
(Gross)
304(670)
Daily Min. Daily Max
6.0
9.0
E. 2.
From January 1, 1978, until the expiration date of this permit,
Blast Furnace (No. 8)
Flow-m3/Day(MGD)
59(130) 177(390)
.6(1.3) 1.8(4oO)
1.2(2.6) 3.6(8.0) -- —
24(52) 71(156)
.7(1.6) 2.3(5)
47(104) 142(312)
Measurement
Frequency
TSS
CN-A
Phenol
N113-N
Sulfide
Flouride
oH. std. units
**
**
**
6.0
9.0
On Days
On Days
On Days
On Days
On Days
On Days
On Days
On Days
of Rain
of Rain
of Rain
of Rain
of Rain
of Rain
of Rain
of Rain
Sample
Type
Instantaneous
24-Hour Composite
Grab
Instantaneous
24-Hour Composite
Grab
Grab
24-Hour Composite
24-Hour Composite
24-Hour Composite
Grab
There shall be no discharge of floating solids or visible foam in other than trace amounts.
Samples taken in compliance with the monitoring requirements specified above shall be taken at the following location(s):
nearest accessible point after final treatment but prior to actual discharge or mixing with th(
receiving waters.
**0n sampled days affected by rainfall or rainfall drainage.
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Page 16 of 16
Permit No. AL 0003646
B, SCHEDULE OF COMPLIANCE
1. The permittee shall achieve compliance with the effluent limitations specified for
discharges in accordance with the following schedule:
I. Discharge Serial No. 002: Permittee shall achieve zero discharge of cyanide
by January 1, 1982. An acceptable compliance schedule shall be submitted
to EPA and AWIC on/or before January 1, 1981, to include steps to be taken
to achieve zero discharge of cyanide by January 1, 1982. The following
compliance schedule shall apply:
Effective date of permit-Achieve interim cyanide effluent limitation of
46 kg/day(100 Ibs/day) daily maximum.
-*
September 1, 1977 - Submit Progress Report.
July 1, 1978 - Submit Progress Report.
January 1, 1979-Achieve interim final cyanide effluent limitations of
23 kg/day(50 Ibs/day) daily maximum and begin preliminary engineering.
April 1, 1979 - Submit Progress Report.
January 1, 1980-Submit Progress Report.
September 1, 1980 - Submit Progress Report.
July 1, 1981 - Submit Progress Report.
January 1, 1982-Achieve zero discharge of cyanide.
II. Discharge Serial Nos. 003-009: There shall be no sanitary discharges from
Ensley Mills after June 30, 1977.
III. Discharge Serial Nos. 010-027: Attain final zinc (total) limitations by
July 1, 1977.
IV. Discharge Serial No. 029: Attain pH limitations by July 1, 1977.
V. Discharge Serial No. 029A: Attain BOD and fecal coliform limitations
by July 1, 1977.
2. No later than 14 calendar days following a date identified in the above schedule of
compliance, the permittee shall submit either a report of progress or, in the case of
specific actions being required by identified dates, a written notice of compliance or
noncompliance. In the latter case, the notice shall include the cause of noncompliance,
any remedial actions taken, and the probability of meeting the next scheduled
requirement.
B-16
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