U.S. DEPMTMENT OF COMMEftCE
Natwul TtclMMul Information Strtici
PB-260 918
State-of-the-Art: Military Explosives
and Propellents Production Industry
Volume II. Wastewater Characterization
s'
American Defense Preparedness Association, Washington, D C
tw
Fvv
Industrial Environmental Research Lob, Cincinnati, Ohio
76
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EPA-600/2-76-213C
August, 1976
STATE-OF-THE-ART:
MILITARY EXPLOSIVES AND
PROPE1,T,ANTS PRODUCTION INDUSTRY
VOLUME H
Wastewater Characterization
by
James Patterson
Norman I. Shapira
John Brown
William Duckert
Jack Poison
Project No. 802872
Project Officer
Richard Tabakin
Industrial Environmental Research Laboratory - Cincinnati
Edison, New Jersey 08817
U. S. ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF RESEARCH AND DEVELOPMENT
INDUSTRIAL ENVIRONMENTAL RESEARCH LABORATORY
CINCINNATI, OHIO 45268
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TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing)
1. REPORT NO.
EPA-600/2-76-213b
3. RECIPIENT'S ACCESSION»NO.
4. TITLE AND SUBTITLE
State-of-the-Art: Military Explosives
and Propellants Production Industry (3 vols)
Vol. II - Wastewater Characterization
5. REPORT DATE
August 1976
s. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
Patterson, James; J. Brown; W. Duckert;
J. Poison; and N. I. Shapira
8. PERFORMING ORGANIZATION REPORT NO.
9. PERFORMING ORG \NIZATION NAME AND ADDRESS
American Defense Preparedness Association
Union Trust Building
15th and H Street, N. W.
Washington, D. C. 20005
10. PROGRAM ELEMENT NO.
1BB610
11. CONTRACT/GRANT NO.
R 802872
12. SPONSORING AGENCY NAME AND ADDRESS
13. TYPE OF REPORT AND PERIOD COVERED
Final
U. S. Environmental Protection Agency
Industrial Environmental Research Laboratory
Cincinnati, OH 45268
14. SPONSORING AGENCY CODE
EPA-ORD
15. SUPPLEMENTARY NOTES
Vol. I - The Military Explosives and Propellants Industry
Vol. Ill - Wastewater Treatment
16. ABSTRACT
This study has surveyed the military explosives and propellant
manufacturing industry, covering both "GOGO" and "GOCO" facilities. Sources of
wastewater, volumes, and pollutant constituents have been reported where such
data existed.
Treatment technology currently in use at the various installations has been
described, including effectiveness of pollutant removal and secondary (air and
solid) waste generation. Systems under development at these military
installations have also been examined and evaluated in light of available
information.
The report consists of three volumes. Volume I presents general conclusions
and recommendations and describes the industry ' s manufacturing operations .
Volume II presents the bulk of the data concerning the wastewaters and the
treatment systems now in place. Volume III reviews and summarizes data from the
first two volumes and describes and evaluates the new treatment processes under
development at this time.
7.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.lDENTIFIERS/OPEN ENDED TERMS C. COSATI Field/Group
Wastewater
Industrial wastes
Explosives
Waste treatment
Propellants
Water pollution control
Chemical wastes
Military
Manufacturing
13B
19A
211
3. DISTRIBUTION STATEMENT
Public Distribution
19. SECURITY CLASS (This Report)
Unclassified
21. NO. OF PAGES
20. SECURITY CLASS (This page)
Unclassified
EPA Form 2220-1 (9-73)
I
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DISCLAIMER
This report has been reviewed by the Industrial Environmental Research
Laboratory, Cincinnati, of the U. S. Environmental Protection Agency, and
approved for publication. Approval does not signify that the contents neces-
sarily reflect the views and policies of the U. S. Environmental Protection
Agency, nor does mention of trade names or commercial products constitute
endorsement or recommendation for use.
ii
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FOREWORD
When energy and material resources are extracted, processed,
converted, and used, the related pollutional impacts on our
environment and even on our health often require that new and
increasingly more efficient pollution control methods be used.
The Industrial Environmental Research Laboratory - Cincinnati
(lERL-Ci) assists in developing and demonstrating new and improved
methodologies that will meet these needs both efficiently and
economically.
This project, "State-of-the-Art: Military Explosives and
Propellants Production Industry", was undertaken as part of
Environmental Protection Agency's Miscellaneous Chemical Industries
program to establish a baseline of information concerning the
military explosives industry, the magnitude of its waste problems,
and the adequacy of the industry's treatment technology. The
results of the study have indicated that many of the wastes do
present significant problems of toxicity and/or resistance to
treatment, in addition to problems unique to explosives. Although
some treatment systems in use do protect the nation's waterways
from contamination, others are inadequate, generate secondary air
or solid waste problems, or are not widely used due to budgetary
limitations. Further research effort is needed by EPA and/or
Department of Defense to control pollutants generated by certain
sectors of the industry. The data and results of the investigation
have been used extensively by EPA's Office of Water Programs in
developing standards for the explosives industry. It will also
allow engineering staffs at several commercial military manufac-
turing facilities to examine their wastes and compare control
technology with that being used or developed at other installations.
Finally, it will enable EPA to determine our own research efforts
in this industry and how they would relate to other programs.
Questions or requests for additional information should be directed
to the Industrial Environmental Research Laboratory - Cincinnati,
Field Station - Edison, New Jersey.
David G. Stephan
Director
Industrial Environmental Research Laboratory
iii
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ABSTRACT
This study, contained in three volumes, addresses the wastewater effluents
of the military explosives and propellants production industry. Both manufac-
turing and LAP (Load, Assemble, and Pack) activities are covered. Volume I
describes the industry, as well as the production processes and technology.
Volume II details the wastewater effluents of manufacture and LAP operations by
product, process, and military installation, to the extent that data are
available. Volume III describes and evaluates the effectiveness of various
treatment technologies for water pollution abatement now in use or under
investigation by product, process, and military installation.
A comprehensive long-term effort has been underway by the Department of
Defense for a number of years for the purpose of modernizing munitions
production plants. Pollution abatement is an integral part of the moderniza-
tion program. Although extensive study, research and development investigations
have been undertaken, and although significant water pollution abatement and
water management plans have been developed, implementation is generally in only
the initial stages at selected military facilities. Major Government emphasis
and very substantial funding are essential to: the continuation of necessary
pollution abatement research and development; the demonstration of promising
new treatment technologies; and the implementation of effective and economical
treatment system construction programs. Recommendations are set forth in
detail in Volume I.
The reader of this report is advised that it consists of six
chapters, contained in three volumes, each addressing separate aspects
of the explosives and propellants wastewater effluents and treatment
situation, and that duplication and repetition among these chapters
has been kept to a minimum. Thus, the reader is cautioned that the use
or interpretation of statements or evaluations taken out of context from
the study in its entirety could lead to serious misunderstandings and
incorrect assessments.
IV
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VOLUME II
TABLE OF CONTENTS
SECTION I - INTRODUCTION 1
SECTION II - SUMMARY 7
SECTION III - ACIDS 23
19. ACETIC ANHYDRIDE MANUFACTURE 23
20. CONCENTRATED ACETIC ACID MANUFACTURE 28
21. WEAK NITRIC ACID (HNO ) PRODUCTION (AOP) 36
22. CONCENTRATED NITRIC ACID MANUFACTURE 39
23. CONCENTRATED SULFURIC ACID PRODUCTION 44
2k. OLEUM PRODUCTION 45
SECTION IV - EXPLOSIVES 48
25. AMMONIUM NITRATE PRODUCTION 48
26. DINITROTOLUENE (DNT) 52
27. TNT PRODUCTION 53
28. TETRYL PRODUCTION 62
29. BLENDS INCLUDING RDX, HMX, AND EXPLOSIVE
FORMULATIONS DERIVED FROM THEM WITH EMPHASIS
ON COMPOSITION-B 70
30. NITROGUANIDINE (NGu) 87
- 31. NITROGLYCERIN (NG) PRODUCTION 88
32. PRIMER COMPOUNDS 96
SECTION V - PROPELLANTS 107
•" 33. NITROCELLULOSE (NC) PRODUCTION 107
-^3U. SINGLE BASE PROPELLANTS 116
^35- MULTIBASE PROPELLANTS 121
36. SOLVENTLESS PROPELLANTS 123
SECTION VI - LOAD AND PACK 142
37. LOAD, ASSEMBLE, AND PACK (LAP) OPERATION 142
APPENDIX I - DETAILED DATA TABLES 162
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SECTION I - INTRODUCTION
1. Chapter V contains detailed characterizations of the liquid effluents
generated in the manufacture of explosives and propellants and load, assem-
ble, and pack (LAP) operations at various ammunition plants.
a. Section II of Chapter V contains summary characterizations of the
waste water effluents by product or process. Detailed characterizations of
products and intermediates are grouped by category in Sections III-VI as
follows:
Section III Acids
IV Explosives
V Propellants
VI Load and Pack
b. The effluents are described on a product basis for each of the
following materials: acetic anhydride; ammonium nitrate;.blends including
RDX and HMX, and explosive formulations derived from them; concentrated
acetic acid; concentrated nitric acid; concentrated sulfuric acid; dinitro-
toluene (DNT); nitrocellulose (NC); nitroglycerin (NG); nitroguanidine (NGu);
oleum; primers, including trinitroresorcinol (TNR), lead styphnate, tetra-
cene, and pentaerythritol tetranitrate (PETN); single base propellants;
multi-base propellants; solventless propellants; tetrylj TNT; and weak
nitric acid. In addition, effluents from LAP operations are described on a
plant-by-plant basis. Detailed data tables are included in Appendix I.
2. Table 1 lists the various plants, their locations, and their principal
activities. Complete coverage of plants listed in Table 1 has not been
possible because of lack of data from several of the plants. Where a dis-
cussion of the wastes generated in the manufacture of a specific material
at a specific site has not been possible, an asterisk appears instead of
the X in the box (see Table l).
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3. A large volume of data characterizing liquid effluents primarily from
the Army explosives production industry have been generated. However, be-
cause of mixing of effluent streams it was not always possible to associate
these data with the production of specific materials. The information pre-
sented in this chapter was derived largely from AEHA reports of various
vintages. Where production figures were available, they were incorporated
into the data base. It may be anticipated, however, that production (gen-
erally reported as percent of full mobilization capacity) today is sub-
stantially less than the data reported in this chapter, since the data pre-
sented herein are based on AEHA studies undertaken primarily during the con-
flict in Southeast Asia. Furthermore, the data presented in this chapter
do not reflect large fluctuations in effluent composition with time. These
fluctuations may result from variations in production rate, periodic shut-
downs, or periodic washouts. Flow rates may vary for these same reasons.
This chapter contains the most complete and thorough product-based
wastewater characterization that can be presented without further detailed
monitoring and analytical work. There are many data gaps in the following
text, and they are noted and can constitute specific subject areas for
future investigations.
k. Much of the information presented in Chapter V is in tabular form.
These tables generally present a chemical characterization of the liquid
effluents from a specific step in the manufacture of one of the above-
mentioned materials prior to treatment. This characterization may include:
%
constituents; maximum, minimum, and mean concentrations; mean concentration
corrected for the mean raw water concentration; discharge in Ibs/day; Ibs of
discharge per ton of final product; flow; and production. Results from
these tables may then be summed to yield the overall discharges (in Ibs/day
-------
and Ibs/ton of product) resulting from the production of each material.
These overall discharges may then be cross-correlated among the various
plants. In only a few instances, however, were enough data available to
complete all of these tables. In many cases, wastewater characterizations
for the manufacture of a specific item were available for only one plant —
the data from the remaining plants manufacturing this item were incomplete
or non-existent.
5. Table 2 summarizes the major constituents in the untreated effluents
from each AAP. This is only a qualitative evaluation and is based on the
results presented in this chapter.
a. Data from Navy munitions facilities are not available in sufficient
detail to be meaningful, since the Navy monitoring program is in an initial im-
plementation stage in most cases. However, four of the six Navy facilities
are LAP only, and the effluents of these plants can be assumed with validity
to be comparable to the effluents of Army LAP plants loading the same in-
gredients . Indianhead is primarily a propellant facility; however, data are
not available.
Table 3 lists the Army Ammunition Plants and their abbreviations.
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TABLE 1
AMMUNITION PLANTS AND THEIR ACTIVITIES
Ammunition
Plants
Badger
Holston
Iowa
Indiana
Joliet
Kansas
Louisiana
Lake City
Longhorn
Lone Star
Milan
Newport
Radford
Redstone
Volunteer
NAD Crane
NAD Hawthorne
NOS
Indianhead
NAD McAlester
Magna
NWS Yorktown
AF Plant 78
Activity
Manu.
X
X
X
X
A
*
A
01
•H
01
o
r-l
ex
X
X
X
X
X
X
A
*
Propellant
X
A
X
*
LAP
Explosive
X
X
X
X
X
X
X
X
X
X
*
X
Propellant
X
*
*
*
*
Acids
Acetic anhydride
X
•a
•H
O
o
•H
4J
0)
CJ
CJ
a
o
CJ
X
T3
•H
0
•H
4J
•H
Z
O
g
CJ
A
X
A
A
*
*
A
•a
•H
U
u
•H
U
•H
al
A
X
*
*
*
•H-
A
Cone. Sulfuric Acid
A
A
*
*
A
*
6
01
rH
O
A
X
A
A
Product Ca
Ex
Q
A
H
X
A
X
A
plosives
X
X
*
*
Tetryl
X
X
X
i
oability
Propellants
Primers
*
A
X
.O
X
A
X
01
(A
n)
CO
01
tH
fit
CO
X
A
X
Multibase
X
X
*
Solventless
X
X
•it-
Composite
X
A
*
*
•it-
Ingredients Used in Formulations
Aluminum
*
*
*
A
#
*
A
*
*
*
*
*
*
Ammonium perchlorate
A
A
*
*
rH
CJ
nl
O
*
O
A
X
*
*
*
*
*
*
O
*
*
*
1
*
o
A
*
*
Ammonium picrate
*
Po lybu tad iene
A
A
*
Polyurethane
1
X
X
X
X
X
X
X
X
X
* ;#
1*
I
X
•X-
X
Solvents
A
*
*
H
X
X
X
X
X
X
X
x
X
X
1
A
#
A
*
Sodium Nitrate
*
X
*
* •
xl*
*
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TABLE 2
MAJOR POLLUTANTS IN UNTREATED EFFLUENTS AS DISCUSSED IN CHAPTER V
Constituent
Total Kjeldahl Nitrogen
Ammonia
Nitrite/Nitrate
Phosphate
Sulfate
Turbidity
Color
Surfactants
Total Organic Carbon
Total Solids
Total Dissolved Solids
Total Suspended Solids
Total Volatile Solids
PH
Trinitrotoluene
Dinitro toluene
IIMX
KDX
Acetic Acid
Acetic Anhydride
Acidity
Alkalinity
Chemical Oxygen Demand
Biological Oxygen Demand
Phenols
Acetaldehyde
Acetonitrile
Methylacetate
Propanol
Propylacetate
Cyclohexanone
Butanol
Toluene
^examine
Acetone
Nitromethane
Methyl nitrate
Nitric acid
Tetryl
Lead Azide
Lead Styphnate
Octyl
Potassium Nitrate
Charcoal
Sulfur
Ammonium Perchlorate
Cyanide
Iron
Cadmium
Manganese
Nitroglycerin
Lead
Trinitroresorcinol
Tetracene
Ethyl Alcohol
Ethyl Ether
Dlethyl Ether
Sodium sulfite
Sodium nitrite
Sodium bisulfite
(Sodium trinitromethane sulfonate
Badger
X
X
X
X
X
X
X
X
X
X
X
X
Holston
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
a
3
0
*->
X
X
X
Indiana
X
Joliet
X
X
X
X
X
X
X
X
X
X
y.
X
Kansas
X
X
X
X
Louisiana
X
X
AA
>
w
v<
(J
01
je
3
X
X
X
p
Lonehorn
X
X
X
X
X
X
X
X
X
1*
t
u
W)
01
c
o
J
X
X
X
X
X
X
X
X
X
X
s
•H
X
X
Newport
X
Radford
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Redstone
Volunteer
X
i
i
i
i
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TABLE 3
ARMY AMMUNITION PLANT (AAP)
AAAF Alabama
BAAF Badger
BuAAF Burlington
CAAP Cornhusker
GAAP Gateway
HAAP Holston
HaAAP Hays
IAAP Iowa
InAAP Indiana
JAAP Joliet
KAAP Kansas
LAAF Louisiana
LCAAP Lake City
LHAAP Long Horn
LSAAP Lone Star
MAAP Milan
NAAP Newport
RAAP Radford
RaAAF Ravenna
RiAAP Riverbank
SAAP Sunflower
ScAAF Scranton
TCAAP Twin Cities
VAAP Volunteer
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SECTION II - WASTEWATER CHARACTERIZATION SUMMARY
6. This Section presents a qualitative summary of the waste water effluents
from explosives production, by major product or intermediate. The summaries
are complied from the data contained in the various tables in Chapter V,
as well as from data on commercial explosives production derived from the
EPA Report by J. W. Patterson et al., "Pollution Control in the Commercial
Explosive Industry." (4d)
Since they are based on the most complete and comprehensive waste water
data available on the military and commercial explosives production indus-
tries, the results presented in this Section can be considered as repre-
sentative. Although data on commercial explosives production plants are
included, these are not highly significant in comparison with the large
volume of detailed data available on military plants.
7. Data from some plants are not fully useful, since they represent com-
bined flows from several products or processes, rather than individual
products or processes. The available specific product or process data were
arithmetical il y averaged (on a flow-proportioned basis) to determine mean
values. Maximum and minimum (range) values were taken directly from the
raw data sources. Based upon the industry-wide average discharge volume
(MS)) and production (TPD), the average effluent concentration was used to
calculate effluent discharge in Ib/day and in Ib/ton of product. The last
column in Tables 5-15 represents the number of plants for which each set
of data was averaged, and from which ranges were determined. For example,
in Table 5 data from four plants were used to determine the mean flow;
however, data from only two plants were available on total organic nitrogen.
For some products, such as HMX or RDX, there is only one plant for which data
are available.
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8. The wastewaters are characterized on a basis of products and inter-
mediates. In some cases, a breakdown into individual process wastewater
is also included. There is a great deal of variability from plant to plant.
9. The "average" plant is defined on the basis of most common and/or most
abundant intermediate and final explosive products, as found in both com-
mercial and military explosive production industries. Although this is only
a hypothetical "average" plant, it can be considered as typical of the waste-
water of the last decade. It is not, however, representative of a plant
after "modernization." "Average" plants producing the following intermediate
and final product are characterized in Tables 5-15.
Nitrogen based compounds (ammonia, nitric acid, ammonium nitrate)
Concentrated Sulfuric Acid
Oleum
Acetic Acid
Acetic Anhydride
Nitrocellulose
Nitroglycerin
TNT
RDX + HMX + Composition B (KDX + TNT)
10. Nitrogen Plant
a. Combined wastewater is from the production of ammonia, weak and
strong nitric acids, ammonium nitrate. The waste sources include cooling
waters and spent acid streams from nitration processes.
b. The waste is acidic with moderate to high nitrate levels as the
result of nitration. Sulfate is also present in appreciable amounts. Total
solids content of the waste is rather high, compared to the suspended solid
concentration, indicating that most of the solids are in dissolved form.
c. Table 5 summarizes available data from all nitrogen plants.
8
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d. The following are characteristics of wastewaters from one weak
and one strong nitric acid plant.
TABLE h - NITRIC ACID WASTEWATER
Parameter
PH
BOD mg/1
COD mg/1
Kjel-N mg/1
NIL-N mg/1
NO- & N02 mg/1
TS mg/1
SS mg/1
sulfate mg/1
waste flow
Weak 61% HNO (2)
3.1
less than U.08
0.1
O.OU8
0.035
5.01
88.95
2.18
na
9.22 MOD
U6100 gal/ton
Strong 9S% HNO (k)
3.5
na
1.0
0.3^
17.7 (15.0 as NO)
1.0
33.0
0.12 MGD
kQOO gal/ton
mg/1 » ppm and are used interchangeably throughout this chapter
9
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TABLE 5 - NITROGEN PLANTS WASTEWATER DISCHARGE
(AMMONIA + NITRIC ACID + AMMONIUM NITRATE)
Concentration* Discharge
PARAMETER MEAN RANGE LB/DAY LB/TON
FLOW-MGD 0.1*89
PROD-TONS/DAY 200
GAL/TON 2l*l*5
pH 2.5 2.3-3.1
TOT. ORG-N 1*82 36V600 859 2.9
N02 + N03-N 206 7^-570 210 0.88
KJEL-N 27.6 17.9-37.2 ll*7 0.66
NH3-N 191 16-532 1*31 1.58
SOl* 312 11-850 1758 0.5l*
TOT. SOLIDS 1551* 35^-2753 Ml2 286
SUSP. SOLIDS 156 l*-5l*3 181 0.96
BOD 13.5 9.0-18.0 81.5 0.07
COD 208 16-556 1*16 0.92
OIL & GREASE 19.1 0.01-1*2.9 1*6.1* 0.06
*A11 parameters mg/1 -unless otherwise indicated.
NR. OF
PLANTS
1*
1*
2
1*
2
I*
1*
1*
I*
2
1*
3
10
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11. Concentrated Sulfuric Acid Production
Although six AAP's conduct sulfuric acid concentration, little data
exist to accurately characterize the liquid wastes. One AAP reports no
pollutants from the process and has no current or future pollution abatement
planned for this production process. Table 6 summarizes available data. The
main source of waste is in the purification-concentration area, where excess
water from the process is condensed and purged as weak sulfuric acid solu-
tion. Three AAP's find the major pollutants to be primarily acid waste.
12. Oleum Production
Raw water is used for cooling in the catalytic oxidation of elemental
sulfur to S0_ gas. Treated water is used for absorption of SO gas. Waste
water is generated only by one-pass, non-contact cooling water. Table 7
summarizes available data.
13. Acetic Acid Concentration
a. Wastewater streams include non-contact cooling water, spent process
water and sludges. These wastes contain nitromethane, methyl nitrate,
acetic acid, n-propylacetate, nitric acid, and trace amounts of RDX and HMX.
However, the concentration of these organics is low since they are not de-
tected in the main outfall from the process area.
b. The sludge is generated in the azeotropic distillation process.
The sludge contains acetic acid, and heavy metals from corrosion of the
distillation column including chromium and copper at sub-ppm levels. Table
8 summarizes available data.
lU. Acetic Anhydride Production and Refining
a. Wastewater contains acetic anhydride, acetic acid, acetaldehyde,
acetonitrile, methylacetate, methyl nitrate, ethanol, methanol, ethyl
acetate, propanol, and propyl acetate.
b. Wastewater sources include cooling and condenser water as well as
process water and some sludges. Table 9 summarizes available data.
11
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TABLE 6 -.CONCENTRATED SULFURIC ACID PRODUCTION WASTEWATER DISCHARGE
PARAMETER
FLOW-MOD
PROD-TONS/DAY
GAL/TON
PH
SOU, mg/1
TABLE 7
PARAMETER
FLOW -MOD
PROD-TONS/DAY
GAL/TON
TEMP-DEG F
PH
CONDUCTANCE
SOU, mg/1
ACIDITY-CAC03, mg/1
ALKALINITY, mg/1
HEXANE EXTR., mg/1
MEAN
0.258
350
737
2.9
25
- OLEUM
MEAN
1.012
120
8,Uoo
86.3
911
133
U.O
100
25 .u
RANGE LB/DAY LB/TON
2.6-9.7
5U 0.153
PRODUCTION WASTEWATER DISCHARGE
RANGE LB/DAY LB/TON
82-90
6. 2-8 A
337-2,625
109-168 1.129 3.73
0.0-28 33.7 0.112
1U8-22U 8U6 2.82
19. 3-25 .U 2lU 0.713
NR. OF
PLANTS
1
1
1
1
1
NR. OF
PLANTS
1
1
1
1
1
1
1
1
1
1
12
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TABLE 8 - ACETIC ACID WASTEWATER DISCHARGE
PRIMARY DISTILLATION & CONCENTRATION
CONCENTRATION*
PARAMETER
FLOW-MOT
PROD-TONS/DAY
GAL/TON
TEMP-DEG F
pH
CONDUCTANCE
N02-W03-N
KJEL-N
SCfc
ACIDITY-CAC03
ALK-CAC03
TOT. SOLIDS
SUSP. SOLIDS
DISSe SOLIDS
BOD
COD
TOG
ACETIC ACID
*Values are ffig/1 unless otherwise indicated.
MEAN
1*2
1250
33,600
75-6
7.^
3.02
1.13
0.56
0.22
0.03
8.9
1*.06
39.7
91
3.58
121*
6.3
11.0
3.1*9
1.17
RANGE
71.8-79.6
6.8-7.9
23l*-l*12
0.12-3.65
0.19-5.59
0.0-0.96
0.0-8.67
8.3-9.^
1.1*9-5.61*
3.7^-1*7
1*2-11*1*
0.0ll*-ll*.9
115-167
0.1-33.2
0. 61-11*. 6
1.16-3.15
LB/DAY
395
196
76.9
105
3110
11*22
13,800
31,800
1250
1*3,300
2200
381*1*
1219
1*09
LB/TON
0.31
0.15
0.06
0.08
2.1*8
1.13
11.1
25.1*
1.00
31*. 7
1.76
3.07
0.97
0.32
NR. OF
PLANTS
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
13
-------
TABLE 9 - ACETIC ANHYDRIDE
CRUDE PRODUCT AND REFINING WASTEWATER DISCHARGE
CONCENTRATION*
PARAMETER
FLOW-MGD
PROD-TONS/DAY
GAL/TON
TEMP-DEG F
pH
CONDUCTANCE ,
N02+N03-N "'
KJEL-N
POU-P
SOU
ACIDITY-CAC03
ALK-CAC03
TOT. SOLIDS
SUSP. SOLIDS
DISS. SOLIDS
BOD
COD
TOG
ACETIC ACID
*Values are mg/1 unless otherwise noted.
MEAN
U.7
360
13,000
7L9
7-U
2U6
l.OU
0.5
0.25
22.0
U.29
80
8k
U.67
73
0.8
12.8
6.02
2.0
RANGE
70.2-7U.U
5.7-8.1
155-955
0.5-lA
0.5-5^.1*
0.1-251
13.9-55.2
2.7-lUO
56-83
12.1-570
0.0-13.8
26-176
0.7-5 .^
10.1|-25.1
3.02-1U.6
2.0-5.0
LB/DAY
Uo.6
19.5
9.77
860
168
3127
3283
182
2850
31.3
500
235
78.2
LB/TON
0.112
0.05U
0.027
2.39
O.U65
8.68
9.12
0.507
7-92
0.086
1.39
0.653
0.217
NR. OF
PLANTS
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
14
-------
15. Nitrocellulose Production
a. High waste volume results from successive washing of products to
remove residual acids and unstable by-products (about 2/3 of total waste
volume).
b. Waste flow is to the acid neutralization plant, and includes acid
wash water and boiling tub wash water, having the following characteristics:
extremely low pH average of l.U (range OA-3.3); high sulfate average of
2600 mg/1 (range 75-5100); high nitrate-N average of 700 mg/1 (range 100-
1350); high COD average of 185 mg/1 (range 80-650); high nitrocellulose
content average of 188 mg/1.
c. The high value of COD is likely due to dissolved and suspended
cellulose and nitrocellulose in the waste water. High solids values are
the results of pulping and blending of NC. NC fines are partially removed
along with waste water (white water) in the final centrifuge to separate NC
from the waste.
d. Some characteristics of the white water are: extremely high NC
average of ^77 mg/1; high COD average of 531* mg/1 (range 28U-78U); high
TS average of 79^ mg/1 (range M4-2-1U62); high SS average of 518 mg/1 (range
3^3-828); nearly neutral pH average of 7.73 (range 7.^-8.2).
e. The pH values vary from extremely acidic in the initial wash water
to neutral or slightly basic in the final washes.
f. Suspended solids in the waste water can be assumed to at least
approximate NC fines being lost. NC fines are recovered and recycled back
for use as "pit cotton" when making up blends which contain both high grade
and low grade NC. This results in lower SS values in the final effluent.
g. The still bottoms from organic solvent recovery have high BOD and
COD due to organic solvent in the waste, which also results in high alka-
linity. Total solids are approximately 50$ SS and 50$ DS, since boiling
15
-------
had removed'most of the volatile solids. Tables 10 and 11 summarize
i )
available data.
16. Nitroglycerin Production
a. The pH of wastewater from NG manufacture ranges from acidic for
the first wash (sour wash) after nitration, to alkaline for the subsequent
washes with sodium carbonate.
b. These wash waters are usually saturated with NG, at up to more —
than 2500 mg/1. The neutralizing wash yields high sodium level (more than
10,000 mg/l), which gives rise to high solids content.
c. Residual nitro- and dinitroglycerin and glycol show up as oil and
grease, and also cause high BOD and COD.
d. The nitrating acids result in high nitrate and sulfate levels,
Sour water, final wash and spent acid characterizations are given in
Table 12.
e. Table 13 summarizes available data.
17. TUT Production
a. Waste water sources include cooling water and process water. Pro-
cess waste water is generated primarily in the steps of washing and purify-
ing of crude TNT, and reclamation of spent nitrating acids. The following
discussion does not include the acid reclamation process.
b. Yellow water is the result of the first washing to remove acids.
Yellow water contains nitric and sulfuric acids as well as dissolved TNT.
Most yellow water is recycled in the continuous TNT process.
c. Red water is the waste from the purification step, utilizing
washing with sellite. Pink water is produced in the final washing of
purified TNT. It contains mainly TNT, and other nitrobodies. Pink water
is also a principal effluent from spills and building and equipment washdown
16
-------
in the LAP operations. One plant cited utilizes b.5 MGD out of 5.15 MGD
for cooling water, and about 0.65 MGD for process water. Cooling water
flow thus represents 87$ of the total process flow.
d. The major pollutants include nitrotoluenes, nitrates, sulfates,
acidity, sodium sulfite, sodium nitrate, sodium bisulfite and sodium
trinitromethane sulfonate. Table lU summarizes waste characteristics.
18. RDX - HMX
a. RDX and HMX are manufactured only at Hols ton AAP. Current pro-
duction averages 2.6U tons/day HMX and 166 tons/day RDX or about 169 tons/
day combined. The wastewater flows average 30.3 MGD, of which about 80$
is utilized for cooling water in the product recrystallization from cyclo-
hexanone. Other sources of wastewater include process and cooling water
for ammonia recovery, nitration process, slurry processing, recrystalliza-
tion, grinding and dewatering, mixing specific product compounds and load-
ing and packing operations.
b. In the explosive production areas,.cooling waters and process
waters are segregated. Process waste water contains amounts of solubilized
RDX and HMX.
c. One of the primary end products of RDX at Holston AAP is a formula-
tion of explosives, "Composition B," which contains RDX and TNT. Thus
Table 15 also considers Composition B as a product of interest.
17
-------
TABLE 10 - NITROCELLULOSE PRODUCTION WASTSfATER DISCHARGE
CONCENTRATION* m QF
PARAMETER MEAN RANGE LB/DAY LB/TON PLANTS
FLOW-MOD
PROD-TONS/DAY
GAL/TON
pH
N02-N03-N
KJEL-N
NH3-N
sol*
ACIDITY-CAC03
ALK-CAC03
TOT. SOLIDS
SUSP. SOLIDS
DISS. SOLIDS
VOL. SOLIDS
BOD
*mg/l unless otherwise noted.
5.01
50
101,100
1.2
513
3.52
0.78
501
0.07
2.83
5031
21*0
1*966
191*8
1.17
2.96-7.07
29-70
1*5,000-157,000
0.9-12.1*
190-61*8.1
0.19-6.81*
0.25-2.05
56.3-10,000
68.1-312
1*7.8-9880
7.9-3889
12,600
86.8
25.05
29,200
1.76
69-9
121*, 000
13,300
123,000
1*8,100
29.0
272
1.33
0.1*5
61*9
0.027
1.07
5676
292
2l*7l*
731
0.1*2
2
2
2
2
2
1
2
1
1
1
2
2
2
1
1
18
-------
TABLE 11 - NITROCELLULOSE
SOLVENT RECOVERY, STILL BOTTOMS WASTEWATER DISCHARGE
CONCENTRATION*
PARAMETER
FLOW-MOD
EROD-TONS/DAY
GAL/TON
PH
N02-N03-N
KJEL-N
ACIDITY-CAC03
ALK-CAC03
TOT. SOLIDS
SUSP. SOLIDS
DISS. SOLIDS
VOL. SOLIDS
BOD
COD
*mg/l unless otherwise noted.
MEAN
0.01^8
19.92
722
7.2
3.0
2.0
7.2
283
1535
7^7
810
39.7
118
104
RANGE
0.0086U-0.021
19.1^-20.71
7. 1-7 A
7-0-7.33
2U6-372
U9. 7-51^6
7.17-25^5
3^.7-2695
25.0-68.0
i«4. 7-295
LB/DAY
0.527
0.351
1.03
38. h
iiU.o
52.2
60.86
6.97
11.7
18.3
LB/TON
O.OCk
0.002
0.006
0.266
0.79
0.36U
33.7
O.OU8
0.083
0.126
NR. OF
PLANTS
2
2
2
1
1
2
2
2
2
2
1
2
1
TABLE 12
PH
BOD mg/1
COD
N03-N
TS
SS
sulfate
Sour Water
1.72
1
63
lll*.l
261*
5
l*ll*
Final Wash
with NaCO_
10
1,130
520
3217
3027
5
Spent 1
22
1*33
760
19
-------
TABLE 13 - NITROGLYCERIN PRODUCTION WASTEWATER DISCHARGE
PARAMETER
FLOW-MGD
PROD-TONS/DAY
GAL/TON
pH
TOT. ORG N
N02-N03-N
KJEL-N
NH3-N
SOL*
ACIDITY-GAC03
ALK-CAC03
TOT. SOLIDS
SUSP. SOLIDS
DISS. SOLIDS
BOD
COD
OIL & GREASE
SODIUM
NG
*mg/l unless otherwise rioted.
CONCENTRATION*
MEAN
o.oia
11.9*
3V73
3.0
2l*2
5565
23.0
12.1
315^
0.01
2023
1*9,165
668
5761
26.0
2260
313
13323
in*
RANGE
o.oio-o. no
9.82-12.9
752-8590
2.7-10
0.0-1*81*
314-5-12500
2.88-14-3.2
0.0-33.7
208-6996
0.0-0.02
2110-81,527
U6-189U
167-352
709-3518
11777-1^879
3114-12,700
LB/DAY LB/TON
0.76
0.43
107.1
0.006
1080
5307
11.9
3075
32.3
231*
10.96
11447
281
0.99
1*0.0
0.05
O.OU
6.68
0.001
110
,286
0.96
313.5
1.73
13.0
0.6l
77.7
15
NR. OF
PLANTS
5
5
5
1*
2
3
3
U
1*
1
1
1*
1*
1
3
1*
1
2
3
20
-------
TABLE Ik - TNT PRODUCTION WASTEWATER DISCHARGE
CONCENTRATION*
PARAMETER
FLOW-MO)
PROD-TONS/DAY
GAL/TON
TEMP-DEG F
PH
NO2-N03-N
KJEL-N
SCfc
ACIDITY-CAC03
ALK-CAC03
TOT. SOLIDS
SUSP. SOLIDS
DISS. SOLIDS
VOL. SOLIDS
COD
TOG
SULFIDE
MEAN
6.11
223
27,1*00
81*. 5
5-9
13.8
3.90
367
69.6
97.1*
761
1*2.2
710
1*1*6
28.3
11*3
5-96
RANGE
2.63-9.60
50-300
78-90
5.6-7.6
11.7-15.9
1.1*1-6.1*0
230-1*96
16.2-123
79.8-115
1*80-101*3
15.5-69.0
1*10-1011
LB/DAY LB/TON
701
198
18,600
3535
1*9**9
38700
36,075
22,600
7266
303
3.ll*
0.852
83.6
15-8
22.2
173.1*
9.61
162
102
6.1*5
32.6
1.36
NR. OF
PLANTS
2
2
2
2
2
2
2
2
2
2
1
1
1
1
*mg/l unless otherwise noted.
**of the 2 plants summarized, one was batch process - 302 tons/day,
the other continuous - ll*5 tons/day.
21
-------
TABLE 15 - PRODUCTION OF RDX, HMX, AND COMPOSITION B,
WASTEvfATER DISCHARGE
CONCENTRATION*
PARAMETER
FLOW-MGD
PROD-TONS/DAY
GAL/TON
TEMP-DEG P
pH
N02-N03-N
KJEL-N
NH3-N
TOT. SOLIDS
DISS. SOLIDS
BOD
COD
TOC
INORG C
RDX
HMX
ACETIC ACID
HEXAMINE
TNT
SOLVENTS**
MEAN
30.3
275
110,200
60
7.3
0.028
0.037
0.015
14.0
14.2
30.2
69.0
2.53
0.607
0.492
0.179
6.75
0.119
0.324
4.88
RAN®! LB/DAY
50-72
7.0-8.3
7.28
9.56
4.02
3520
3570
7620
17,400
638
153
124
45.2
1700
30
81.8
1230
LB/TON
0.026
0.035
0.015
12.8
13.0
27.7
63.3
2.32
0.556
0.451
0.164
6.18
0.109
0.297
4.47
NR. OF
PLANTS
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
*mg/l unless otherwise noted.
**acetone, cyclohexahe, toluene, butanol.
22
-------
SECTION III - ACIDS
19. ACETIC ANHYDRIDE MANUFACTURE
a. Process Description
Acetic anhydride ((CH3CO)20) is manufactured at HAAP. The manu-
facturing process involves two steps, the first of which is carried out in
Buildings 7 and 20 (Area A) and the second in Buildings 6 and 6A (also in
Area A). For a detailed process description the reader is referred to
Chapter IV of this report.
Crude acetic anhydride is manufactured in Buildings 7 and 20. To
obtain this product, glacial acetic acid vapor is catalytically cracked and
the cracking products are absorbed in glacial acetic acid. The crude anhy-
dride is then fed to Buildings 6 and 6A where it undergoes two distinct
operations — acetic anhydride refining and concentration of recovered ace-
tic acid.
b. Water Use and Wastewater Volume
(l) Water Use. Water use figures were not available. However,
because cooling and process waters are discharged jointly, wastewater volumes
may be used as an approximation of the necessary feed volumes.
(2) Distribution of Wastewater Volumes. Table 16 summarizes
the wastewater volumes generated in producing acetic anhydride. Source data
for Table 16. can be found in Tables I.A.I through I .A.3 (Appendix I ).
c. Qualitative and Quantitative Aspects of the Liquid Wastes
Wastewaters from the crude acetic anhydride manufacturing process
are reported (1+a) to contain acetic anhydride, acetic acid, acetaldehyde,
acetonitrile, methyl acetate, methyl nitrate, ethanol, methanol, ethyl ace-
tate, propanol, and propyl acetate. The various waste streams are mixed
with cooling waters needed in the anhydride manufacturing and then discharged
to the South Fork of the Holston River.
23
-------
Wastewaters from the acetic anhydride refinery area include cooling
and condenser waters and process waters plus a portion of the sludges from
the refining and azeotropic distillation columns (acetic acid concentration).
These wastes are discharged to the industrial sewer.
Results of analyses of the major wastewater discharges from
Building 7 are presented in Tables I .A.I and I .A.2. Similar results
for Buildings 6 and 6A appear in Table i .A.3 (Appendix I ). Note that
the constituent(s) responsible for the dissolved solids content are not
defined by this data. No treatment is currently being provided for any of
these wastes.
Table 17 lists the calculated overall discharges in both Ib/day
and Ib/ton of final product for the entire process carried out in Buildings
6, 6A, and 7.
d. The Effects of Process Change on the Wastewaters
The following actions have been proposed as part of the pollution
abatement program for HAAF Area A.
Installment of flash columns in Building 6 is expected to reduce
solvent concentrations in wastewater by 50 percent and improve propyl ace-
tate recovery. The possible substitution of a surface condenser for baro-
metric condensers in Building 7 is expected to reduce water pollution. How-
ever, the mechanism whereby this is to be accomplished and the specific
pollutants to be eliminated or reduced have not been detailed (Ifa). Al-
ternate means of handling and disposing of ball mill and sludge heater
sludges generated in Buildings 6 and 6A are being sought. These sludges
are a likely major waste source that should be handled and disposed of in
slurry or semi-solids form. Heavy metal and acidity problems are apparently
associated with the disposal-/of these waters.
24
-------
Although the presence of trace organics has been discussed in a
qualitative manner, the quantitative aspects of this problem need to be de-
fined. In other words, data of this sort has to be generated.
Segregation of cooling and process waters in the future will, of
course, increase discharge concentrations in process wastewater. Overall
discharge loads (Ibs/day and Ibs/ton of product) should, however, remain
the same except as noted above.
e. Data Limitations
Water usage data was not available. Such data is of considerable
aid in identifying process efficiency. In addition, it allows for an assign-
ment of significance of the process based on water needs and for verifica-
tion of wastewater volumes and subsequent discharge loads. Analysis of pro-
cess feedwaters would also prove useful in calculating discharge loads.
The constituents responsible for the dissolved solids content of
the wastewater streams were not identified. Planning for future handling
of these wastes requires that the source(s) of dissolved solids be identi-
fied.
25
-------
TABLE 16
WASTEWATER VOLUMES GENERATED
IN THE PRODUCTION OF
ACETIC ANHYDRIDE
AT HAAP
Crude Anhydride
Production
Acetic Anhydride Refining
and
Acetic Acid Concentration
Overall
MGD
Gal per Ton of Final Product
7.39
23.5001
1.15
3,1902
23.700
8.54
2
O5
. lb/day crude acetic anhydride
2720,000 lb/day refined acetic anhydride
-------
TABLE 17
OVERALL DISCHARGES RESULTING FROM THE PRODUCTION OF ACETIC ANHYDRIDE
AT HAAP
TKN/N
o-P04/P
Acidity/CaC03
Total Solids
Suspended Solids
Total Dissolved Solids
804
COD
TOC
Discharge Discharge
(Ib/day) (Ib/ton of product*)
>95.8 >0.266
326 0.906
756 2.10
5,130 14.3
190 0.53
3,147 8,74
102 0.294
11.5 0.032
69 0.19
*Refined acetic anhydride produced
27
-------
20. CONCENTRATED ACETIC ACID MANUFACTURE
a. Process Description
Acetic acid (C^CQOH) is recovered from the manufacture of RDX/HMX
at HAAP, concentrated, and reused in the nitration of hexamethylenetetramine
(hexamine) to form RDX and HMX and in the production of acetic anhydride.
A hypothetical charge of 100 pounds of chemicals used in the pro-
duction of RDX ("Bachman Method") requires 15.0 pounds of acetic acid. HMX
requires the same reactants but in different proportions. Again considering
a hypothetical 100 pound reactant charge, about 18 pounds of acetic acid is
required to produce HMX (2c).
When the heated reaction mixture used in the nitration step has
cooled and most of the crude RDX or HMX has precipitated, nearly all of the
supernatant liquid is drawn off by vacuum and transferred to a recovery
building (primary distillation building). Here the nitric acid content is
neutralized with sodium hydroxide slurry. About 80 percent of the resulting
solution is then evaporated. Acetic acid is recovered from the vapors and
sent to Area A for concentration. As it leaves the primary distillation
buildings, the acid-water solution is approximately 60 percent acetic acid.
Upon final concentration in Area A the solution is 99+ percent acetic acid.
b. Water Use and Wastewater Volume
(l) Water Use. Water use figures were not available for either
the primary distillation (recovery) or acetic acid concentration processes. .
However, comparison of the total process waste flow from acetic acid concen-
tration, 15.8 mgd (id(2)), to the .average raw water intake for Area A, U8.7
mgd (l»a), indicates that a significant proportion of the total water use in
HAAP Area A is used in this step. In a similar manner, comparison of the
total flow from the primary distillation step, 26.0 mgd (ld(2)), to the total
28
-------
water consumption for Area B, 84.4 mgd(ld(2)), indicates that this step also
consumes a sizeable fraction of the total water used in its respective area.
(2) Distribution of Wastewater Volumes. There are essentially
two steps involved in the production of concentrated acetic acid at HAAP.
The first step involves the recovery of acetic acid from the manufacture of
RDX or HMX (and eventually composition B) in Area B. In the E Buildings in
a typical Area B production line, spent acid is removed from the RDX pro-
duct, diluted with product wash water and transferred through glass lines to
a collection tank where it awaits transfer to the B line. This weak acid
filtrate contains some dissolved explosives. At primary distillation (B
line) nitric acid is neutralized and most of the acetic acid is distilled
off as a 60 percent solution in water and pumped to Area A. Explosives are
recovered and returned to the E Buildings, and the remaining sludge is
treated with caustic (sodium hydroxide) and converted to sodium nitrate to
be sold as a commercial fertilizer.
Total wastewater generated in this recovery step is 26.0 mgd.
This is an estimated figure based on flow measurements made on the principal
effluent from Building B-ll (id(2)) and extrapolation of this figure to include
all the distillation units in operation. Production averages 1,500,000
pounds 60 percent acetic acid per day (ld(2)).
The distillation facilities in Building 2 Area A concentrate the
acetic acid returned from the primary distillation line in the explosives
manufacturing area, Area B. To achieve the separation of water from acetic
acid within a finite distillation column size, azeotropic distillation
techniques are used. The reader is referred to Chapter IV of this report
for a more detailed description of this process.
29
-------
Total wastewater flow from the concentration step is 16,0 mgd
(Id(2)). There are several outfalls from Building 2; however, each outfall
discharges to the main waste stream from Area A. The total wastewater flow
cited above is the sum of these individual process streams. Production at
the time of flow measurements averaged 1,600,000 pounds of concentrated
acetic acid per day (ld(2)).
Table 18 summarizes the wastewater volumes generated in the pro-
duction of concentrated acetic acid. Source data for Table .18 can be found
in Tables I .D.I through I.D.3 (Appendix I ).
c. Qualitative and Quantitative Aspects of the Liquid Wastes
Wastewaters from acetic acid concentrations, Area A HAAP, include
cooling water, spent process water, and sludges. These wastes are reported
(^a) to contain nitromethane,methyl nitrate, acetic acid, n-propyl acetate,
nitric acid, and trace amounts of explosives. It is likely, however, that
the concentration of these organic constituents is low since they were not
detected in the main outfall from Area A which receives these wastes (ifb).
In the course of the azeotropic distillation, as a result of the
character of the feed to the Building 2 distillation units, a certain amount
of solids buildup occurs in the base heater or reboiler section of the col-
umn. To maintain approximately one percent solids concentration in the
reboiler, a small bleed stream is removed from the reboiler approximately
once every hour or once every two hours of operation of the still. This
• 1 ,
bleed stream is sent to a storage tank until sufficient volume (approximately
8,100 gallons) is accumulated to charge a sludge heater. The sludge heater
operation is simply an extension of the distillation process in which as
much acetic acid as is economically recoverable is removed from the solids-
bearing liquid. Elevated temperature and vacuum are applied to the contents
30
-------
of the sludge heater, and the acetic acid vapor is taken overhead until the
concentration of solids in the sludge heater reaches 18 percent. At this
point in time, water is added to the contents of the sludge heater, and
distillation is continued until the overhead concentration of acetic acid
vapor is less than or equal to two percent. At this point, the contents of
the sludge heater are discharged to the sewer. The contents of sludge
heaters are discharged approximately twice each week. Recently, attention
has been called to the fact that the sludge heater sludge, as discharged to
the sewer, contains heavy metals. Analyses of these sludges on several oc-
casions have yielded high concentrations of chromium, copper, iron, and man-
ganese. The reported source of these heavy metals is the corrosive des-
truction of the distillation columns in Building 2.
Chromium and copper have been detected at sub-part-per-million
levels in the main effluent from Area A (5a).. However, to what extent this
is a result of the discharge of sludge heater sludges is unknown.
Results of a USAEHA study (ld(2)) monitoring the two major wastewater
discharges from the acetic acid concentration process are reported in
Tables I.D.I and I.D.2 (Appendix I ). Unfortunately, the constituent(s)
responsible for the high dissolved solids content (6700 Ibs/day) are not
identifiable from the data. The low COD/BOD ratio, < 1.33 in the case of
the 42-inch outfall and approximately 2.0 in the case of the 15-inch outfall,
is an indicator of low-level toxicity and readily oxidizable nature of the
substrate.
A pilot aeration pond was set up to receive wastes from the strip-
ping operation carried out in Building 2, Area A, HAAP. This operation re-
moves (recovers) propyl acetate and other low boilers from the water phase
resulting from azeotropic distillation to concentrate acetic acid. After
31
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solvent recovery, part of the effluent water was diverted to the pilot
aeration pond. This diverted waste stream was found to contain four percent
organics, chief among these being formaldehyde. Chromium, copper, and lead
were not detected (5a> I5a)-
USAEHA data (ld(2)) for the primary distillation process (acetic
acid recovery) carried on in Building B-ll, HAAP Area B are presented in
Table I .D.3 (Appendix I ). Again the ion balance is incomplete, and
the data does not identify the item(s) responsible for the dissolved solids
content (10,200 Ibs/day) of the waste. The TRW report (3f) cites a some-
what higher ammonia concentration (5 ppm) than reported here. Whether or
not this value has been corrected for background is not stated.
Currently these wastes receive no treatment other than that they
are routed through settling basins prior to discharge into the industrial
sewer. When the sludge is cleaned from these basins by dippers, however,
fines are often resuspended (ld(2)).
Table 19 lists the calculated overall discharges in both Ibs/day
and Ib/ton of final product for the entire process (acetic acid recovery
and acetic acid concentration).
(3. lu Effects of Process Change on the Wastewaters
Installation of flash columns in Buildings 2 and 6 (HAAP Area A)
is expected to reduce solvent pollution oy 50 percent (Ua). In addition,
modernization plans call for replacement of the 316 stainless steel columns
currently in use in the sludge heater (Building 2). The replacement col-
umns will be constructed with an alloy of the Hastelloy group and should
alleviate the heavy metal problem associated with the sludge heater wastes
(see Para. 20.c. above). In the interim, CERL personnel have recommended
that sludge heater sludges be discharged in proportion to other wastes gen-
32
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erated in Building 2 in order to reduce the potential for major toxic ef-
fects (ld(2)).
Segregation of uncontaminated cooling water from process water
will increase discharge concentrations. Ammonia concentration in wastewater
from primary distillation (Building B-ll, HAAP Area B) is reported to be on
the order of 900 ppm prior to mixing with cooling water. Ammonia stripping
has been suggested for ammonia-rich waste streams (3f).
e. Data Limitations
Production of concentrated acetic acid apparently results in the
discharge of a particularly high dissolved solids load (see Tables I.D.I
through I .D.3, Appendix I ). The constituent(s) responsible for this
load have not been identified, and it is essential to future treatment plan-
ning that they should be.
Water usage figures were not available.
33
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TABLE Id
WASTEWATER VOLUMES GENERATED
IN THE PRODUCTION OF
CONCENTRATED ACETIC ACID
AT HAAP
Primary Distillation Acetic Acid Concentration Overall
MGD 26.0 16.0 42.0
gal/ton of Final Product 34,700! 20,0002 52,500
Ib/day 60 percent acetic acid
21, 600, 000 Ib/day 99+ percent acetic acid
CO
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TABLE 19
OVERALL DISCHARGES RESULTING FROM THE PRODUCTION OF CONCENTRATED ACETIC ACID
AT HAAP
Item
TKN/N
NH3/N
N02 + N03/N
0-P04/P
Acidity/CaC03
Total Solids
Suspended Solids
Dissolved Solids
COD
TOC
BOD
S04
Acetic Acid
Discharge
(Ib/day)
138
£ 20.4
127
87
140
17,480
460
16,900
12,000
3,710
5: 8,569
>- 64
2- 2.7
Discharge
(Ib/ton of product*)
0.172
2^0.025
0.159
0.11
0.175
21.9
0.575
21.1
15.0
4.64
^10.7
^ 0.08
^0.003
*1,600,000 Ib/day (800 ton/day) 99+ percent acetic acid
35
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21. WEAK NITRIC ACID (HNOQ PRODUCTION (AOP)*
a. Process Description
There are two ammonia oxidation processes at HAAP. Currently,
only one of these, the Dupont Process (Bldg 302-B), is in use. The Hercules
Process (Bldg 302) is not presently being employed. For further details of
both processes refer to Chapter IV of this report.
b. Water Use and Wastewater Volumes
(l) Water Use. Water usage data was not available.
(2) Distribution of Wastewater Volumes. Refer to Tables I.S.I
through I.S.4 for flow rates of individual waste streams. Overall flow
from this operation is 9.22 mgd (46,100 gal per ton of product) at a pro-
duction rate of 400,000 Ib/day 61 percent HN03 (as 100 percent HN03).
c. Qualitative and Quantitative Aspects of the Liquid Wastes
Wastewater characterization data is presented in Tables I.S.I
through I.S.4. This data is summarized in Table 20.. Dissolved solids
discharges appear to present a problem. However, the nature of these ma-
terials is not apparent from the given data.
d. Effects of Process Change on the Wastewaters
A new 300 ton/day ammonia oxidation plant, PEMA project number
570-2072, is scheduled for completion in 1974. No predictions as to the
quantity and character of the wastewaters is available. The six Hercules
units will be used only to meet peak requirements (ld(2)).
e. Data Limitations
AOP wastewaters at HAAP appear to have been well characterized;
however, data from similar waste streams generated at BAAP, InAAP, RAAP,
SAAP, VAAP, AAAP, and NAAP was not available at the time this report was
written.
36
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*At JAAP, weak (60 percent) HN03 is produced by the ammonia oxidation pro-
cess (AOP). This dilute acid and spent acids recovered from the nitration
processes (TNT manufacture) are utilized to produce strong (98 percent)
nitric acid by the nitric acid concentration (NAC) process. Dilute sulfur-
ic acid yielded by the NAC process and explosive manufacturing process is
utilized to produce strong sulfuric acid (93 percent) by the sulfuric con-
centration (SAC) process. It was not possible, however, to separate waste-
streams from AOP, NAC, and NAC operations. Wastewater characterization
data for the combined effluent from all three processes is presented in
Tables I.S.5 and I.S.6 (3f).
Joliet AAP has the manufacturing capability to meet mobilization require-
ments for TNT, DNT, and tetryl, but not for the required nitric acid and
oleum quantities. The acid manufacturing facilities are old and outdated.
They could probably be kept operating indefinitely by increasing mainten-
ance budgets, but because of their lags and the pollution problems created,
they will be replaced with modern processes and equipment. Modernization
of the acid facilities is scheduled for completion in 1976 and will include
replacement of weak nitric acid facilities with updated AOP, replacement
of the AOP/NAC nitric acid concentration process with the direct strong
acid (DSNA) process, replacement of the sulfuric acid concentration pro-
cess by the sulfuric acid regeneration (SAR) process (used to produce oleum
directly as end product) (3f).
37
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TABLE 20
CALCULATED OVERALL DISCHARGE RESULTING FROM THE PRODUCTION OF
WEAK NITRIC ACID (ld(2»
Item
NH3/N
N02 + N03/N
TKN/N
Acidity/CaC03
Alkalinity/CaC03
Total Solids
Suspended Solids
Dissolved Solids
COD
TOC
BOD
Discharge
(Ib/day)
2.7
385
3.67
25.0
14.8
6,840
168
6,540
797
35
O14
Discharge
(Ib/ton of product*)
.014
1.92
.018
.125
.074
34.2
.84
32.7
3.98
.175
1.57
*200 ton/day 61 percent HN03 (as 100 percent HN03) produced
38
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22. CONCENTRATED NITRIC ACID MANUFACTURE*
a. Process Description
Although concentrated nitric acid is manufactured at VAAP, RAAP, BAAP;
InAAP, NAAP, AND JAAP, data concerning this process was not available for these
plants. Nitric acid is concentrated at HAAP (Buildings 303-B and 334,
Area B) using the magnesium nitrate process. The nitric acid concentration
(NAG) units concentrate the weak acid manufactured in the ammonia oxidation
area by removing water from the acid. Magnesi-
um nitrate has a chemical attraction for water and can be used in the ter-
nary system, magnesium nitrate-nitric acid-water, to remove water from the
acid by extractive distillation.
Weak (61 percent) nitric acid and concentrated (72 percent) mag-
nesium nitrate solution are fed to the top of a three-stage stripping col-
umn together with the intermediate (80-90 percent) nitric acid from the
base of the rectifying column. Overhead vapors from the stripping column
are condensed and then divided into reflux and product streams. The pro-
duct portion (99 percent nitric acid) is further cooled in cascade coolers.
The uncondensed overhead vapors from the strong nitric acid condensers are
led to a rectifying column and scrubbed with water before being vented to
the atmosphere. The bottoms from the stripping column, which have been
denitrated to less than 0.1 percent nitric acid, contain roughly 60 percent
magnesium nitrate. This solution is first concentrated to approximately
64 percent Mg(N03)£ in a steam heated reboiler (base heater) which also
supplies the heat for the stripping and rectifying columns. Further con-
centration to the original feed strength of 72 percent Mg(N03)2 is carried
out in1a vacuum evaporator. Water is removed in the vacuum evaporator and
discharged to the sewer (ld(2)).
Magnesium nitrate is not consumed in the NAG process. Fresh
magnesium nitrate is added only to replace losses due to leaks and equip-
39
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*At JAAP, weak (60 percent) HNO-j is produced by the ammonia oxidation pro-
cess (AOP). This dilute acid and spent acids recovered from the nitration
processes (TNT manufacture) are utilized to produce strong (98 percent) ni-
tric acid by the nitric acid concentration (NAG) process. Dilute sulfuric
acid yielded by the NAC process and explosive manufacturing process is
utilized to produce strong sulfuric acid (93 percent) by the sulfuric con-
centration (SAC) process. It was not possible, however, to separate waste-
streams from AOP, NAC, and SAC operations. Wastewater characterization
data for the combined effluent from all three processes is.presented in
Tables I.E.2 and I.E.3 (3f).
Joliet AAP has the manufacturing capability to meet mobilization require-
ments for TNT, DNT, and tetryl, but not for the required nitric acid and
oleum quantities. The acid manufacturing facilities are old and outdated.
They could probably be kept operating indefinitely by increasing mainten-
ance budgets, but because of their age and the pollution problems created,
they will be replaced with modern processes and equipment. Modernization
of the acid facilities is scheduled for completion in 1976 and will in-
clude replacement of weak nitric acid facilities with updated AOP, re-
placement of the AOP/NAC nitric acid concentration process with the direct
strong nitric acid (DSNA) process, replacement of the sulfuric acid con-
centration (SAR) process (used to produce oleum directly as end product
(3f).
40
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ment cleaning. A concentrated (72%) solution of this material will freeze
unless kept above 100°C. The magnesium nitrate content of each unit is
roughly 20,000 pounds (as 72% magnesium nitrate). To keep from wasting this
amount when a unit goes down for repairs, the solution is slowly diluted and
cooled and then sent to settling tanks (numbered 334-14 and 334-15) located
adjacent to the magnesium nitrate receiving tank. Solids that settle out
in these tanks are washed to the drainage ditch at present (id(2)).
Further details of the nitric acid concentration process can be
• -'\fr *
found in Chapter IV of this report.
b. Water Use and Wastewater Volume
(l) Water Use. Water use figures for nitric acid concentration
were not available. At a production rate of 9,210,000 Ib per month (approx-
imately 307,000 Ib/day) nitric acid (as 100 percent acid), the weak acid
feed rate is approximately 33.6 gpm (48,000 gpd) (id(2)).
(2) Wastewater Distribution. An estimated wastewater discharge
of 5.0 mgd arises from nitric acid concentration. In terms of production of
99 percent nitric acid this constitutes an effluent of 32,500 gal per ton of
final product. Table I.E.I gives further details of the wastewater flow.
Liquid wastes from the ammonia oxidation step (Building 302-B, HAAP Area B)
are intermingled with other measured NAG waste streams and prevent further
association of waste volume with specific process subdivisions.
c. Qualitative and Quantitative Aspects of the Liquid Wastes
It has been reported (l*a) that wastewaters from the concentrating
process are essentially all cooling waters. In establishing the discharges
reported in Table 21 from data gathered in the 1971 USAEHA study (id(2)) the
assumption has' therefore been made that all pollutants measured in streams
containing liquid wastes from both ammonia oxidation and nitric acid con-
41
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centration are due solely to the ammonia oxidation process. It is acknow-
ledged that this is a (somewhat erroneous) oversimplification. However, it
is also the only step that can be taken to allow some degree of quantifica-
tion and qualification of the wastewater character based on existing data.
As mentioned above, overall discharges from NAC (HAAP Area B) are
cited in Table 21. It is immediately obvious that this data does not ac-
count for the high measured value of dissolved solids.
No treatment is currently being provided for these wastes, and
they are being discharged directly to the Holston River.
d. The Effects of Process Change on the Wastewaters
There appears to be little planned in the way of process change or
modification (including pollution abatement) that will affect the nature of
the watewaters resulting from the production of concentrated nitric acid.
e. Data Limitations
Existing data does not allow identification of the constituent(s)
comprising the high dissolved solids content in the waste streams from this
process. Dissolved solids ranged from 473 to 866 ppm, and summation of the
other dissolved materials does not even approach these values.
42
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TABLE 21
OVERALL DISCHARGES RESULTING FROM THE PRODUCTION OF CONCENTRATED NITRIC ACID
AT HAAP
Discharge Discharge
Item (Ib/day) (Ib/ton of product*)
N02 + N03/N
Acidity (as CaC03)
Total Solids
Suspended Solids
Dissolved Solids
COD
BOD
423
94
5650
94
5560
264
<75**
2.75
0.61
36.6
0.61
36.1
1.71
<0.49**
* 99% HN03 produced
**No correction for filtered raw water - Area B, Holston AAP
43
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23. CONCENTRATED SULFURIC ACID PRODUCTION
Sulfuric acid concentration (SAC) processes are carried out at BAAP,
InAAP, VAAP, RAAP, and NAAP (3e). However, insufficient data exist to
accurately characterize the liquid wastes. A discussion incorporating what
information is available is presented below.
At RAAP, no pollutants are reported to arise from SAC operations. Cur-
rently there are no existing SAC water pollution abatement practices at
Radford, and there are none proposed (3f).
At InAAP, lime is added to the acid waste sewers to control pH (lf(l)).
A 1971 USAEHA study (la(l)) lists sulfuric acid concentration as one of
the six main contributors to water pollution at BAAP. The primary pollu-
tants from SAC operations are described as acid wastes. These wastes are
currently controlled by lime neutralization. Recently, relocation of pH
sensors has resulted in better control of pH adjustments in the acid neu-
tralization area. A new 350 ton per day OV/SAR plant was constructed in
1972; however, the effects this may have had on wastes from the SAC pro-
cess are unknown.
At VAAP, wastewaters from the SAC process are listed as a major source
of potential pollution (lr(l)). These wastes are neutralized with lime prior
to discharge to Waconda Bay.
NAAP has constructed a new sulfuric acid regeneration facility in
support of TNT manufacture. Wastewater flow from this facility is gener-
ated in the purification area where excess water from the process is con-
densed out and purged from the system as a weak E^SO* solution. Approxi-
mately 89,600 Ib/hr (258,000 gpd) 2.5 percent ^804 solution results (3f).
In summary, it may be stated that the wastestreams resulting from SAC
appear to present largely pH problems which are currently being handled by
lime neutralization.
44
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2l». OLEUM PRODUCTION
a'. Process Description
The reader is referred to Chapter IV of this report for a more detailed
process description.
Oleum is sulfuric acid containing an excess of free sulfur trioxide.
Oleum (40%) is produced at BAAP by the catalytic oxidation of elemental sulfur
and absorption in a multiple phase absorber with water and recycled sulfuric-
nitric acid mixture. Raw water is used for cooling purposes and treated water
for absorption. The only liquid waste generated from this area during normal
operations is one-pass cooling water. Occasional process upsets and cleanup
operations allow oleum or sulfuric acid to enter the waste streams. These up-
sets are not a common occurrence. All industrial waste from this area drains to
the oleum area waste pond, a sand bottom pond with no discharge to surface waters.
All waste is disposed of by evaporation or percolation (la(£)).
At JAAP, a recent USAEHA study (lg(3)) found one of three oleum production
units in operation. This unit produced 40% oleum (109% H2S04) and continuously
mixed it with an antifreeze (HNOs). Sulfur is first melted, then burned, pro-
ducing 803 gas which passes through filters to remove dirt. The gas is cooled
to the proper temperature for entering the absorption towers. Acid towers are
provided for drying the air and absorbing 803 to proper strengths. All towers
are equipped with pumps for continuously circulating acid. Each tower has its
own cooling system, piping, and transfer lines. Equipment is provided to con-
tinuously mix the oleum leaving the absorption towers with antifreeze (lg(3)).
b. Water Use and Wastewater Volume
(1) Water Use. RAAP reports using 3,500,000 gpd in their old oleum
facilities. No associated production figures were available. However, new
facilities employing recycle are scheduled (6a). At JAAP, no water usage
figures were available.
45
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(2) Wastewater Flows. The liquid waste discharged from the
oleum production area at BAAP is one pass cooling water, however, there are
occasional process upsets and waste streams. All industrial wastes from
this area are drained to the oleum area waste pond, a sand bottom pond with
no discharge to surface waters. All waste is disposed of by evaporation or
percolation. The presence of lower biological and animal forms in nearby
areas indicates that wastewater from this area does not constitute a source
of groundwater pollution (3f).
Wastewater at JAAP is primarily cooling water. Acid spills and
blowdown also account for some of the wastewater volume. Slowdown is nec-
essary because of the water softeners and contains organophosphate compounds.
No treatment is currently provided for these waters. Total wastewater flow
at a production rate of 600,000 bl/day 40% oleum was observed to be 1.01 mgd.
c. Qualitative and Quantitative Aspects of the Liquid Wastes
Table I.L.I presents the results of wastewater analyses on the
oleum ditch north of the plant prior to combination with flow from the Acid
3 Area at JAAP. These wastewater characteristics will vary significantly
when other production facilities not in operation at the time of the measure-
ments resume production. Flow in this ditch is influenced by rain as well
as flow from the acid tank car area.
An idea of the extreme varia-
bility in data obtained from wastewater characterization of this ditch can
be seen by comparison of data in Tables I.L.I and I.L.2. Unfortunately,
related production data was not available for the information presented in
Table I.L.2. Table I.L.3 indicates the nature of the wastewater from
acid tank car draining as it enters the oleum ditch at JAAP.
46
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Although eight plants produce or have produced oleum (BAAP, InAAP,
VAAP, RAAP, SAAP, AAAP, NAAP, and JAAP), qualitative and quantitative data
was available only from JAAP (see above). BAAP, however, did report evi-
dence of biological growth in their oleum waste pond (la(2)) which may be in-
terpreted as an indicator that these wastes do not constitute a significant
source of groundwater pollution.
d. Effects of Process Change on the Wastewaters
No information on planned procedural changes was available.
e. Data Limitations
With the exception of RAAP, poor wastewater characterization data
exists, and a lack of information on modernization and pollution abatement
plans is evident.
47
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SECTION IV - EXPLOSIVES
25. AMMONIUM NITRATE PRODUCTION
a. Process Description
The reader is referred to Chapter IV of this report for a detailed
process description.
Production of ammonium nitrate (NH^N03) *s uni
-------
worsen the quality of the waste stream rather than Improve it. Since the
stream appears reasonably "clean," it appears that segregation of cooling
waters would also have little effect.
e. Data Limitations
Once again the distressing problem of not being able to determine
the source of dissolved solids content prevents a truly detailed and accur-
ate assessment of the character of the waste stream. In addition, where
its relative abundance is important, the suspended solids content too should
be characterized. Such a characterization does not appear to be necessary
for ammonium nitrate production.
49
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TABLE 22
WASTEWATER VOLUMES GENERATED
IN THE PRODUCTION OF
'AMMONIUM NITRATE
AT HAAP
Overall
MGD
Gal per Ton of Final Product
9,250
1.85
1
01
o
1400,000 Ib/day NH.NOo/HNOo solution
-------
TABLE 23
OVERALL DISCHARGES RESULTING FROM THE PRODUCTION OF AMMONIUM NITRATE
AT HAAP
Discharge Discharge
Item (Ib/day) (Ib/ton of product*)
NH3/N 9.40 .047
N02 + N03/N 28.7 .144
TKN/N 17.2 .086
Total Solids 3,060 15.3
Dissolved Solids 3,080 15.4
COD 185 .924
TOC 46.2 .232
BOD 15.4 .077
*Ammonium nitrate produced
51
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26. DINITROTOLUENE (DNT)
At one time DNT was manufactured at JAAF and AAAP. Now, however, DNT
is purchased commercially and purified at JAAP by a process known as "sweat-
ing." The commercial material is about 75 percent 2,4-DNT and 20 percent
2,6-DNT. The mixture is melted and subjected to a controlled cooling-heat-
ing program. In the cooling step, DNT containing mostly the 2,4-isomer
crystallizes, while the liquid impurity-rich fraction is drained off (or
sweated). This fraction includes most of the 2,6-DNT in a eutectic mixture
of about 57 percent 2,6-DNT and 43 percent 2,4-DNT. The remaining solid
(about 65 percent of the initial charge) is withdrawn for packaging and
shipment. The impurity-rich fraction is added to the intermediate product
entering a "bi-house" (the second of three nitration buildings in a batch
TNT production line) (2c).
DNT is also formed as an intermediate in the production of TNT. However,
DNT discharge as a result of TNT manufacturing operations will be considered
in Para. 27 of this Chapter.
DNT is used extensively in smokeless propellant powder. This propellant
consists of about 85 percent nitrocellulose, 9 percent DNT, and lesser
amounts of dyphenylamine and dibutylphthalate. The main function of DNT is
to control the burning rate of the propellant (2c).
An excellent discussion of the sources of DNT wastewaters appears in
Reference (2c). Surprisingly, the "sweating" process generates only minor
amounts of DNT-containing wastewater. Much more significant DNT-containing
wasatewaters result from the preparation and production of smokeless powder
and TNT.
DNT wastes appear to be somewhat resistant to biodegradation.
52
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27. TNT PRODUCTION
a. Process Description
TNT (or more specifically, ot-TNT) is the common designation for
2,4,6-trinitroluene, the military high-explosive manufactured in greatest
quantity. Along with °t -TNT, five TNT isomers are found in the crude pro-
duct of the reaction of toluene with nitric acid in the presence of sulfur-
ic acid. The nitration occurs in steps, and the nitro groups initially in-
troduced deactivate the intermediates towards further nitration. Hence,
toluene is first treated with a mixture of 60% nitric acid and 70% sulfuric
acid, while a mixture of 109% sulfuric acid (sulfuric acid containing 40%
sulfur trioxide) and 98.5% nitric acid is needed for the final nitration.
The process is carried out in batches or continuously. Following nitration,
crude TNT is "scrubbed" by washing with water to remove acid. In the con-
tinuous process, most of these washings ("yellow water") are returned to
an early state nitrator; any non-recycled yellow water is incinerated.
Spent acid is sent to a spent acid recovery (SAR) unit. Crude TNT con-
tains about 5% of the undesirable isomers. These isomers are removed by
washing the crude product with 16% aqueous sodium sulfite ("sellite"). The
TNT is further washed, solidified, flaked and bagged for shipment (2b).
TNT wastes have a unique terminology. "Nitrobodies" include «t-
TNT, other isomers, sellite process products and by-products from the pro-
duction process. The high-solids spent "sellite" washings (see above) are
called "red water." Such water is intensely red-colored and is either sold
to paper mills for sulfur content or is concentrated by evaporation and in-
cinerated. It is not amenable to purification and discharge into streams.
"Pink water" comes from both manufacturing plants and LAP's. That from
manufacturing plants arises from Mahon fog filter effluents (Volunteer AAP
53
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batch process only); nitrator fume scrubber discharges; "red water" dis-
tillates; finishing building hood scrubber and washdown effluents; and
possibly spent acid recovery wastes. The first two types of "pink water"
may contain TNT isomers, and the first three may contain dinitrotoluenes.
"Pink water" from LAP's, resulting primarily from shell washout operations,
contains essentially pure TNT, usually contaminated with RDX or other addi-
tives. The "pink" color — pale straw to brick red — arises under neutral
or basic conditions, especially when the wastes are exposed to sunlight.
The breakdown products of TNT responsible for this color have not been
identified (lOa). Research is being conducted to identify the degradation
products of TNT in "pink water," notably at the Naval Ordnance Laboratory
White Oak, Maryland, at Tufts University, Boston, Massachusetts (l5b),
(I5c) and at US Army Natick Laboratories (l6a, l6b), Natick, Massachusetts
(2b).
At present, TNT is produced at Volunteer, Joliet, and Radford AAP's,
The Radford plant is currently the only plant exclusively using the contin-
uous process to produce TNT; the other two plants are installing continuous
lines. A fourth AAP, Newport, has continuous TNT lines and the most ad-
vanced designs in peripheral acid production and pollution abatement. This
plant was scheduled for startup in early FY74. The activity of these plants
is summarized in Table 2h (2b). RAAP ->nd JAAP are discussed below.
These two plants were the only AAP's possessing available- wastewater char-
t
acterization data at the time of the present study.
TNT is used at Holston AAP (HAAP) for blending into their HMX and
RDX for explosives such as "Composition B," "Cyclotol 70/30," and "Octol."
Table 25 presents 1970 HAAP production data which approximates current
levels (2b).
54
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The reader is referred to Chapter IV of this report for further
process details.
b. Water Use and Wastewater Volumes
(l) Water Use. Current water usage in the TNT area at RAAP is
estimated to be 5.15 mgd (6a). This is in close agreement with the
USAMEERU report which records a "pink water" discharge stream volume of
163,000 gpd diluted with about 4.5 mgd of cooling water (2b) Water us-
age figures from JAAP were not available.
(2) Distribution'of Wastewater Volumes. Major wastestream vol-
umes from TNT production at RAAP are detailed in Tables I.R.I through
I.R.7, and major wastewater volumes at JAAP are detailed in Tables I.R.8
through I.R. 10 (Appendix I ). Assuming three active (continuous) pro-
duction lines at RAAP and six active (batch) production lines at JAAP, over-
all wastewater discharges from the manufacture of TNT at these two plants
is depicted in Table 26. These waste, streams do not include the wastewater
generated in the Acid Neutralization and Red Water Treatment Facilities.
Figure 1 details the process flow and wastewaters generated in
a typical batch production line at JAAP.
Treatment of TNT wastewaters will be discussed in Chapter IV .
c. Qualitative and Quantitative Aspects of the Liquid Wastes
Wastewater characterizations of the major wastestreams generated
at RAAP and JAAP appear in Tables I.R.I through I.R.7 and I.R.8
through I.R.10, respectively. These results are summarized in Table 27
assuming three active production lines at RAAP and six active lines at JAAP.
In general, the major pollutants generated in TNT production are
nitrobodies, nitrates, sulfates, and pH. In addition, significant quanti-
ties of Na2S03, NaN02, NaHS03, and sodium trinitromethane sulfonate are
generated.
55
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d. Effects of Process Change
(1) RAAP. At RAAP a cooling tower will be constructed to re-"
place the once-through cooling water system (MCA 105D(a)). Slowdown from
the tower will be controlled so that the dissolved solids content is with-
in acceptable discharge limits (6a).
Acidic and non-acidic contaminated wastewaters will be segregated.
An area will be provided for storage of these waters and equalization of
any shock loads. The segregated wastewater will be reused in the TNT manu-
facturing operations (6a).
I
Rainwater which becomes contaminated will be treated and released
(6a).
Also, a study (PE-290) will provide for improvement of water usage
at RAAP. TNT process wastewaters are expected to decrease 100 percent from
their current level of 150,000 gpd. Current cooling water usage of 5 x 10
gpd is expected to be reduced to approximately 500,000 gpd — a 90 percent
reduction (6a).
(2) JAAP. No information regarding proposed process changes
was available at the time of this study.
e. Data Limitations
Significant analytical data was available from only two of the
four AAP's producing TNT. In addition, major process modifications at
RAAP and new and modern facilities at NAAP will lead to the generation of
X
wastewaters of a highly different nature in terms of pollutant concentra-
tions . It is suggested here that a wastewater characterization study
closely correlated with production is necessary as soon as production at
NAAP and JAAP has normalized using the new equipment.
Future plans for process changes at JAAP and VAAP should be
specified.
56
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TABLE 2h
PRODUCTION OF TRINITROLUENE IN LATE FY73 (2b)
Plant
Radford
Joliet
Vol unteer
Newport
Lines
Available
3
12
10
5
Lines
Active
3
6
4
•i**
Type
Production
Continuous
Batch
Batch*
Continuous
Recent
Production
Ib/mo
9-10,000,000
18,000,000
6,000,000
3,000,000
Cited
Capacity
Ib/rao
9,000,000
36,000,000
30,000,000
15,000,000
continuous lines under construction.
** Planned for FY74.
57
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TABLE 25
1970 TRINITROTOLUENE USAGE AT HOLSTON ARMY AMMUNITION PLANT (12a, Id(2))
oo
Explosive
Composition
Explosive Requirements, TO3 Pounds
Amount Produced, 103 Pounds RDX HMX TNT
Composition B
Composition B-4
Cycl otol
Octol
60% RDX,
1% wax
60%
0.5%
70%
75%
39%
RDX, 39.
Calcium
RDX,
HMX,
30%
25%
TNT,
5% TNT,
Silicate
TNT
TNT
168
16
10
2
198
,700
,500
,010
,860
,070*
101
9
7
107
,000
,900
,010
2,140
,910 2,140
66
6
3
75
,000
,500
,000
720
,220
* Total 1970 Production cited at 211,927,000 pounds.
-------
TABLE 26
WASTEWATER VOLUMES GENERATED IN THE PRODUCTION OF TNT (in(3), lg(3))
Unit RAAP JAAP
mgd f 2.63 9.60
Gal pet Ton of Final Product 18,100 31,800
59
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TABLE 27
OVERALL DISCHARGES RESULTING FROM THE PRODUCTION OF TNT (in(3), lg(3))
AAP
Chemical Parameter
Acidity/CaC03
Alkalinity/CaC03
Total Solids
Suspended Solids
Dissolved Solids
Volatile Solids
COD
TKN
N02 + N03/N
N03/N
804
TNT
RAAP*
Discharge
(Ib/day)
2,700
2,530
10,500
1,510
8,980
620
30.9
255
5,230
167
TOC 1
I
Sulfides
i
Discharge
(Ib/ton of product)
18.6
17,4
72.4
10.4
61,9
4.27
,213
1.76
36,1
1.15
JAAP**
Discharge
(Ib/day)
1,290
12,200
83,274
1,240
80,700
35,600
511
1,270
39 ,-600
60
11,400
476
Discharge
(Ib/ton of product)
4.27
40.4
275
4.10
267
117
1.69
4,20
131
,199
37.7
1,58
*145 ton/day TNT prpduced; **302 ton/day TNT produced
-------
FIGURE 1
TNT BATCH PRODUCTION PROCESS. JAAP (lg(3))
COOLING WATER
AOPJ60%HJlflji.
MONO
HOUSE
Bl
WASTE
AGIO
COOLING WATER
AOP
Bl
HOUSE
TRI
WASTE
ACID
COOLING WATER
MIXED ACID(HNO,a
TRI
HOUSE
OLEUM
SELLITE
SAMPLE POINT-
G-5
COOLING
WATER
WASH
HOUSE
MONO
WASTE-
ACID
MONO
OIL
AGIO
RECOVERY
HOUSE
,REC HNO, (60%)
COOLING
WATER
Bl
OIL
TRI
OIL
RED WATER a FLOOR WASH WATER
X- *— TO RED WATER
SAMPLE PT.tPl^- TREATMENT PLANT
,XSCRU8BER
WATER
TNT
-SAMPLE POINT
G-6
NAIL
HOUSE
61
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28. TETRYL PRODUCTION
Tetryl (2,4,6-trinitrophenyl methyl nitramine) has been used as a boos-
ter explosive, or the explosive ignited by a detonation charge, which in
turn detonates the bursting charge. Its sensitivity and explosive proper-
ties are similar to those of RDX. Because of this similarity, economic
considerations, and the explosive and toxic hazards involved with handling
dry tetryl, the Army has phased out tetryl production (l5d). The RDX-based
explosives Composition A-3 and Composition A-5 are being used as boosters
in lieu of tetryl in many munitions (l5e). Sufficient supplies of tetryl
are on hand to handle the limited anticipated needs of the Army and other
services (2c).
At IAAP, booster charges are molded from bulk explosives. Currently,
about 11,000 Ib/day of tetryl are so processed (3.0). Only small amounts
of tetryl-containing wastewater, estimated at 1,500 gallons/week, are gen-
erated (3.0). This wastewater is transported to a sedimentation pond, for
which no estimate of tetryl content is available (2c)
a. Process Description and Wastes Generated
Tetryl production was confined to JAAP, and ceased as of 31 July
1973 (8b). The process was carried out in a batch mode. The starting
material, N,N-dimethylaniline was dissolved in 96-99% sulfuric acid. This
mixture was pumped to a nitrator house . ..jrein it was reacted with about
9 parts of 67% nitric acid for 70 minutes. The crude product was isolated
from the spent acid, washed four times and sent to a refinery house. These
washes removed more soluble impurities such as 2,3,4,6-tetranitrophenylni-
tramine from the crude tetryl. At the refinery house, the tetryl was dis-
solved in aqueous acetone solution. The acetone was distilled off, leaving
a better sized product in the remaining water. This process water was dis-
62
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carded, the tetryl given a final wash, screened, and sent to be dried and
packaged. The major source of tetryl in wastewater was from the four washes
in the nitrator house; a second important source was from the process water
discarded after the refining step. Additional tetryl was discharged during
periodic washdowns of floors in the various processing buildings (2c). A
process flow diagram including points of wastewater discharge is presented
in Figure 2.
Since tetryl is no longer produced at JAAP, any tetryl discharges
to surface or subsurface waters would now emanate from ground deposits. It
would seem that cooling water in the amounts cited, at 20°C, would have
sufficed to dissolve all discharged tetryl. Yet, in 1969, during production,
Griffin reported tetryl particles visible in the drainage ditches (3p).
A visit was made to JAAP on 14 August 1973 to collect water and'
soil samples (8b). At the time of the visit, nitrator houses 10 and 11,
which had just ceased operation, were being cleaned out. The nitrator
ditch was running full; this precluded sampling from that ditch. The re-
finery ditch was receiving some water from refinery house 10, but flow was
slow and sluggish. A sample transect was found in the ditch downstream of
refinery houses 10 and 11, where the width of flow narrowed. The samples
collected from there are presented in Table 28 (2c).
Except for .the surface water sample, tetryl was detected in all
samples. The presence of tetryl in sample 3 was probably due to seepage
of surface water through tetryl-rich soil. The depth of tetryl-rich soil
is not known. It does not appear to be very wide, as evidenced by the much
lower concentration in sample 6 as compared to sample 4. Surface soils had
much lower tetryl contents than sub-surface soils at the same location,
Cleanout waters may have leached surface soils of tetryl faster than tetryl
63
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could diffuse to the surface from sub-surface water. Evidence for this is
inferred from the presence of an unidentified compound, perhaps removed in
the refining process, in samples 1, 3, 4, and 6, but to a much lesser ex-
tent in surface soil samples. This impurity was also noted in the produc-
tion grade tetryl used for analytical calibration (2c).
The transect selected was considered a likely place to isolate
tetryl-rich soil, and concentrations may decrease further downstream. There
are probably tetryl deposits in the nitrator ditch since most tetryl dis-
charges went there (2c).
A rough estimate of potential tetryl loadings at JAAP may be de-
termined from reasonable assumptions of drainage area, rainfall, run-off,
and the amount of tetryl dissolving into ditchwater from the ground. The
drainage area of the tetryl ditches is estimated to be about 800 feet by
1200 feet or 960,000 feet (l5f). Rainfall at JAAP is assumed to be the
same as that at Chicago, or 33.2 inch/year (l6c). If winter is repre-
sented as December-February, etc., the seasonal rainfalls are: winter,
5.4 inch; spring, 9.4 inch; summer, 10.7 inch; and fall, 7.7 inch. The
average run-off temperature is assumed as 0°C for winter, 10°C for spring,
25°C for summer, and 13°C for fall. The last three temperatures are the
respective average April, July, and October temperatures for Chicago (l6c).
The tetryl area, other than that occupied by buildings and roads, is grassy
and flat. The underlying strata are considered impermeable; hence somewhat
larger percentages of run-off than expected for grassy, flat areas are as-
sumed. A winter run-off of 50% is assumed, a 40% run-off in the spring and
fall, and a 30% run-off in the summer. It is further assumed that all run-
off becomes saturated with tetryl. Based on these assumptions, the season-
al loadings of tetryl would be: winter, 710 Ib; spring, 1210 Ib; summer,
64
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1370 Ib; and fall, 1080 Ib. The yearly total is 4470 Ib or a nominal 12
Ib/day tetryl loading. In terms of an Illinois River low flow of 1500 mgd,
a river concentration of 0.001 mg/1 is obtained. This is probably a high-
sided estimate, since normal rainfall usually causes normal flow conditions
(2c).
The amount of tetryl in soil at JAAP is estimated at 31,000 Ib.
This estimate is based on the assumptions that all tetryl is in the nitra-
tor and refinery ditches; each ditch is 1000 ft long; the tetryl is con-
tained in a 2 ft deep by 1 ft wide section in each ditch; there is a mean
soil content of 5% tetryl in these sections; and the soil has a 2.5 g/cc
bulk density. At a constant depletion rate of about 4,500 Ib/year, the
soil would be leached of all tetryl in seven years. Hence, the chronic
aspects of potential tetryl toxlcity based on an 0.001 mg/1 concentration
may be quite limited (2c).
b. Water Use
Water usage data was unavailable.
c. Distribution of Wastewater Volumes
The following are estimates of wastewaters generated from the pro-
duction of tetryl on one of JAAP's twelve lines, assuming 3-8-5 operations*
and a 150,000 Ib/mo per line production rate: (a) from a nitration house,
about 0.7 mgd cooling water and about 20 batch dumps per day of wash water.
Each dump contained about 410 gallons with a tetryl concentration of about
460 mg/1; and (b) from a refinery house, about 0.2 mgd cooling water and
about 8 batch dumps per day of process water (2c). Each dump contained
about 150 gallons (l5g) with a tetryl concentration of about 400 mg/1. The
*This is a common notation for three eight-hour shifts per day, five days
per week operations. (I5g)
65
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daily discharge of tetryl from each line, based on the above data, was 36
Ib/day. These wastewaters were routed through two parallel drainage ditches,
one serving the nitrator houses and one serving the refinery houses (2c).
d. Qualitative and Quantitative Aspects of the Liquid Wastes
The results of three separate studies are presented in Tables
I.Q.I through I.Q.3 (3f), I.Q.4 and I.Q.5 (lg(3))and I.Q.6 (8a).
These results and the determinations made in the USAMBRDL study (2c) are
summarized in Table 29. A high variance in the data obtained is immedi-
ately apparent upon examination of Table 29. Unfortunately, only two of
the investigations (lg(3) and (2c)) included related production data.
e. Effects of Process Change on the Wastewaters
Production of tetryl has been discontinued at JAAP.
f. Data Limitations
A definitive study characterizing the wastes from this area appar-
ently cannot be done since production has been terminated.
66
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TABLE 28
ASSAY OF WATER AND SOIL SAMPLES FROM TETRYL REFINERY DITCH
JOLIET ARMY AMMUNITION PLANT, 14 AUGUST 1973 (8b)
SAMPLE
1
2
3
4
DESCRIPTION
Standing water in ditch
Surface soil approximately 6 inches from edge of flow
Seepage water from 4- inch deep hole dug at
sample 2
.
Sub-surface soil from hole dug at site of
site of
sample 3
5 , Surface soil approximately 2 feet from edge of flow
1 6 , Sub-surface soil, 4 inches deep from site
of sample 5
TETRYL CONTENT
mg/1 Liquid or
jng/10 g Soil
0
4.72
44
844
5.62
14.5
67
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FIGURE 2
TETRYL PRODUCTION. JAAP (lg(3))
DMA
H.SO,
SULFATOR
NHO,
COOLING
DMAS
NITRATOR
WATER
REFINERY
FLOOR
WASH
WASH
ACETONE
ACID
RECOVERY
COOLING
WATER
G-IA-
COOLING
r-G-IB
WATER
COOLING POT *
WATER
G-7
WATER
\.
SAMPLE POINT
G-B
L
SAMPLE POINT
G-Z
TETRYL
•SAMPLE POINT
C-3
68
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TABLE 29
RESULTS OF ANALYTICAL STUDIES: TETRYL PRODUCTION. JAAP
Parameter \ Study .Reference:
Flow (mgd)
Gal per Ton of Product
Acidity as CaC03 (Ib/day)
S04 (Ib/day)
N03/N
Total Solids (Ib/day)
Dissolved Solids (Ib/day)
Volatile Solids (Ib/day)
IOC (Ib/day)
COD (Ib/day)
Tetryl (Ib/day)
(q.l)
1.21
16793
16200
3270
(q.2)
1.91
406000
3,760
9850
9870
8760
6573
96.4
i
(q.3)
.245
40600
37800
5510
44500
755
847
(q.6)
.909
266568
36
69
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29. BLENDS INCLUDING RDX, HMX, AND EXPLOSIVE FORMULATIONS DERIVED FROM
THEM WITH EMPHASIS ON COMPOSITION-B
Figure 3 depicts the molecular structure for RDX, HMX, and related
compounds. Both RDX and HMX are more powerful explosives than TNT, but
they are also considerably more susceptible to shock detonation than is
TNT. The explosive mixtures offer a compromise of properties.
RDX and HMX are found in numerous explosives mixtures. HMX is used as
a component of solid-fuel missile rocket propellant. Mixtures of RDX and
wax, "Composition-A" explosives, are suitable for press loading into small
artillery shells. Compositions A-3 and A-5 are being used for booster
charges in many Army munitions in lieu of tetryl. Mixtures of RDX and HMX
with special plasticizers and solvents give rise to numerous plastic explo-
sives and demolition charges designated as "Composition-C," "PBX," or "PBXN"
explosives. RDX and HMX find widest use as burster charges for artillery
shells. For this use they are mixed with TNT to form mixtures called
"Composition-B," "cyclolols," or "octols." The most extensively produced
of these is "Composition-B" which contains 60.5 percent RDX, 38.7 percent
TNT, and 0.8 percent wax. Composition-B is readily melted for pouring into
shells, and, after solidification, can be drilled for insertion of non-
bursting charge components. Table 30 indicates 1972 production for the
most extensively produced RDX- and HMX-derived explosives. It has been es-
timated that Table 30 production figures represent about 95 percent of the
total RDX output and 85 percent of the total HMX output (2c).
a. Process Description
RDX, HMX, and the explosive blends derived from them are produced
at HAAP. The reader is referred to Chapter IV of this report for a more de-
tailed process description.
70
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KDX is formed by reacting hexamine (hexamethylenetetramine) with
ammonium nitrate/nitric acid mixture in the presence of acetic acid and
acetic anhydride. The initial product contains roughly 79 percent RDX, 6
percent HMX, and various intermediate products. The major single intermed-
iate appears to be "BSX" (CH3COOCH2-N(N02>-CH2)2-N-N02). The primary reac-
tion mixture goes through an aging and simmering process to convert such
intermediates to RDX or decompose them. HMX is not considered detrimental
to RDX performance and is neither destroyed or recovered from the product.
Military grade HMX and RDX each contain some amounts of the other explosive
(2c).
When this reaction mixture is cooled, most of the crude RDX pre-
cipitates. Nearly all the supernatant liquid is drawn off by vacuum and
transferred to a recovery building. Here HN03 is neutralized with sodium
hydroxide slurry, and about 80 percent of the resulting solution is then
evaporated. Acetic acid is recovered from the vapors and sent to Area A
for reuse (see Para. 20, Chapter V). The remaining solution is heated to
about 100°C and slowly cooled to 30°C. RDX is crystallized from the super-
cooled solution by seeding and is sent back to the main process for purifi-
cation. More sodium hydroxide slurry is added to the residual solution to
convert any remaining ammonium nitrate and explosive to sodium nitrate and
ammonia, and any acetic acid to sodium acetate. The ammonia vaporizes and
is condensed for purification and sale as fertilizer. Impurities such as
methylamine and dimethylamine preclude its reuse. The sodium nitrate
formed has been stored in ponds for processing into fertilizer since an
old processing facility burned down in 1969. A new processing facility be-
came operational in 1974 (2c).
71
-------
After vacuum filtering, the crude RDX is water washed, and the wash
water is withdrawn by vacuum and recycled to the simmering process cited
above. The RDX is then slurried in additional water and transferred to a
reerystallization building. There cyclohexanone is added to the slurry,
the slurry heated, and the cyclohexanone distilled. RDX recrystallizes in
particles of acceptable size. Then RDX in water slurry is poured into
special vacuum carts (nutsches) and most of the water is withdrawn. The
resulting explosive contains about 10 percent water (2c).
TNT from other Army ammunition plants is melted with steam in 550-
pound batches and transferred to incorporation kettles. Wet RDX is next
added to the molten TNT. The water content of the RDX rises to the surface
of the melts and is decanted during RDX addition.
The formation of HMX requires the same reactants as are used for
RDX, but in different proportions. A hypothetical 100-pound reactant
charge consists of: 11 pounds of the ammonium nitrate/98 percent nitric
acid mixture cited previously; 17 pounds of the hexamethylenetetramine/
acetic acid mixtured cited previously; 54 pounds of acetic anhydride; and
18 pounds of acetic acid. The reaction is carried out in batch fashion.
About 27 percent of the crude product mixture is RDX, whereas specifica-
tion grades of HMX may contain only 2 or 7 percent RDX. Most of the RDX
is extracted in the acid drawoff by vacuum and the washing step, and even-
tually is added to RDX production. The HMX recrystallization process is
usually done with acetone (2c).
b. Water Use and Wastewater Volume
(l) Water Use. Water usage data for the explosives production
line was not available.
72
-------
(2) Distribution of Wastewater Volumes. Examination of Table
31 reveals that the overall wastewater discharged from the explosives pro-
duction lines (HAAP Area B) during a recent USAEHA study (Id(2)) averaged
30.3 mgd. To the extent possible the flows contributing to this overall
figure have been itemized in this table. Also, overall wastewater volumes
have been related to the Composition-B production rate at the time of the
study; however, itemized flows have generally been related to the immediate
product of that step. This is to ensure that the researcher can extract
data relating to only HMX, RDX, or blended explosives (viz. Composition-B).
Unlike HAAP Area A, some segregation of cooling and process waste-
waters has been effected in Area B. It has been possible to distinguish
between these for the nitration and recrystallization steps described in
Tables 31 and .32.
Note that the cooling water requirement for recrystallization oper-
ations carried out in buildings G-2, 3, 4, and 8 accounts for 80.2 percent
of the calculated wastewater generated in explosives production.
c. Qualitative and Quantitative Aspects of the Liquid Wastes
Effluents from the explosives production lines dump directly into
the HOIston River after settling of these wastes in catch basins located at
each building in the production line. The process effluents are character-
ized by' the presence of: soluble explosive compounds such as RDX, HMX, and
^ ' •
TNT; solvents such as acetone and cyclohexanone; nitrogenous organic com-
pounds; and a high dissolved solids content. Inspection of Table 32 and
Tables I.C.I through I.C.ll (Appendix I) again reveal that the major consti-
tuent (s) of the dissolved solids have not been identified.
73
-------
In the explosives production area proper, process wastewaters are
emptied to process sewers, and cooling waters are discharged to open ditches.
HAAP had planned to route the process wastes to an aerated lagoon where bio-
logical degradation of wastes could occur. Expectation for successful
treatment in this manner was derived from high BOD measurements on many of
the waste streams. In addition, the relatively low (by industrial waste
standards) BOD/COD ratio (2.28); see Table 32 ) for the overall discharge
supports this view. However, EPA has established a precedent by ruling
out such a plan for HAAP Area A wastes. It was claimed (by EPA) that such
treatment would not provide sufficient reduction and does not include the
best practical control technology currently available (2c).
In 1972, Green (l6d) used a 70-liter pilot activated sludge unit
with a five-day hydraulic retention time to treat plant wastes containing
cyclohexanone, acetone, ROX, HMX, and TNI. The major genera of the active
mass were Pseudomonas and Alcaligines. Partial degradation of these mater-
ials was indicated. Burrows (2d) presents a detailed overview of the
chemistry, toxicology, and biodegradability of RDX/HMX wastes.
The major explosives sources from the processes described in
Para. 29 are the steps involved in dewatering of RDX in nutsches and
in decanting water from the hot RDX/TNT mixtures. These steps take place
in Buildings H-2, 3, 4, 8 and in Buildings J-l, 2, 9; 1-1, 2, 9: L-l, 2, 9;
and M-l, 2, 3, 9; respectively, and are referred to in Tables I.C.6 and
I.C.1, respectively. The major HMX-containing discharges arising from
production of HMX also occur during the dewatering and incorporation steps.
However, sufficient HMX is present in the RDX, as produced, so that more
HMX enters wastewater from RDX production than from HMX production (2c).
74
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Estimates of RDX and HMX loadings are based on data presented in
Table 33. The RDX data are from a study performed by the EPA in April
1973 (I5h) as a follow-up to their December 1972 investigations (l5i). The
April 1973 study featured an intensive analysis of organic species, in which
the gas chromatograph and mass spectrometer were used. Flow measurements
were also performed during the April study; hence mass loadings based on
these data can be directly calculated. The concentrations used in these
calculations are taken from 24-hour time composite samples. During the 24-
hour period of April 2-3, 1973, about 1200 pounds of RDX were discharged;
during the 24-hour period of April 3-4, 1973, about 910 pounds of RDX were
discharged. HAAP performs analyses of grab samples collected once weekly
from these outfalls. A summary of the RDX assays for the first six months
of 1973 (15j) appears in Table 33. Unfortunately, concurrent flow measure-
ments from which load comparisons to the EPA results might be made were not
performed by HAAP. It does appear that, even in periods of steady production,
RDX concentrations in wastewaters are subject to wide variation and that
the EPA assays probably represent a period of rather heavy explosives dis-
charge (2c).
The EPA study did not include HMX analyses. Such assays are per-
formed by HAAP on weekly grab saples, and the results of these from the
first half of 1973 are summarized in Table 33. The "HMX content for pur-
poses of overall estimate" concentrations in Table 33 are mean concentra-
tions plus one standard deviation. An HMX loading of 207 Ib/day is based
on these concentrations and averaged EPA flow data. This method is not
rigorous, since RDX and HMX concentrations from HAAP assays are not highly
correlated, and flows are subject to variation. The loading estimate
should tend to be on the liberal side. For estimation purposes, 1000 Ib/day
75
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of RDX and 200 Ib/day of HMX are assumed to be discharged into 520 mgd of
Holston River flow (2c).
The explosive wastes from HAAP also include by-products of RDX and
HMX processing that carry through the purification process. Two of these,
known as "TAX" and "SEX," and whose structures appear in Figure 30 , are
the most abundant by-products. HAAP does not assay quantitatively for
these compounds (l6e, 2c)).
Table 32 indicates an average daily discharge of 124 Ib RDX and
45.2 Ib HMX. in comparison to 1000 Ib/day RDX and 200 Ib/day HMX cited above,
Table 33 values represent 12.4 and 22.6 percent, respectively, of these fi-
gures. Data in Table 32- are based on the 1971 USAEHA study (ld(2)), and, al-
though they are not unreliable, they are generally inconclusive since the same
parameters were not measured at each location and since flow data omissions are
frequent. The data is erratic; methodology and equipment used to obtain the
data are not discussed in the source document (id(2)); and failure to obtain
a mass balance is evident — i.e., sources of total and dissolved solids,
COD, and BOD cannot be determined from the sum of other constituents pre-
sented in the table. It may be hypothesized that the high BOD and COD
values not accounted for by total organic carbon measurements are the result
of a.nitrogenous oxygen demand. However, the sum discharge of all organic
nitrogenous compounds from the explosives production lines, is only 2,28 Ib/
day as nitrogen if one uses the cited TKN/N discharge, 9.56 Ib/day, and
corrects this value for the NH3/N, 7.28 Ib/day — all in all, a highly un-
likely figure when one considers the sum of discharges of TNT, hexamine,
RDX, and HMX also cited in Table 32. It is therefore evident that the
usefulness of this table lies in its ability to indicate the qualitative
76
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nature of discharges resulting from production of RDX, HMX, and blended
explosives. These discharges have been itemized in Tables I .C.I through
I.C.11, but, in general, they suffer from the same deficiencies (cited
above) as does Table 32 itself. This is not too surprising considering
that they are source documents for calculations presented in Table 32.
The ammonia recovery process is discussed in connection with
explosives production since the waste stream on which it operates is gen-
erated in the explosives production area. However, it would be equally
logical to consider this process as a separate entity or in connection
with acetic acid recovery from which it directly receives the liquid
wastes.
The 1971 USAEHA study (id(2)) indicates that some reduction in pollu-
tant discharge is achieved by catch basins located outside the production
buildings in the explosives manufacturing area. Tables I.C.2 through
I .C.7, I.C.10, and I.C.11 illustrate this reduction. To what extent
cleaning of these basins resuspends and solubilizes materials deposited'in
them is unknown. HAAP officials have, however, expressed a desire to in-
stitute a vacuum cleaning system rather than retain the current hand-dipping
method of cleaning.
d. The Effects of Process Change on the Wastewaters
A great deal of uncertainty has existed as to the best method for
treatment of wastewaters generated in explosives production (HAAP Area B).
Aeration in treatment ponds has been objected to on the grounds that, al-
though COD and BOD are effectively removed, removal of RDX/HMX, cyclohexa-
none, and other slightly soluble organics is questionable. Little in the
way of process change has been suggested to reduce the discharge load re-
quiring treatment. Tank dikes to contain possible spills are being con-
77
-------
structed. However, cooling and process waters have already been segregated,
and it appears that recycle is not going to be considered in the near future.
e '. Data Limitations
The data base necessary for an extensive characterization of the
liquid wastes from explosives production does not exist. This becomes ob-
vious when one attempts a mass (ion) balance using calculations presented
in Table 32~ Moreover, there are indications that discharge loads are
highly variable both qualitatively and quantitatively. It appears that an
extensive monitoring program over a fairly lengthy time period would be
necessary to characterize the various waste streams arising from explosives
production. It is doubtful that the returns from such a study would justi-
fy the expenditure since plant treatment facilities are generally designed
to treat the combined liquid wastes from many processes.
78
-------
N02
I
„
02N
\
\
„
N02
i
!—N —CH2—N—"N02
02N — N— CH2-N-N02
Hexamethylenetetramine (Hexamine)
NO
N
02N
CH
N
CH
.2
0
II
N — C— CH3
02N—N—CH2
CH2 CH2
— N—CH2 — N — N02
0
II
C—CH3
CH2
ncpy"
"TAX" ^
FIGURE 3
MOLECULAR STRUCTURE OF RDX, HMX, AND RELATED COMPOUNDS (2c)
79
-------
TABLE 30
1972 PRODUCTION FIGURES FOR PRINCIPAL HMX/RDX BASED EXPLOSIVES (2c)
00
Explosive
Product
Composition A- 3
Composition A-5
Composition 8
Composition B-4
Composition C-4
Cyclotol
Octol
Totals
Components
91% RDX, 9% Wax
98.5* RDX, 1.535 Wax
60. 5% RDX, 38.7* TNT,
0.8% Wax
60.5% RDX, 39.0% TNT
91% RDX, 9% Plastldzers
and Desensitizers
70% RDX, 30% TNT
75% HHX, 25* TNT
Production, 106 Ib
2.41
1.68
152.10
2.64
2.46
3.06
3.18
167.53
Amount of Cited Explosive
1n Product, 106 Ib
RDX HHX TNT
2.19
1.66
92.02
1.60
2.24
2.14
101.82
MM«B MMW
•W9 •»«»••
58.86
1.03
—
0.92
2.38 0.80
2.38 61.61
-------
TABLE 31
WASTEWATERS GENERATED IN THE PRODUCTION OF BLENDED EXPLOSIVES
AT HAAP
Item
Ammonia Recovery
Building A-l
Acid Mixture Distribution
Building C-5
(Composition-B Production)
Building C-3
(PBX Production)
Nitration Buildings
Building D-6
(HMX Production)
Process
Cooling
Buildings D-1,2,8
(RDX Production)
Prodess
Cooling
Slurry Processing
Buildings E-2,3,4,8
(RDX Production)
Building E-6
(HMX Production)
Recrystallization
Buildings G-2,3,4,8
(RDX Production)
Process
Cooling
Building G-6
(Specialty Products)
Process
Cooling
MGD
1.51
0.0176
0.004
0.01883
1.733
0.1506
1.426
0.1916
0.009243
0.1106
24.36
0.1363
N.A.8
Grinding and Dewatering
Buildings H-2,3,4,8 0.154
(Dewatering only; RDX Production)
Building H-6 0.092
Gal. per Ton of
Final Product
252,OOO1
642
5,OOO3'4
7,1343'5
656,OOO3»5
9047
8,5507
5,0007
3,6203»5
6647
147,OOO7
N.A.8
N.A.8
9307
N.A.
8
81
-------
TABLE 31
(continued)
Item MGD Gal. per Ton of
Final Product
Incorporation
Buildings J-1,2,9;
1-1,2,9;
L-1,2,9;
M-1,2,3,9 1.55b 5,640/
Buildings I-3;J-3;L-3 0.153 6802
Buildings L-5;M-5 0.106 4712
Receipt of TNT , fi
Buildings K-1,3,7 0.0518° 230°
Packaging of Explosives
Building K-5 0.0173 76.92
Packaging and Loading of Explosives
Buildings N-1,2,3,4,5,6,8 0.5246 2,330Z
Overall 30.32 135,OOO2
12,000 Ib/day (6 ton/day) anhydrous NH3 produced.
o
550,000 Ib/day (275 ton/day) Composition-B produced.
3Not included in estimate of overall wastewater volume generated in the
production of Composition-B.
41,600 Ib/day (0.8 ton/day) PBX produced.
55,270 Ib/day (2.635 ton/day) HMX produced.
Estimated.
7331,200 Ib/day (166 ton/day) RDX produced.
8NA = not available.
82
-------
TABLE 32 .
OVERALL DISCHARGES RESULTING FROM THE PRODUCTION OF BLENDED EXPLOSIVES
AT HAAP
Item
Ammonia Recovery
Building A-l
N02 + N03/N
TKN/N
Total Solids
Dissolved Solids
Chemical Oxygen Demand
Acid Mixture Distribution
Hexamine
Nitration Buildings
Building D-6 (HMX Production)
COD
Total Carbon
Organic Carbon
Inorganic Carbon
Nitrates
Buildings D-1,2,8 (RDX Production)
BOD
COD
RDX
HMX
Acetic Acid (100%)
Slurry Processing
Buildings E-2,3,4,8 (RDX Production)
BOD
COD
RDX
HMX
HAc
TOC
Building E-6 (HMX Production)
BOD
COD
RDX
HMX
HAc
TOC
Ib/day
4.02
5.41
8.18
3,520
3,570
377
30
22,2
5.48
3.44
2.04
< 0.658
1,218
1,440
2.63
1.05
200
Ib/ton of product
0.770*
0.0901
1.361
5861
5961
62.81
0.1092
8.423
,083
313
683
2503
7.244
8.544
0.0154
0.0064
1.194
206
10.4
9.62
0.592
511
33.8
1,460
3,260
1.38
0.90
146
10.6
1.244
0.0634
0.0584
0.0044
3.084
0.2044
5543
1,2403
0.5243
0.3423
55. 43
4.023
83
-------
TABLE 32
(continued)
Item Ib/day Ib/ton of product
Recrystallization
Buildings G-2,3,4,8 (RDX Production)
BOD 8166 4.924»6
COD 4246 2.554'6
Organic Carbon 2146 1-294;6t
Inorganic Carbon 20.I6 0.1214*6
Cyclohexanone 1966 1.184»6
Building G-6 (Specialty Products)
BOD 3766 N.A.5»6
COD 1,4046 N.A.5»6
Organic Carbon 2996 N.A.5»jj
Inorganic Carbon 11.O6 N.A.5»6
HMX 12.O6 N.A.5»6
RDX 5.666 N.A.5'6
Acetone 91.86 N'A'C'A
Cyclohexanone 6656 N.A.J»°
Toluene 3.066 N'A'c'5
Butanol 91.86 N.A.5*6
Grinding and Dewatering
Buildings H-2,3,4,8 (Dewatering Only; RDX Production)
BOD 3,5406 21.34»6
COD 5,4806 33.04»6
RDX 62.86 0.3784'6
HMX 1.926 0.0124'6
Cyclohexanone 1826 1.094»J
Acetic Acid 8406 5.064»6
Incorporation Buildings
Buildings I-1,2,9;J-1,2,9;L-1,2,9;M-1,2,3,9
COD 4,9506 1.382'6
RDX 40.36 0.0112'6
TNT 81.86 0.0232'6
HMX <13.06 <0.0042»6
Organic Carbon 122J? 0.0342>^
Inorganic Carbon 120° 0.0342»°
Total Carbon 2206 0.0622»6
Receipt of TNT
Buildings K-1,3,7
COD 28.96 0.1056
TOC 13.46 0.0496
N02 + NOs/N 1.216 0.00446
TKN/N 1.38° 0.0056
Soluble RDX 1.216 0.00446
Soluble HMX 15.76 0.0576
TNT N.A.5 N.A:5
84
-------
TABLE 32
(continued)
Item
Estimated Overall Discharges2^
NH3/N
N02 + N03/N
TKN/N
Total Solids
Dissolved Solids
COD
Organic Carbon
Inorganic Carbon
BOD
RDX
HMX
Acetic Acid
Hexamine
Acetone
Cyclohexanone
Toluene
Butanol
TNT
Ib/dav
02
28
56
4,
7,
9.
3,520
3,570
17,400
638
153
7,620
124
45.2
1,700
30
91.8
1,043
3.06
91.8
81.8
Ib/ton of product
0.0152
0.0262
0.0352
12.82
13.02
63.32
2.322
0.5562
27.72
0.4512
0.1642
6.182
0.1092
0.3342
3.792
0.0112
0.3342
0.2972
Ib/day (6 ton/day) anhydrous NH3 produced.
7
550,000 Ib/day (275 ton/day) Composit.ion-B produced.
35,270 Ib/day (2.635 ton/day) HMX produced.
^331,200 Ib/day (166 ton/day) RDX produced.
5NA = not available.
No correction for feed concentration.
As discussed in the text, these values are of questionable value. At
best they represent minimum discharge levels.
85
-------
TABLE 33
WASTEWATER DISCHARGES FROM AREA B, HOLSTON ARMY AMMUNITION PLANT (2c)
Outfall
River Mile
a.
Flow, MGD
4/2-4/3/73
Flow; MGD
4/3-4/4/73
RDX content, mg/1
4/2-4/3/73
RDX content, mg/1
4/3-4/4/73
b.
Mean, mg/1
Std. Deviation, mg/1
Minimum, mg/1
Maximum, mg/1
;, . C.
Mean, mg/1 ...
Std. Deviation, mg/1
Minimum, mg/1
Maximum, mg/1
HMX content for
purposes of overall
estimate, mg/1
Arnott
Branch
137.9
Process
Waste
139.2
Process
Waste
139.6
13^
EPA Study of 2-4 April 1973
30.2
24.5
0.35
0/20
•*.
HAAP RDX
0.5
2.4
Nil
11.2*
HAAP HMX
0.2
0.9
Nil
4.4*
t
1.17
1.17
24
38
Assays, Jan-June
6.5
4.7
Nil
12.8
Assays, Jan-June
2.1
2.3
Nil
7.5
4.4
3.35
3.88
32
15
1973
10.4
6.4
Nil
24.3
1973
2.6
2.6
Nil
8.9
5.2
1.62
2.68
Nil
1.2
0.6
1.4
Nil
4.3
0.1
0.3
Nil
1.4*
0.4
t-Not used due- to isolated occurrence.
86
-------
30. NITROGUANIDINE (NGu)
NGu (H2NC(NH)NHN02> is of particular interest as an explosives waste
because it is more soluble in water than most explosives (4.4 g/1 at 25°C).
NGu is used only as a component of M30 triple base propellant (the
other components being nitrocellulose and nitroglycerin), which is used for
76 mm, 90 mm, and 105 mm tank-fired artillery rounds (l5k). In FY 73,
11,500,000 Ib of this propellant were produced at RAAP (151). The NGu con-
tent of M30 propellant is 47.7 percent, hence some 5,500,000 Ib of NGu was
used. (2c).
At present, NGu is purchased from Cyanamide LTD of Canada (15k). A NGu
production facility with 30,000,000 Ib/year capacity is planned for opera-
tion at Sunflower Army Ammunition Plant (SAAP), KS by September 1978(15k).
The British Aqueous Fusion Process has been selected to manufacture this
material. In this process, guanidine nitrate is produced from urea and
ammonium nitrate in the presence of a silica bead catalyst. Guanidine ni-
trate is subsequently converted to nitroguanidine bisulfate by dehydration
in concentrated sulfuric acid. The nitroguanidine is precipitated from the
reaction solution by adding water. After the resulting weak acid solution
has been filtered off, the NGu is further purified, dried, and packaged
(3q).
The nitroguanidine facility at SAAP will be designed so that no explo-
sives-bearing discharges to surface streams occur. Discharges.from fume
scrubbers and accidental dumps (the most likely source of which are from
material cleaned out of plugged pipelines) will be contained in concrete-
lined pits. These wastes, depending on their source, would be either
burned or recycled for processing (2c).
87
-------
31. PRODUCTION OF NITROGLYCERIN (NG)
a. Process Description
Nitroglycerln, or more correctly glyceryl trinitrate, is made by
adding glycerol in a batch or continuous process to a mixture of concentrated
nitric and sulfuric acids. Agitation and external cooling keep the tempera-
ture below 25°C. When reaction is complete, the residual acid phase is de-
canted and the product is washed with aqueous sodium carbonate solution and
water (2b).
Currently, nitroglycerin is made at BAAP and at RAAP. BAAP employs
a batch process, while a continuous process is used at RAAP. Nitroglycerin
is a principal ingredient of double-base and triple-base propellants (com-
bined with nitrocellulose in double-base; with nitrocellulose and nitroguan-
idine in triple-base), which are formulated at the two plants. Monthly pro-
duction is now 205,200 Ibs at BAAP and 500,000 Ibs at RAAP. The maximum po-
tential monthly production figures are 2,250,000 Ibs for BAAP, 2,500,000 Ibs
for RAAP, and 3,600,000 for Sunflower Army Ammunition Plant (inactive) (2b).
The reader is referred to Chapter IV of this report for a more de-
tailed discussion of process.
b. Water Use and Wastewater Volume
(l) Water Use
(a) BAAP. In the batch process manufacture of NG at
BAAP, approximately 0.05 gallon of process water is used per pound of NG
produced (9a). This amounts to a process water requirement of 1,280 gpd at
a production level of 25 percent of capacity (12.8 ton/day). Note that this
does not include cooling water. If total wastewater discharge at this level
of production is roughly 110,000 gpd,. then the cooling water requirement is
about 109,000 gpd.
(b) RAAP. At RAAP, two NG production areas exist. NG
Area 1 is currently inactive-. NG Area 2 employs the Biazzi Process (contin-
88
-------
uous), and currently produces approximately 17,000 Ib/day NG. Approximately
50,000 gpd of water are used in the process (6a). Note that this figure
includes cooling water requirements.
(2) Distribution of Wastewater Volumes
(a) BAAP. Measurements made when NG production was
at 25 percent of capacity at BAAP indicated a wastewater flow of 120,000
gpd (2b) (Note that the figure used in this report is 110,000 gpd — see
Table I .J.I). Compressor cooling waters from the compressed air agitator
and refrigeration systems are mixed with the NG process wash waters. All
waste streams eventually drain into two ponds from which the pollutants
present can leach into the ground.
(b) RAAP. Nitroglycerin is manufactured in Nitrogly-
cerin Area No. 2. In the Nitration Building, glycerin is nitrated by mix-
ing and reacting with nitric acid. Oleum (concentrated sulfuric acid) is
used as a dehydrating agent to remove a portion of water formed during the
nitration process. Wastewaters generated here consist of soda ash wash
and freshwater wash, as well as washdown water and some acid, which is
drawn off from the process and neutralized (ln(3)).
The processed NG is placed in a storehouse until needed for
propellant manufacture. At the storehouse, NG is placed in tanks and ex-
cess water drained off to a specified level. This water goes to a. catch
tank and then to an open gutter for discharge. When needed the NG is sent
to the NG Mixhouse for combination with various solvents prior to premixlng.
Wastewaters generated here are from mixing tank washout and floor washdowns
The NG proceeds to the Premix Building which is utilized
for mixing NC, NG, and certain other stabilizing compounds. Wastewaters
89
-------
from this building result solely from washdown of floors and equipment.
A Slurry Mix Building is also often used for mixing, in a slurry form,
nitrocotton, NG, and stabilizing compounds (ln(3-)).
All wastewaters from the N6 Area No. 2 and Premix Area No.
2, after passing through catch tanks, empty into open gutters, and are dis-
charged subsequently to the New River without further treatment (in(3)).
Currently, catch basins are the only treatment provided be-
fore the nitroglycerin waste streams empty into the New River.
Table 3^ summarizes NG wastewater sources at RAAP. The
discharges which can be calculated from the given flows and concentrations
have not been used in calculating the overall discharges presented in
Table 36.
Table 35 compares the wastewater volumes generated at BAAP
and RAAP. The continuous process employed at RAAP is only slightly more
efficient in terms of wastewater generated than the batch process used at
BAAP.
c> Qualitative and Quantitative Aspects of the Liquid Wastes
(l) BAAP. Tables I.J.I and 36 fairly well summarize the
character of the wastewater from NG production at BAAP.
The wastewater from this area is characterized by a low pH (range
1.7-9.5, average 4.7) and significant concentrations of nitrate (range 0.5-
200 mg/1, average 117 mg/1) and sulfate (range 62-415 mg/1, average 240
mg/1). Occasional discharges of sodium carbonate solutions used to neutral-
ize residual acids in the nitroglycerin raise the pH to 9.5. The pond which
accepts all wastewater flow from the Nitroglycerin Plant has a sandy bottom
and all flow percolates to groundwater. The pH is not low enough, and the
nitrate and sulfate concentrations are not high enough to present a ground-
90
-------
water pollution problem. There are no wells producing water used for human
or livestock consumption in nearby areas (la(2)).
(2) RAAP. Wastewater characteristics for NG production at RAAP
are detailed in Tables I.J.2 through I.J.8, 35, and 36.
Evaluation of results reveal that the largest concentration of
contaminants, principally in the form of dissolved solids, nitrates, sul-
fates, and NG, come from the wastes generated at the Nitration Building.
Concentration of dissolved solids was as high as 70,000 mg/1 in one sample.
The major source of the dissolved solids is from the neutralization with
soda ash of waste acid released from the Nitration Building. The high con-
centrations in samples were particularly noticeable for eight-hour composite
samples collected over periods during the operation of the Nitration Build-
ing. This was noted from large deviation from mean concentrations, espec-
ially for N02-N03/N and dissolved solids. Approximately 3600 pounds of
dissolved solids, 210 pounds of N02-N03/N, and 47 pounds of NG were being
discharged daily to the New River from the combined effluent. Concentra-
tions of dissolved solids and N02-N03/N were also significant in wastewaters
being discharged from the Mixhouse (In(3)).
Small metal catch basins are provided for settling out NG at ef-
fluent lines from the Nitration Building, Storehouse, Mixhouse, and Fremix
Buildings. Observation of these catch basins revealed little accumulation
of solids (in(3)).
Note that acid wastes have been neutralized prior to gathering the
wastewater data from RAAP (see Tables I.J.2 through I.J.8) while such
was not the casa with BAAP (see Table I.J.I).
91
-------
d. The Effects of Process Change on Wastewater Volumes
(l) BAAP. The Biazzi continuous process for manufacturing NG
is scheduled to replace the present method at BAAP. It is anticipated that
this will decrease somewhat the amount of process wastewater, and thereby
perhaps reduce the NG output in the wastes (since these waters are generally
saturated with NG).
(2) RAAP. An oil separator (gravity type) will be installed
to reduce the oil released by washdown of the compressors. In addition,
an ion exchange resin (Duolite ES63) may be employed to remove lead from
the NG nitrator wash- and slurry mix waters (6a)..
A 60 percent reduction in water usage has also been proposed
(PE 290). This will be accomplished by recirculating water from the: air
compressor house, store house, transfer line heat, and separator.
e. Data Limitations
Data on the solids content of wastes from the current batch process
at BAAP would have proved extremely useful in the present study.
92
-------
TABLE 314.
NITROGLYCERIN WASTEWATER SOURCES AT RADFORD ARMY AMMUNITION PLANT (6b, 6c, In (3))
Source
Nitrator
Air Compressor
Spent Acid
Store House
Flow
(BPd)
2,500
15,000
20,000
2,500
COD
(mg/1)
1,228
72
22
912
N05(N)
(mg/D
13,280
3
433
477
Sulfate
Ong/1)
1,416
28
760
130
Nitroglycerln
(rng/D
1,300
Nil
Nil
266
(Ib/day)
27
Nil
Nil
6
CO
CO
-------
TABLE 35
WASTEWATER VOLUMES GENERATED IN THE PRODUCTION OF NITROGLYCERIN
RAAP BAAP
MGD .064 .110
Gal per Ton of Final Product 6,520^ 8,5902
19,600 Ib/day (9.8 ton/day) NG on continuous process basis
225,600 Ib/day (12.8 ton/day) NG on batch process basis
94
-------
TABLE 36
OVERALL DISCHARGES RESULTING FROM THE PRODUCTION OF NITROGLYCERIN
^--^^^ AAP
Parameter ^"~"~~~~--^
IKN/N
NH3/N
N02+ N03/N
PO^/P
804
COD
roc
Pb
Fe
Acidity (as CaC03>
Alkalinity (as CaCOs)
Total Solids
Suspended Solids
Dissolved Solids
NG
Volatile Solids
E1N03
H9SOA
RAAP
Discharge
UK/day)
,724-L
2081
68.3-L
48. 41
40. 81
.0061
10801
40301(2120)2
3.29l(.359)/
40301(2120)2
47.71
(416)2
Discharge
(Ib/ton of product*)
.073
21.2
6.97
4.94
4.16
.001
110
411(216)
.336 (.037)
411(216)
4.87
(42.4)
BAAP
Discharge
(Ib/day)
.2383
.8433
1063
.5313
187^
58. 73
7.603
0.6693
13. 74
51204
2564
Discharge
(Ib/ton of product*)
.018
.066
8.28
.041
14.6
4.58
.594
.052
*19,600 Ib/day (9.8 ton/day) NG
**25,600 Ib/day (12.8 ton/day) NG
^Reference (j.5)
^Reference (j.6)
3Reference (j.2)
^Reference (j.l)
-------
32. PRIMER COMPOUNDS
A primer is a mixture of explosives and ignitable chemicals which ini-
tiates a sequence of increasingly powerful detonations which lead to the
bursting of a charge or the ignition of a propellant. The explosives used
are generally very sensitive to shock or impact. The most widely used small
arms primer mixtures and their compositions appear in Table 37- Of these
compounds, TNR, lead styphnate, tetracene and FETN are discussed in detail
in this section. TNR is of interest not only as a primary ingredient but
as the precursor of lead styphnate, the major explosive constituent of the
primer mixtures in Table 37.. PETN has been used as a shaped charge ingred-
ient (mostly in a 50% PETN-50% TNT mixtured called "pentolite"), but other
explosive mixtures have replaced it(15m).- PETN is used to a limited extent
in boosters and detonators (l5m). However, the amounts involved are be-
lieved small compared with primer requirements, and PETN will be discussed
only in terms of its use in the primers of Table 37-• The structures of
the various primer ingredients appear in Figure !»..
a. Production Methods and Wastewaters Generated
Figure 5 is an overall flowsheet of primer composition and use,
and indicates where wastewaters are generated. The discussion is restricted
to methods employed at Lake City Army Ammunition Plant (LCAAP), Independence,
Missouri, which is currently the only AAP where primers are handled. In
October, 1973, the primer facilities of the Twin Cities Army Ammunition
Plant (TCAAP), Minneapolis, Minnesota, were placed in stand-by status (2c).-
Data on PETN production was unavailable.
(l) TNR. To produce TNR, a 30-lb batch of resorcinol is first
mixed with 240 Ib of 98% sulfuric acid (15.0). Then 72 Ib of 95% nitric
acid is added to the crude resulting mixture of resorcinol-4,6-disulfonate
96
-------
in sulfuric acid . (l5p) The crude TNR is removed from the spent acid and
pooled with two other TNR batches. The batches are washed with about 100
gallons of 1 N nitric acid to remove traces of sulfate and filtered (l5p).
The acids from all these processes are collected in a sump and treated with
sodium carbonate solution. Once a week, the collected TNR sludge is treated
with a mixture of 30 Ib sodium hydroxide and 20 Ib powdered aluminum (15q).
The resultant degraded sludge is a black, possibly polymeric material. The
neutralized acids and the treated sludge are routed to a series of waste-
water evaporation lagoons (2c).
Lake City AAF personnel indicate that about 60 Ib TNR is produced
per 30 Ib of resorcinol charge (159)• This is about a 90% yield; smaller
scale TNR production (a slightly different process) at Frankford Arsenal,
Philadelphia, Pennsylvania, has resulted in 76% yields (I5n). Their pro-
duct has been analyzed and found to be 93.5% TNR (lla). The identified im-
purities include a 1:1 TNR-dinitroresprcinol addition product (0.8%), dini-
troresorcinol (1%), 6-nitroso-2-resorcinol (1%), 2-nitroresorcinol (0.5%),
and mesoxalic acid oxime* (0.2%). On the basis of 90% conversion at LCAAP,
about 6 Ib of TNR is lost per batch produced. With a solubility of the or-
der of 7 g/1, some of this TNR could be washed out with the IN nitric acid
washes and be discharged to the evaporation pond as the sodium salt of TNR
(2c).
(2) Lead Styphnate. Two "master solutions" are prepared for
lead styphnate synthesis, the first a 720-liter solution of 130 Ib TNR and
21 Ib magnesium oxide, the other a 150-liter solution containing 100 Ib of
lead nitrate (15q). Seventy liters of the first solution are mixed with 26
*OH-N»C-(COOH)2. It is formed from cleavage of the ring and oxidation of
the end hydroxyl groups (2c).
97
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liters of the second, whereupon lead styphnate precipitates. The spent
solution with product is drained through 50 mesh screen on which the pro-
duct is collected. The spent solution is neutralized (the solution becomes
acid as the reaction progresses) with sodium carbonate. The lead styphnate
is washed several times, the washwater from each wash being removed by va-
cuum. These washwaters and spent solution are routed to storage tanks.
Once daily, sodium hydroxide and aluminum powder are added to these tanks,
and the contents steam boiled. The contents of the tanks are then dis«
charged to a series of evaporation lagoons, different lagoons from the ones
used for TNR disposal (2c).
About 19 Ib of lead styphnate are produced per batch (l5q), which
indicates 79% yield. The remaining 21% of yield, or about 5 Ib of lead
styphnate, is lost per batch (2c).
(3) Tetracene. To produce tetracene, a 65 liter solution of
26.2 Ib aminoguanidine bicarbonate in dilute sulfuric acid is mixed with
15 liters of solution containing 22.5 Ib sodium nitrite (I5q). Tetracene
precipitates, and its further processing is similar to that used for lead
styphnate. However, the collected mother liquors (previously neutralized
with sodium carbonate) and washwaters are simply boiled after collection.
The wastes are then routed to the lead styphnate lagoons. The tetracene
yield is about 16 Ib/batch (15 q.), which indicated 87% conversion. It is
assumed that the remainder is lost product, or about 2.4 Ib tetracene/batch.
This tetracene would be readily decomposed by boiling to the substances men-
tioned above (2c).
(k) Primary Mixtures. Because of their high explosive sensitivity,
primer mixtures are prepared in small quantities and used rapidly after
preparation. To prepare the primers listed in Table 37 screened iagred-
98
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ients are mixed in a blender. There Is no definitive breakdown of primer
losses In formulation or use. Lake City AAP supervisory personnel estimate
that about 12% of the amount of primer used in small arms ammunition is
wasted (I5n). This percentage represents primer material cleaned out from
screens and blenders, spills, unused or-rdf ±ed-out ;ndxttires,- and washdowns.
The wastewaters with primer ingredients are dosed with sodium hydroxide and
aluminum powder and then heated. The primer-desensitized wastewaters are
then routed to the LCAAP industrial wastewater treatment plant (IWTP) where
they contact other wastes from LCAAP activities (l5q). The IWTP treatment
at LCAAP consists of aeration, with subsequent skimming to remove oils and
greases, dosing with alum and lime to adjust pH and promote flocculation,
and settling of solids from effluent prior to discharge to surface flow
(2c).
b. Qualitative and Quantitative Aspects of the Wastewaters Generated
The magnitude of primer waste loading to lagoons and the IWTP at
LCAAP may be estimated on the basis of-round production, the 12% waste fac-
tor, batch sizes, and estimated losses from batch productions melted previ-
ously. The computations Involved are summarized in Table 38 for LCAAP
production for September-December, 1972 (I5r). The primer consumptions re-
ported in the first footnote of Table 38 were determined from the Technical
Data Packages of the rounds involved and are mean or nominal weights. The
nominal daily primer loading routed to the IWTP is about 18 Ib/day, which
»
consists of about 16 Ib of lead styphnate, about 1.5 Ib each of tetracene
and PETN, and a trace of TNR. The nominal daily primer waste loading that
would be routed to lagoons is about 50 Ib/day, of which 38 Ib is lead styph-
nate, 10 Ib is TNR-and 2 Ib is tetracene (2c).
99
-------
The wastewater associated with TNR production cited in Table M.2
is about 500 gallons/day. An additional 700 gallon dump containing treated
TNR sludge is added once a week. This wastewater is routed to lagoons, and
once every few years the sludge therefrom is removed to a landfill (I5q).*
The lagoons and the landfill sites are located on a substratum considered re-
latively impervious to seepage from the lagoons to groundwater (li(2)). Some
dissolved TNR, probably occurring as the sodium salt, may be present in la-
goon wastewaters. The components of the TNR sludge have not been charac-
terized. One proposed end product is phenylenetriamine (l5n), and poly-
meric products featuring amine linkages between phenyl groups may also oc-
cur. (2c).
About 1500 gallons/day of wastewater discharges are associated
with the lead styphnate and tetracene production cited in Table 38.. These
wastewaters are routed to lagoons (a different set from those used for TNR
waste) which are infrequently cleaned of sludge. Lead styphnate should
undergo decomposition to inorganic lead salts and the organic species
formed from TNR decomposition. The tetracene decomposition products should
initially be in the form of those generated in the boiling water treatment
of tetracene. However, in the basic environment of the lagoons, the 5-
aminotetrazole and 1-H-tetrazole should be converted to basic salts. The
relative amounts of these tetracene decomposition products have not been
determined (2c).
The wastewaters associated with LCAAP primer preparation and use
(Table 38 ) are about 5000 gallons/day. This wastewater would contain the
decomposition products of the primer ingredients. The primer wastewater
*Sludge is removed from these lagoons only when the lagoons actually dry
out. Recent wet weather at LCAAP has been filling up the lagoons faster
than evaporation can remove water (I5q).
100
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loading to the IWTP is about 0.5% of the total input to the IWTP as deter-
mined by the USAEHA Survey of 1971 directed by Graven (li(2)). The fate of
primer wastes proceeding through the IWTP would depend to a large extent
upon the solubilities of the decomposition products, which are generally
unknown (2c).
The production levels Indicated in Table 38 are, in terms of full
capacity, by round size: 5.56 mm rounds, 74%; 7,62 mm rounds, 35%; 30
Caliber Ml rounds, 49%; 30 Caliber Carbine rounds, 100%; 50 Caliber rounds,
3%; and 20 mm rounds, 51%. Production levels and attendant pollutant dis-
charges are subject to change. One indication of this can be inferred from
an analysis of primer production on the basis of raw material purchases.
In 1971, purchases of raw materials of interest were: resorcinol, 8200 Ib;
lead nitrate, 21,000 Ib; aminoguanidine bicarbonate, 5,000 Ib; and PETN,
2,000 Ib (m.10). From the production methods discussed, the nominal monthly
production of primer ingredients and their comparison to Table 38 estimates
are: TNR, 1,366 Ib vs 2,880 Ib; lead styphnate, 1,920 Ib vs 4,290 Ib; tetra-
cene, 246 Ib vs 530 Ib; and PETN, 167 Ib vs 414 Ib. Presuming no accumula-
tion or depletion of inventory, late 1972 production was generally more than
double that indicated from 1971 purchases (2c).
The situation at TCAAP merits review since demilitarization of
existing primer ingredient stocks is being done due to the switch to stand-
by status (ijt). At TCAAP, TNR was purchased from commercial sources, so
any TNR-derived wastes would come from the demilitarization of stock. All
other wastewaters from primer ingredient preparation, primer mixing, and
use were diverted to one lagoon. This lagoon is underlaid by sandy porous
soil into which water leaches. In the USAEHA survey report issued in 1973,
Kirmeyer (lq(l)) recommended monitoring for potential lead leaching by drill-
101
-------
ing observation wells. During plant operation, the lagoon wastes were
normally alkaline (pH of 10 or higher), hence lead salts would be insoluble.
However, dilution of lagoon water with rain or snow, especially under stand-
by conditions, could change this situation.
102
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FIGURE h
MOLECULAR STRUCTURES OF PRIMER COMPOUNDS (2c)
_ C
H-C
0
C — N02 N()2: - C V"~^\'
C—OH H — i
NO-
a. TNR
b. Lead Styphnate
N
II
N
— N
— N
I
H
C—N = N—N — -C — NH2- H20
N
II
I
NH£
c. Tetracene
CH2ON02
02N— 6 — CH2— C —CH2— 0 — N02
— 0—N02
d. PETN
103
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TABLE 37
PRIMER MIXTURES AND COMPOSITONS (l5n)
PRIMER DESIGNATION
FA 874
FA 956
5061W
5067W
Ingredient
Lead Styphnate
Te tracene
PtTN
TNR
Barium Nitrate
Antimony Sulfide
Aluminum
Others
Percent of Cited Ingredient in Primer Mixture
40
1
44
37
4
5
32
15
7
38
2
38
2
43.5
9
7.5
60
15
104
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FIGURE 5
FLOWSHEET OF PRIMER MANUFACTURING AND WASTEWATER TREATMENT
AT LAKE CITY ARMY AMMUNITION PLANT (2c)
HNO.
RESORCINOL
HS04
t * rr
AMINOGUANIDINE
BICARBONATE
I Wastewater
I (Boll)
PRODUCE
TETRACENE
PRODUCE
TNR
[ Spent Acid
\ (Add Na2C03 /
\
\ Sludge
(Add NaOH
& Al)
Pb(M03)2
PRODUCE
LEAD
STYPHNATE/ Wastewater
(Add NaOH,
Al & Boil)
MAKE
BATCHES
OF PRIMER
MIX
Blender Washout
Spills, Washdowns
USE
PRIMER
MIX
( Add NaOH
Wasted Primer
IND.
WASTE
TREATMENT
PLANT
Other
LCAAP
Waste-
water
Overflow to Little Blue River < 1
Sludge 'to Landfill
-------
TABLE 38
SMALL AKMS PRODUCTION, ESTIMATED PRIMER CONSUMPTION AND LOSSES AT LAKE CITY ARMY AMMUNITION PLANT
SEPTEMBER-DECEMBER, 1972 (151-)
Item Production Primer Primer Use
106 rounds/mo Ib/mo*
5.56 mm Ball 93
7.62 mm Ball 24.5
30 Caliber Ml 13.0
30 Caliber ^ 12.0
Carbine
50 Caliber 0.2
20 ran 5.7
Total amount used for primer
Estimated waste sent to IWTP
FA 956
FA 956
FA 956
5067 U
5061 W
FA 874
fills, Ib/mo
(1255 of above)
4520
1890
1000
580
64
2130
Sum of above (estimated monthly production)
Batches needed for estimated
monthly production
Estimated loss of explosive .from batch production
(sent to lagoons)
Use of Prlmar Component, Ib/mo
TNR Lead Styphnate Tetracene PETN
—
_..
—
—
21
21
3
24
48t
288
1670
700
370
220
24
850
3834
460
4290
226
1150
180
00
40
10
1
—
311
37
350
22
57
230
90
50
— •.
— - •;
370
44
Purchase
"""" '
4
*Pr1mer usage expressed in pounds per million rounds based on nominal or mean loadings are: 48.6 Ib for
5.56 mm rounds, 77.1 Ib for 7.62 mm or 30 Caliber MI rounds, 48.6 Ib for 30 Caliber Carbine rounds,
321.4 Ib for 50 Caliber rounds, and 374.3 Ib for 20 mm rounds.
tlncludes TNR required for lead styphnate production.
-------
SECTION V - EROFELLANTS
33- NITROCELLULOSE (NC) PRODUCTION
Nitrocellulose is not readily biodegraded in water. However, its in-
solubility and probable ease of removal therefrom by coagulation and/or
filtration make it unlikely that this material will pose a serious toxic
hazard. It is only its relatively high rate of discharge into receiving
waters that gives NC such high priority in studies of munitions industry
wastes.
a. Process Description
The reader is referred to Chapter IV of this report for a detailed
discussion of the production processes.
Nitrocellulose, more properly called "cellulose nitrate," is made
by treating cotton linters or wood pulp cellulose with mixed nitric and sul-
furic acids at 30-34°C for about 25 minutes. After this, the material is
wrung and "drowned" in water to remove most of the acid. The crude product,
containing roughly three nitrate ester groups per glucose unit, is subjected
to prolonged treatment (about 70 hours) with boiling dilute sulfuric acid.
Following this, it is cut and beaten in a large volume of slightly alkaline
water to remove residual acid and reduce the average fiber length. It is
then poached, i.e., treated with several changes of boiling water, washed,
and screened to remove most of the water. During the post-nitration processes,
some of the less stable ester groups are removed; thus, even the most highly
nitrated form of nitrocellulose used, guncotton, has a maximum nitrogen con-
tent of 13.55%, while three nitrate ester groups would give an analysis of
14.1% nitrogen (and two would show 11.1% nitrogen). The purification pro-
cess removes unstable impurities, such as cellulose sulfate and nitrates of
oxidized cellulose. (Quite likely, there is no cellulose sulfate as such,
but random sulfate ester groups are removed from crude nitrocellulose.) (2b).
107
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Currently, nitrocellulose is made only at RAAP and BAAP. Both
make single and double base propellants, and RAAP also makes triple base
propellant. At RAAP, nitrocellulose production is now 5,000,000 Ibs per
month, and could be raised, with existing facilities, to 12,000,000 Ibs
per month. Producton at BAAP is 2,700,000 Ibs per month with a maximum
potential of 16,300,000 Ibs per month. Indiana, Sunflower, and Alabama
Army Ammunition Plants, presently inactive, have potentials for 24,000,000
Ibs, 9,300,000 Ibs, and 12,000,000 Ibs per month, respectively f'2b).
b. Water Use 'and Wastewater Volume
(l) Water Use. Batch NC production requires a large amount of
process water (16 to 22 gallons/lb nitrocellulose produced) (2b). This
corresponds to 38,000 gallons per ton of final product. Current water us-
age at RAAP is 4,750,000 gpd or 72,519 gallons/lb of NC produced. Water
usage figures for BAAP were not available.
(2) Distribution of Wastewater Volume. Table 39 summarizes
the wastewater volumes generated in the production of NC at RAAP and BAAP.
Note that solvent recovery (alcohol rectification) operations have also been
included. Note also that the volume of wastewater generated in each case
far exceeds the 38,000 gallon per ton of final product water usage figure
reported by USAMEERU (2b). This would tend to discredit the validity of
that figure. It should be added that the effluent volumes listed in Table
39 were arrived at by summing flow tabulated in Tables I.I.I through
I.I.32, and there is good reason to doubt the completeness of this data
(e.g., see conflicting data presented in Table ^0 which is also based on
Tables I.I.I through I.I.32).
At BAAP, nitrocellulose acid wash water and boiling tub washwater
drain to a settling sump where nitrocellulose fines are removed. Overflow
108
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from the sumps flows to waste acid neutralization facilities at each line,
where lime slurry is added to neutralize the acids present. The flow of
lime slurry is controlled by a feed back pH controller. Waste from the acid
neutralization facilities flows to the industrial waste sewer. Water from
nitrocellulose washing, beating, and blending, flow to "poacher pits" where
nitrocellulose fines settle out. The effluent from these pits is either re-
cycled to the wash lines, or overflows to the industrial waste sewer (la(l)).
At MAP, acid wastewater generated from washing the NC after each
process step in the Boiling Tub House is diverted through a closed drain
system to the Boiling Tub Settling Pits. These are large rectangular con-
crete pits, lined with acid resistant bricks. Neutralized wastes which
flow from the Jordon Beater House, the Poacher-Blender House, and Final
Wringer House are also carried through a closed piping system to another set
of pits. Much of the NC carried in the drain water settles to the bottom of
the pits. At scheduled intervals this accumulation of NC fines is pumped
back into the system and used as "pit cotton" when making up blends which
contain both "Low Grade" (LG) and "High Grade" (HG) NC. Some fines are lost
in pit overflow and some escape to the New River after flowing through the
A/B-line Waste Acid Neutralization Facility (ln(3».
c. Qualitative and Quantitative Aspects of the Liquid Wastes
(l) BAAP. Acid wastes are the biggest problem posed by the pro-
duction of NC at BAAP. The wastewater flow to the acid neutralization plants
is characterized by extremely low pH (range 0.4-3.3, average 1.4), high sul-
fate concentrations (range 75-5100 mg/1, average 2600 mg/1), high nitrates
(range 100-1350 mg/1, average 700 mg/1), and fairly high concentrations of
'COD (range 80-650 mg/1, average 185 mg/1). The low pH and high concentra-
tions of sulfates and nitrates are expected from the washing of entrained
109
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acid from the crude nitrocellulose, and the fairly high concentrations of
COD are most likely due to dissolved and suspended cellulose and nitrocel-
lulose in the wastewater. No other contaminants appeared to be present in
significant quantities (la(2)).
The wastewater flow from the acid neutralization plants is char-
acterized by widely ranging pH (range 0.9-12.4, average 9.4) and high
concentrations of nitrate (range 50-600 mg/1, average 400 mg/1) and sulfates
(range 100-3000 mg/1, average 1350 mg/1). The acid neutralization plant
uses lime for neutralization which reacts with the sulfates present to form
the slightly soluble salt, calcium sulfate. As the calcium sulfate parti-
cles form, some nitrates and other materials ate entrained in the particle
structure. Although no facilities for removal of these solids exist at the
neutralization plant, the methods of analyses used required filtration of
samples, thus showing some reduction in sulfate and nitrate concentrations.
The extremely high pH values are due to the location of the pH measuring
probe and the type of controlling equipment. The pH measuring electrode is
placed quite close to the lime addition equipment. Because lime requires
102 minutes for complete reaction and the pH measuring probe is only 2-3
seconds downstream from the point cf lime addition, the pH control equipment
feeds lime at a much greater rate than is necessary. Consequently, when the
reaction is complete, the pH is much higher than the 6.5 set point on the
controller. Lime and calcium sulfate deposits on the mixing apparatus build
up quickly, so to avoid complete shutdowns for cleaning, the lime feeders
are locked off for 4-6 hours per day to allow the strong acids in the stream
to clean those deposits from the equipment. When the lime feeders are locked
off, the pH drops to equal the influent pH. A study by BAAF personnel to
determine possible methods of modifying the existing acid neutralization
equipment to provide more effective pH control has been conducted (la(2)).
110
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The characteristics of the wastewater from the two "Poacher Pits"
differed considerably during the 1970 USAEHA study (la(2)). The "Poacher
Pits" had not been cleaned for an extended period, and operational diffi-
culties in the "C" line nitrocellulose washing process were being encoun-
tered. The wastewater from "B" line "Poacher Pit" is characterized by
high COD concentrations (range 43-2100 mg/1, average 750 mg/1) and high TOC
concentrations (range 29-720 mg/1, average 320 mg/1) with low suspended
solids (range 0-13.6 mg/1, average 7.6 mg/1). These data indicate that
considerable concentrations of soluble organic compounds are in the waste-
water. These organic compounds may be from powder blocks rejected in the
Greenline Nitrocellulose Area and recycled. It could not be determined
during the survey if any studies had been performed to determine alternate
methods of recycling these rejected powder blocks. The wastewater from the
"Poacher Pit" in the "C" line area was characterized by significant pH fluc-
tuations (range 1.5-6.9, average 5.4) and high suspended solids. The pH
fluctuations are caused by operational difficulties in the nitrocellulose
washing process. These difficulties were temporary and were expected to be
eliminated shortly thereafter. The high suspended solids (range 64-140
mg/1, average 105 mg/1) are presumably caused by the buildup of solids in
the pit. This difficulty was expected to be resolved by scheduled cleaning
of the pit shortly after the survey (la(2)).
All contaminated wastewater from the greenline nitrocellulose area
except that from solvent drying is pumped to the settling basin in the near-
est nitrocellulose line. Wastewater from solvent drying of smokeless powder
is pumped to the solvent recovery area.
Tables I.I.I through I.I.5 present detailed analyses of the
major waste streams from the NC area at BAAP as determined by a later USAEHA
111
-------
study (la(l)). Overall discharges resulting from the production of NC at
BAAP are presented in Table UO. it appears that pollutant discharge per
ton of final product is somewhat higher at BAAP than at RAAP. Considering
that the wastewater volumes generated at BAAP are also somewhat higher, it
may be that the apparently more efficient process at RAAP is due to a some-
what greater degree of recycle at this plant. Both plants utilize batch
operations.
(2) RAAP. Suspended solids in the NC Area wastewater drain
lines can be assumed to at least approximate NC fines being lost. Suspended
solids increased significantly from small losses in the Boiling Tub House
of approximately 150 Ibs/day to average daily losses of approximately 650
Ibs/day in the Jordon Beater House and 650 Ibs/day from the poaching opera-
tion. This amounts to approximately 45 pounds lost in the drain of a single
tub in the Jordon Beater House and 91 pounds per 24,000-pound batch of NC
processed in the building, and 126 pounds of suspended solids lost per batch
of NC processed in the poacher operation (ln(3)).
Highest concentrations of N02-N03/N were noted in wastewater sam-
ples collected from the initial fill and drain operation in the Boiling Tub
House amounting to a loss of approximately 830 pounds per batch of NC pro-
cessed. Higher specific conductance as well as total organic carbon con-
centrations were also noted in the samples. Wastewater samples from initial
process steps were highly acidic as expected, and samples taken from later
steps were neutral or slightly alkaline in nature.
Detailed analyses of the waste streams generated in the NC and
alcohol rectification areas are presented in Tables I.I.6 through I.I.32.
Overall discharges resulting from the production of NC at RAAP are presented
in Table 1|0.
112
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d. The Effects of Process Change on the Wastewaters
(l) BAAP. A good deal of the process water management technol-
ogy to be employed at BAAP in the future will be derived from the model
study being conducted at RAAP. The most recent process change affecting
the character of NC liquid wastes was a purification facility scheduled for
completion in 1973. This facility will reduce acid wastes and suspended
nitrocellulose fibers; however, the extent of this reduction is unknown.
(2) RAAP. Switchover to a more or less continuous NC production
process with recycle is expected to reduce water usage from 4,750,000 gpd to
200,000 gpd (6a). Nitrocellulose fines separation illustrates the type of
process that will be employed to implement recycle. Wash water will be
passed through centrifuges as it flows from purification vessels to remove
the solid particles to be returned to the process. The clarified water will
be reused to the extent possible with the remainder being discharged to the
A/B-line waste neutralization facility. It is estimated that 50 percent of
the effluent from the use of centrifuges can be recycled. Presented below
are results from the Delaval Centrifuge pilot study (6a).
Effluent Flow
8420 gph
9000 gph
Test Results
Boiling Tub Pit
Poacher Pit
Tail Waters
NC Content
188 ppm
477 ppm
230 ppm
Clarified Effluent
25 ppm
25 ppm
Average flow rate from centrifuge = 8000 gph
The centrifuges will be located at the end of the settling pits ir. the pur-
ification area. Fines will be recycled ,?.lso.
e« Data Limitations
Poor agreement exists among results from various analytical studies
of the wastes from NC production at these two plants. This is particularly
true of RAAP.
113
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TABLE 39
WASTEWATER VOLUMES GENERATED IN THE PRODUCTION OF NITROCELLULOSE
RAAP BAAP
MGD 2.961 7.074
Gal per Ton of Final Product 45,2002 157,OOO3
1.87 mgd of this is generated in the alcohol rectification process
2131,000 Ib/day (65.5 ton/day) NC produced
390,000 Ib/day (45 ton/day) NC produced
not include solvent recovery flow
114
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TABLE 1*0
OVERALL DISCHARGES RESULTING FROM THE PRODUCTION OF NITROCELLULOSE
"~^^^^ AAP
Parameter — ~^_
N02 + N03/N
TKN/N
COD
BOD
Total Solids
Suspended Solids
Dissolved Solids
Volatile Solids
Acidity
Alkalinity
roc
NHq/N
P04/P
Fe
SO^
RAAP
Discharge
(Ib/day)
4,700! (16,400)2
4.65 (169)2
9.4601
29. 01
1,390-"- (247,000)^
L.6801 (4,330)2
L.1801 (244,000)2
1951 (96,000)2
1.761
69. 91
3,4201
50.52
3.82
Discharge
(Ib/ton of product*)
71.8 (250)
.070 (2.58)
144
.442
21.2 (3,780)
25.6 (66.0)
18.0 (3,730)
2.98 (1,460)
.027
1.07
52.2
.771
.058
BAAP
Discharge
(Ib/day)
16.0003
12,0003
240, 000 J
18,2003
222, OOO3
3,0503
14.43
37.83
57.43
29,2003
Discharge
(Ib/ton of product**)
356
267
5,330
404
4,930
67.8
.32
.84
1.28
649
*65.5 ton/day NC
**45.0 ton/day NC
^-Reference (i.3)
2Reference (i.4)
3Reference (i.2)
-------
3*4. SINGLE BASE PROPELLANTS
Single base propellants are manufactured at RAAP, InAAP, and BAAP (3e).
However, while data concerning the wastes generated in the production of this
solvent propellant was available only from RAAP, it may be considered typical.
It should be noted that BAAP greenline nitrocellulose wastes (specifically,
solvent recovery wastes) are discussed in Para. 33 of this report. Multibase
propellants are discussed in Para. 35 and solventless propellants in Para. 36.
a. Process Description (RAAP)
For further details of process, the reader is referred to Chapter
IV of this report.
The process steps are essentially the same in the production of the
solvent-type single, double, and triple base propellants. Major differences are
in the specific chemicals and explosive ingredients added. The production of
all of the propellants begins with a dehy process which replaces water in the
NC with alcohol and presses the NC into blocks. In the production of single
base propellant, previously stored NC is sent to the Mixhouse where the blocks
are charged into a mixer with solvents (alchol and ether) and various other chem-
ical ingredients. The propellant is then sent to a Blocker House where it is
screened and pressed into blocks. From the Blocker House, the propellant is
taken to the Press and Cutting House where it is pressed and cut into strands and
cut into specified lengths. The propellant is sent from here to the Solvent
Recovery Area for further processing. In the production of multi-base propellants,
other explosive materials are mixed with NC. In double and triple base propel-
lant manufacturing, NG is combined with NC in the Premix Area. No. 2 and then sent
to the Propellant manufacturing areas for mixing with solvent and other chemicals,
as in the Single Base Area. In the Mixhouse, nitroguanidine is combined
with the NG-NC mixture, solvents, and other chemicals to form triple base
propellants. High energy propellants require a separate blending process
for the addition of ammonium perchlorate. Solvents used in the production
116
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of multi-base and high energy propellants include acetone and alcohol.
Other chemicals vary depending upon the specific intended use of the pro-
pellant and are outlined in Table h 1 (ln(3).
TABLE M
CHEMICALS USED IN PROPELLANT MANUFACTURING (in (3))
Propellant
Chemicals
juble Base
riple Base
JHigh Energy
Barium Nitrate, Potassium Nitrate, Ethylcentralite, Graphite,
Carbon Black
Ethylcentralite, Potassium Sulfate, Cryolite
Resorcinol and HMX
6. Water Use and Wastewater Volume (RAAP)
(l) Water Use. Water use figures were not available, however,
overall water use in the propellant area is estimated to be 2,740,000 gpd
(2) Distribution of Wastewater Volumes. Data allowing calcu-
lation of the overall volume of wastewater generated was not available.
Tables I.N.I through I. N. 5, however, indicate discharge volumes of
several of the major wastestreams.
Wastewaters generated in each solvent- type propellant manufacturing
area are primarily the result of periodic (usually weekly) equipment and
building washdowns. The wastewaters, after leaving the process buildings
(in some cases passing through small screening devices and/or catch tanks),
flow to the C-line Acid Neutralization Facility (from the Multi-Base Area)
or directly to Stroubles Creek via an industrial sewer line (from the
Single Base, A-line Area) (ln(3)).
Volumes of wastewater generated in this area were small compared
to many other process operations within the plant and were almost entirely
the result of water from shift and weekly equipment cleaaup and floor wash-
117
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down operations. Estimated volumes generated from the weekly washdown and
cleanup operation in Buildings 1500, 1508, 1510, 1511, 1512, and 1513 amount
to approximately 3700 gallons (in(3)). The .038 rngd flow measured on the in-
dustrial waste sewer north of A-Line Single Base Propellant Area appears to
be an adequate estimate of the total wastewater (including cooling water)
generated in this line (see Table I.N.I, Appendix I ).
c. Qualitative and Quantitative Aspects of the Pollutants Present in
Liquid Wastes (RAAP)
What data is available is presented in Tables I.N.I through
I.N.5 (Appendix I ).
Wastewaters resulting from washdown of individual bays in the
Mixhouse contained very high concentrations of contaminants, most probably
propellant. This was indicated by high concentrations of total solids,
volatile solids, and extremely high COD. The five-day BOD of greater than
350 mg/1 was due mainly to high concentrationsof ethyl alcohol, greater
than 900 mg/1. Quantities of waste propellant were visibly present in all
samples collected (see Table I.N.3, Appendix I ) (ln(3)).
Significant quantities of diethyl and ethyl alcohol were found in
wastewaters from the Blocker House and Press and Cutting House (see Tables
I.N.4 and I.N.5, Appendix I ) (ln(3)).
Wastewaters from the Mixhouse flow directly from drains under the
building to a sewer line located northwest of the building, with no solids
removal being accomplished by screens or catch basins. Screens and catch
basins are located outside of other buildings in the area. No regular
schedule of cleaning and maintenance of the screens and catch basins was
being undertaken and accumulations of various waste materials was visually
noted in several basins (in(3)).
118
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Dry sweeping prior to washdowns is done to reduce the amount of
propellant washed out of the buildings. Study personnel were not able to
ascertain fully the completeness and effectiveness of the operation. Per-
formed with care, thorough sweeping would certainly reduce propellant loss
during washdowns (in(3)).
d. The Effects of Process Changes on Wastewater Characteristics (RAAP)
The following discussion applies to project activities at RAAP. A
20 percent sodium hydroxide solution heated to 217°F is used to clean metal
objects, dies and screens which become contaminated with propellant during
the shaping and extrusion opeations. After dipping in the caustic solution,
the parts are rinsed with water. The caustic and the rinse tank are drained
and the waste hauled by tank truck to the acid sewer. The planned Military
Construction Army (MCA) project proposed neutralization of the waste with
73 percent sulfuric acid from the acid area. The neutralized solution is
then to be hauled by tank truck to a waste propellant incinerator (design
criteria being developed under Task 10 of the MM&T). Elimination of the
waste from this operation will require further study. Consideration should
be .given to a method where both the caustic solution and the rinse water are
recycled with the addition of sodium hydroxide and make-up water. Physical-
chemical methods should be investigated which would make the recycling fea-
sible. Propellant and sludge extracted could be treated in this area or
transported to one of the other treatment facilities at the plant (in(3)).
MCA 105A(b), "Wastewater Collection and Primary and Secondary
Treatment System for Propellant Manufacturing Areas," calls for:
o Open drain guttering and primary solids separation facilities at
individual process buildings to remove settleable solids;
o Sewer lines to secondary treatment;
119
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o Separate storm systems for uncontaminated cooling water and storm
runoff waters; and
o Secondary treatment facility with 3,000,000 gpd capacity.
This project will include both the solvent and rolled powder areas
and should reduce both hydraulic and solids loadings (6a).
PE 210 will alleviate pollution from Solvent Recovery/Wash and
Dry operations (6a).. One solvent recovery building will be modified, five
wash and dry buildings will be modified, and funding has been requested for
the remaining buildings (ln(3)).
e. Data Limitations
Clearly, the data base necessary for making a detailed single-base
wastewater characterization at RAAP or any of the other plants manufacturing
this product does not exist.
Note that TRW (3f) reports discharges of 675,000 Ib/day solids,
8,000 Ib/day suspended solids, and 1,200 gal/day caustic solution for the
single- and multi-base propellant areas. Examination of Tables I.N.I
through I.N.5 and I.O.I through 1.0.6 (Appendix I) reveals that only about
3 Ib/day of total solids can be accounted for by the data presented here.
120
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35- MULTIBASE PROPELLANTS
Multibase propellants are manufactured at RAAP and BAAP. Limited data
characterizing some of the waste flows from the multibase production area
at RAAP are incorporated in the present study.
a. Process Description (RAAP)
Refer to Para. 3^.
b. Water Use and Wastewater Volume (RAAP)
(l) Water Use. Refer to Para 314-.
(2) Distribution of Wastewater Volumes. Data allowing calcula-
tion of the overall volume of wastewater generated was not available.
Tables I.O.I through 1.0.6 indicate discharge volumes of several of the
major wastestreams. The sum of these flows is roughly 7,360 gpd.
As in the Single Base Propellant Area, wastewater flows generated
in this area result primarily from cleaning of equipment and washdown of
floors in production buildings (in(3)).
c. Qualitative and Quantitative Aspects of the Liquid Wastes (RAAP)
Available data is presented in Tables I.O.I through 1.0.6
(Appendix I ).
Washdown waters from the Multibase Mixhouse (see Tables I.O.I
and 1.0.2, Appendix I ) contained higher total volatile and dissolved
solids leaving than found in floor wash waters from the Press and Cutting
Bouse (see Table 1.0.4, Appendix I ). Although only one sample was ob-
tained frwm the High Energy Mixhouse washdown water during the USAEHA sur-
vey (ln(3))> solids concentration in the sample was in the same range as the
measured solids values for the Mixhouses. It was felt that this indicated
that propellant is being washed out of the buildings, and, where screening
is inadequate, much of this is being lost to major plant outfalls.
121
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High TOC concentrations (5000 mg/1; see Table 1.0.6, Appendix
I ) in samples of wash water taken from the outside catch tank of the
Slurry Mlxhouse indicate that organic material (likely propellant) is being
lost to the evaporation pond beside the building. The pond effluent showed
a TOC concentration of 2000 mg/1 (in(3)).
d. The Effects of Process Changes on Wastewater Characteristics (RAAP)
The reader is referred to Para. 3U.
e. Data Limitations (RAAP)
The discussion presented in Para. 3^ is also applicable here.
122
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36. SOLVENTLESS PROPELLANTS
There are several plants engaged in the manufacture of solventless
propellents. It appears, however, that the final products at each plant
are too different in terms of structure, production rate, and manufacturing
processes to allow cross-correlation analysis.
Data on solventless propellant operations exists only from RAAP and
BAAP.
a. Rolled Powder (RAAP)
(l) Process Description. Production of solventless propellants,
referred to as rolled powder, involves similar process steps, but without
the addition of solvents in the mixing step. Propellant, after the addi-
tion of NG, air drying and temporary storage, is processed through a blen-
der. From the blender, the "powder" is transported to the Preroll Building
and then to the Final Roll Process. The sheets produced from the rolling
operations are cut and made into "carpet rolls" or otherwise shaped as de-
sired. These products then proceed for final processing and preparation
for shipment. Again the primary source of wastewaters are from building
and equipment washdown. During washdowns in the Preroll Building, waste-
water flows from concrete gutters within the buildings into catch tanks
outside the buildings and then into a general purpose sewer line. After
passing through a larger settling tank the effluent is discharged to the
New River. Certain cleaning mixtures are used in conjunction with the wash-
down of equipment in this area. These include a mixture of 58 percent soda
ash and Johns-Manville No. 450 Insulating Cement (asbestos) used to clean
chemical salts from the differential rolls in the Preroll Building. Rolls
are subsequently cleaned using a solution of Oakite 20, Colgate Arctic
Syntex M-Beads with water. Now and then, accidental ignition of propellant
123
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while on the prefolls in Building 9309-4 activates an automatic sprinkling
system which drowns the fire; but in the process, quantities of propellant
are washed out of the building and into the wash water gutters. From the
blending operation, wastewaters are produced from floor and equipment wash-
down during and after operation, plus from a rotoclone used to pick up dust
in the air during the blending operation. Wastewaters flow to a catch tank,
to a larger settling tank and then to an open ditch (in(3)).
(2) Water Use. Water usage figures were not available. Process
water use will be roughly equivalent to the measured wastewater volume.
(3) Distribution of Wastewater Volumes. Tables I.P.I through
I.P.5 indicate some of the major wastewater flows. Total wastestream
flow indicated by these tables is 89,600 gpd. This is primarily washdown
water. TRW (3f) indicates a wastewater volume of 3,000,000 gpd for this
area.
(14-) Qualitative and Quantitative Aspects of the Liquid Wastes.
Examination of Tables I.P.I through I.P.5 indicates the absence of ex-
cessively large discharge loads except possibly for the total solids
(largely dissolved) content (approximately 200 Ib/day). TRW indicates
(3f) discharges of 5000 Ib/day total solids, 5000 Ib/day BOD, and 12000
Ib/day COD. In view of the large disparity between USAEHA data (ln(3)) and
TRW data (3f ) it would seem likely that data from either or both of the
reports is inadequate or inaccurate.
(5) Effects of Process Change cm the Wastewaters. Since a
detailed wastewater characterization has not been effected, it is impossible
to predict what effects process changes will have on the wastestreams in
their entirety. The discussion presented in Para. 3^ is applicable here
since MCA 105A(b) includes the Rolled Powder Area.
124
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(6) Data Limitations. Again it may be stated that the data
base for a detailed wastewater characterization simply does not exist.
b. Ball Powder (BAAP)
BAAP is the only AAP in the U.S. Army Armament Command Complex
that manufactures ball powder. Current production rate is 900,000 Ib/month
(30,000 Ib/day). Mobilization-rate production is projected to be 2.7
million pound/month (90,000 Ib/day) (3a).
(l) Process Description and Water Usage. The entire ball pow-
der operation prior to reaching the drier is accomplished with the propel-
lant in a water slurry. A flow chart of the manufacturing process is shown
in Figure 6. A house-by-house breakdown of water usage up to the drier
can be seen in Table ^2.
In the ball powder operation, 100 percent of the cooling water is
recycled. Fifty percent of the wastewater consumed is in the wet screen
operation (3a).
(2) Qualitative and Quantitative Aspects of the Liquid Wastes.
Table I.P.6 (Appendix I ) presents the detailed results of USAEHA mea-
surements made in 1970 (la(2)). It must be assumed that cooling water wastes
were not included in these measurements and that the concentrations listed
correspond only to process waters. Benzene, ethyl acetate, NC, NG, sodium
sulfate, and protein colloids have also been indicated to be contaminants of
the wastewater discharged from ball powder operations.
The use of protein colloids (animal glue from Swift & Co.) in the
manufacture of ball powder increases the BOD and causes a foam problem
which manifests itself in the plant effluent at the exit of the 25-acre
sedimentation pond. The colloid is used to keep particles separate during
ball powder manufacturing (to avoid conglomeration). It collects on the
bottom of ponds and also produces surface foam (3f)•
125
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(3) Effects of Process Change on the Wastewaters. Steps have
been undertaken to allow recycle of the water at the Wet Screen House (3a).
since this house uses 50 percent of the water in the ball powder area.
Due to the widespread nature of the ball powder manufacturing oper-
ation, additional recycling would not be feasible on an economic basis only.
However, in the single base extraction and ball powder hardening operations,
a closed-water system would be environmentally advantageous since benzene
is used in the former and sodium sulfate and colloid are used in the latter.
Engineering changes are being implemented to prevent large quantities of
benzene from entering the sewer. A project has been initiated to evaluate
the use of a trickle filter for processing the colloid waste from the harden-
ing operation (3a).
If it is assumed that the wet screen operation can be made a self-
contained, closed-loop system, the total effluent at full production would
be approximately 76.87 million gallons per month. Of this, approximately
20.99 million gallons would be contamined with benzene, ethyl acetate, ni-
trocellulose, nitroglycerine, and sodium sulfate (3a).
Further investigation into the types of contamination, suitable
means of processing, and the economic impact of processing and recycling
in the existing facilities is required (3a).
A complete listing of water usage at the current production rates
and the projected water usage at full mobilization production rate are
given in Table k3-
Data Limitations. Insufficient data exists on either the
distribution of wastewater volumes or the nature of the waste streams. A
complete and detailed characterization of the wastewaters generated in ball
powder operations at BAAP is not possible with the given data base.
126
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c. Rocket Area (BAAP)
(l) Process Description and Water Usage. Rocket manufacturing
is basically a solventless operation. An initial water slurry is made at
the premix house and transferred to the final mix process where it is cen-
trifuged. Almost all the process water remains in a closed system. After
the slurry is centrifuged, no water is added to the mixing mixture through-
out the remainder of the operation. The remaining process water is consumed
at House 6731 and House 6814. A flow chart of the rocket manufacturing pro-
cess is shown in Figure 7 (3a).
Current production rate of rocket propellant is 280,000 Ib/month
(9330 Ib/day). At mobilization for the existing facilities this production
rate would increase to 2.7 million Ib/month (90,000 Ib/day).
Water usage by manufacturing operations are shown in Table kk .
It can be seen that the Dowel and Spiral Wrap chip collector uses only 3.8
percent of the 16,000,000 gallons total; therefore, recycling would be im-
practical for economic reasons only. This is an important point since the
only process water which is not being recycled is from the Dowel and Spiral
Wrap operations and wash down in the Roll and Press Area. This wastewater
accounts for 6.5 percent of the water entering the sewage system from the
Rocket Area. Due to the small quantity (988,520 gal/month) and low cost
($54.37/month) of this amount of water, recycling these streams would not
be practical from an economic standpoint in the present operation (3»).
The major areas of concern are those where large volumes of water
are used for cooling water. Due to procedural changes that have resulted,
the pre-mix and final mix houses in the Paste Area have cut water consump-
tion by 50 percent. This was accomplished by reducing the flow through
heat exchangers in operation and by closing and draining the lines which
127
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were running to prevent freeze up. Water usage by area, after the proced-
ural change, is shown in Table 1+5. Cooling water usage in the Roll and
Press Area was found to be optimized and will remain unchanged (3a).
Projections were made of water usage in the Rocket Area at in-
creased production rates. Table 1*5 shows the projected water usage by
manufacturing operations. In arriving at the projected water usage rates,
it was assumed that the reduced flow rate through heat exchangers which
resulted from procedure changes would apply at the increased production
rates. The figures given were obtained by determining a gallon per pound
ratio based on present production and expanding to the increased production
capabilities (3a).
(2) Qualitative and Quantitative Aspects of the Liquid Wastes.
No analytical data for the wastewater streams from this area was available.
Heat can be expected to be of primary consideration as a potential pollu-
tant.
At maximum production rates (mobilization), process water consump-
tion is expected to be roughly 9.8 million gallons per month. This water
would be slightly contaminated with NC fines, NG (dissolved), and small
quantities of other chemicals used in the production of various formula-
tions of rocket propellant (3a).
(3) Effects of Process Changes on the Wastewaters. No further
modernization or pollution abatement programs that would directly affect
the nature of the wastewaters generated in the Rocket Area are planned.
(1+) Data Limitations. Presently existing chemical and physical
data is inadequate for characterization of the liquid wastes from this
area.
128
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FIGURE 6
FLOW CHART BALL POWDER (3a)
-------
.
TABLE ^2
BALL POWDER WET LINE WATER USAGE
AT CURRENT PRODUCTION RATES OF 900,000 POUNDS /MONTH (3a)
House
US3
Gallons/Mont.'i
9590
Storage Pits
21 day month
HOUSE TOTAL
debagger spray
debagger flush v/ater
storage pit replenish water
201 ,600
685,440
•
1,251,936
2,138,976
Percentage of
Grand Total
Percentage of
Grand Total
HOUSE TOTAL
Percentage of
Grand Total
(highly contaminated)
sewer flush
vacuum pump seal
transfer water
3.1%
9591
Grinding
30 day month
HOUSE TOTAL
sump pump flush water
ground powdar tub flush v/ater
receiving tub flush water
grinding mill flush water
receiving hopper
sewer flush
pyc tank
220,800
110,400
55,200
504,528
750,720
662,400
2,630,200
4,934,248
7.1%
9592
Extraction
30 day month
from stripper still to sewer
(highly contaminated)
from recovsry still to sewer
;375,360
1,218,816
1,324,800
662,400
1,523.520
5,104,896
7.3%
130
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TABLE ^2
(continued)
House
Use
Gal Ions/Month
9500-3
Hardening l.'oigh
21 day month
HOUSE TOTAL
Percentage of
Grand Total
pyc tank
water required to fill line
1,402,758
873.600
2,276,358
3.3%
9501-3
Hardening House
21 day month
HOUSE TOTAL
Percentage of
Grand Total
initial water layer in still
wash water
(contaminated with colloid
and salt)
pump seal water
make up water
379,300
11,684,736
988,217
834,624
13,986,877
20.0^
9501-2
Hardening House for
Solvent Stripping
21 day month
HOUSE TOTAL
Percentage of
Grand Total
initial tank f111
wash water
65,730
676.330
742,060
1.1X
9503
Wet Screen
21 day month
HOUSE TOTAL
Percentage of
Grand Total
slurry water
36,288.000
36,288,000
51.9%
131
-------
TABLE U2
(continued)
House
Use
Gallons/Month
9522
Cooling Tower
30 day month
HOUSE TOTAL
Percentage of
Grand Total
water added to system
1.468.800
1,468,800
2.1%
9505
Single Base
Clarifler
30 day month
HOUSE TOTAL
Percentage of
Grand Total
make up water
596.160
596.160
0.9%
9507
N.G. Transfer House
21 day month
HOUSE TOTAL
Percentage of
Grand Total
N.G. transfer
302.400
302,400
0.4%
9506-1
Coating
21 day month
HOUSE TOTAL
Percentage of
Grand Total
transfer flush water
wash tub
decant water
vacuum pump seal
241.920
1.163,770
155,230
272.160
1,833,080
2.6%
132
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TABLE b2 .
(continued)
House Use^ ._ Gallons/Month
9509-1
Roll and Dewater
21 day month
HOUSE TOTAL
Percentage of
Grand Total
roll spray ' 85,680
pump flush to dcwater operation . 18,900
spray for racsivinq hopper 86^400
190,980
0.3%
BALL POWDER AREA GRAND TOTAL: 69,862,835
133
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TABLE U3 i
BALL POWDER WET LINE PROJECTED WATER USAGE
AT PRODUCTION RATES OF 2,800,000 POUNDS/MONTH AFTER PROCEDURAL CHANGES (3a)
House
Use
Gallons/Month
9590
Storage Pits
21 day month
HOUSE TOTAL
debagger spray
debagger flush water
storage pit replenish water
201 ,600
685,440
1 ,251 ,936
2,138,976
Percentage of
Grand Total
Percentage of
Grand Total
HOUSE TOTAL
Percentage of
Grand Total
2.7%
9591
Grinding
30 day month
HOUSE TOTAL
sump pump flush water
ground powder tub flush water
receiving tub flush water
grinding mill flush water
receiving hopper
sewer flush
pyc tank
220,800
110,400
55,200
504,528
750,720
662,400
2,630,200
4,934,248
(highly contaminated)
sewer flush
vacuum pump seal
transfer water
6.3%
9592
Extraction
30 day month
from stripper still to sewer
(highly contaminated)
from recovery still to sewer
375,360
1,218,816
1,324,800
662,400
1,523.520
5,104,896
6.5%
134
-------
TABLE U3
(continued)
House
Use
Gallons/Month
9500 - 2 I 3
Hardening V.'eigh
30 day month
HOUSE TOTAL
Percentage of
Grand Total
pyc tank
water required to fill line
4,364,136
2.717,867
7,082,003
9.0%
9501 - 2 & 3
Hardening House
30 day month
HOUSE TOTAL
Percentage of
Grand Total
initial water layer in still
wash water
(contaminated with colloid
and salt)
pump seal v/ater •
make up v/ater
1,180,044
36,352,512
3,074,453
2.596,608
43,203,617
55.1%
9501-1
Hardening House
used for Solvent
Stripping
21 day month
HOUSE TOTAL
Percentage of
Grand Total
initial tank fill
wash water
204,493
2.104.138
2,308,631
2.9%
9503
Wet Screen
30 day month
Percentage of
Grand Total
slurry water - recycled
135
-------
TABLE ^3
(continued)
House
Use
Gallons/Month
9522
Cooling Tower
30 day month
HOUSE TOTAL
Percentage of
Grand Total
water added to system
4.569.600
4,569,600
5.8%
9505
Single Base Clarifier
30 day month
HOUSE TOTAL
Percentage of
Grand Total
make up water
1.854.720
1,854,720
2.4%
9507
N.G. Transfer House
30 day month
HOUSE TOTAL
Percentage of
Grand Total
N.G. transfer
940.800
940,800
1.2%
9506-1
Coating
30 day month
HOUSE TOTAL
Percentage of
Grand Total
transfer flush water
wash tub
decant water
vacuum pump seal
752,640
3,620,618
482,938
846,720
5,702,916
7.3%
136
-------
TABLE 1*3
(continued)
House
9509-1
Roll and
Dev/ater
30 day month
HOUSE TOTAL
Percentage of
Grand Total
BALL POUDER AREA
Use
roll spray
pump flush to dewater operation
spray for receiving hopper
GRAND TOTAL:
Gallons/Month
266,560
53,800
268,800
594,160
0.8%
78,434,568
137
-------
CO
GO
FIGURE 7
FLOW CHART-MARK 43 & N5 (3a)
IS UC.tt
MIE-ORTHOUM
PASTE CDEAUR
»KO BLENDER
CM
REST HOUSE
•*?
cri
ROLL HOUSE
CA^.'ITfULL
•01
•• •-
eacENL
S
STU J
tER HOUSE
*
. ua
X-RAY REST
KQU1E
/
Y
en
FLUOSOSCOPE
REST HOUSE
-------
TABLE
ROCKET AREA WATER USAGE DETERMINED AT CURRENT PRODUCTION RATES (3a)
fial Ions/Month
Area Recycled
Paste:
Process 333,200
Cooling 0
Area Total
Percentage of
Grand Total 2.1%
Roll 5 Press:
Process 0
Cooling 0
Area Total
Percentaqe of
Grand Total 0
Finishing:
Process 0
Cooling 0
Area Total
Percentage of
Grand Total 0
Gallons/Month to Total
Waste Water Streams ^allons/Montri
25,700 (Tank Wash)
216,720 (Wet Floor)'
10,696,700
11,272,320
68 5% 70.6%
167,000 (Washdown)
• 604,800 (Vacuum)
3,316,320 (Hydraulic)
4,088,120
25.62 25.6%
604,800 (D 3 SW)*
0
604,800
3.8% 3.8%
GRAilD TOTAL 15,965,243
* Dowell and Spiral Wrap
139
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TABLE 1+5' ,
ROCKET AREA WATER USAGE AFTER PROCEDURAL CHANGES AT
PRESENT PRODUCTION RATE OF 0.28 MILLION POUNDS/MONTH (3a)
Area Usg of Water Gallons/Month
Paste tank wash 25,700
wet floors 216,720
cooling hydraulic system 3,696,700
TOTAL 3,939,120
Roll & Press wash down • 167,000
cooling vacuum system 604,800
cooling hydraulic system 3,316,320
TOTAL 4,088,120
Finishing .dowel1 and spiral wrap flush 604,800
TOTAL 604,800
•
TOTAL AREA USAGE ' 8,632,040
140
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TABLE J46
ROCKET AREA PROJECTED WATER USAGE AFTER PROCEDURAL CHANGES
AT PPODUCTION RATE OF 2.7 MILLION POUNDS/MONTH (3a)
Area
Usie of Hater
Gallons/Month
Paste
TOTAL
tank wash
wet floor
cooling hydraulic system
247,821
2,089,800
35.646.750
37,984,371
Roll & Press
TOTAL
washdown
cooling vacuum system
cooling hydraulic system
1,610,357
5,832,000
31.978.800
39,421,157
Finishing
TOTAL
.dowel 1 and spiral wrap flush
5,832.000
5,832,000
TOTAL AREA USAGE
83,237,520
141
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SECTION VI - LAP
37. LOAD. ASSEMBLE. AND PACK (LAP) OPERATIONS
Information as to the nature, source, and quantity of wastewaters gen-
erated in LAP operations is not complete. Information on surface water
pollutant loading situations from LAP's is also somewhat sketchy because of
the general practice of disposing of TNT wastewaters in evaporation ponds.
In these situations, the mode of TNT introduction into surface streams could
be either by pond washout during heavy rains or by groundwater infiltration.
There have been no TNT analyses performed at wells with drawdowns below the
levels of LAP evaporation ponds which would indicate infiltration (2b).
What LAP wastewater data is available is discussed below on a plant-by-plant
basis.
a- Aspects of LAP Wastewaters
(l) Cornhusker Army Ammunition Plant (CAAP) (Note; Currently
inactive). Industrial wastewaters generated on the installation are attri-
butable primarily to the load lines. Each of these lines is similar in con-
figuration and in quantity of wastewater discharged. Also, liquid wastes
from each line are primarily washdown waters. Average daily waste volume
per line is approximately 6,300 gallons. Other sources (cited in Reference
(2b)) estimate waste flows from active LAP lines at between 9,600 and 28,800
gpd per line. These waters are disposed of by percolation and evaporation
in a network of tanks and basins located throughout the load line area. It
has been suggested that these wastes instead be directed to adequately sized
evaporation ponds located appropriately within the loading area lc(l).
Table U? presents a breakdown of the industrial wastewater volumes
generated on a typical load line at CAAP. The primary mission of this plant
is the loading of heavy munitions. Operations consist of the loading of
eight-inch shells, as well as 500-, 750-, and 1,000-pound bombs. The eight-
142
-------
inch shells are loaded with pure TNT, while the bombs are loaded with tritonal,
a composition consisting of 80 percent TNT and 20 percent flaked aluminum
As discussed, wastewater from these operations is routed through
settling ponds which are periodically cleaned of solids. The discharge from
these ponds averages 57 mg/1 TNT content (l6f ) . Assuming a compromise flow
rate of about 10,000 gpd from each line, a 9.5 pound per day TNT loading
(discharge) is estimated. These wastewaters are discharged to pits with no
apparent outfalls. Laundry wastes, estimated at 15 gallons per minute, con-
tain about 2.7 mg/1 TNT (3r). Assuming 16-hour flow, this amounts to an
additional 0.3 pounds per day TNT discharge. This waste flows into inter-
mittent streams which normally dry up and have no surface outfall (3r).
Overall TNT discharge may therefore be estimated at 9.8 Ib/day. Entrance of
this discharge into more or less consistent water flows must be by ground-
water infiltration.
(2) Iowa Army Ammunition Plant (IAAP) . IAAP loads a variety of
explosives into shells and is currently operating at about 40 percent capa-
city. Wastewaters from these activities are estimated at 90,000 gpd (3s).
These wastewaters are subjected to diatomaceous earth filtration followed
by adsorption on granular carbon in packed columns.
Of the 90,000 gpd discharged at IAAP, roughly 25,000 gpd is pink
water generated from LAP activities (2t). Some TNT (perhaps 10 mg/1) ap-
pears in laundry wastewaters, estimated at 8,000 gpd, which are being dis-
charged into surface streams (15U)« Assuming that carbon column discharges
contain 1 mg/1 TNT and laundry flows are as previously cited, TNT loadings
would be about one pound per day
143
-------
If the RDX content of IAAP wastewaters is similar to those of JAAP
(145 ppm raw and 20 ppm final carbon column), then the discharge of RDX to
the diatomaceous earth filters is approximately 109 Ib/day RDX. Under the
same considerations, roughly 15 Ib/day RDX may be discharged to surface
streams from the granular carbon packed columns. IAAP has measured RDX in
spot tests of Brush Creek, a stream which originates on the installation
and carries the bulk of explosive wastewater. RDX concentrations of 0.1 to
0.15 mg/1 have been measured, but no corresponding flow data was taken (3s).
At IAAP, booster charges are molded from bulk explosives. In 1973,
about 11,000 Ib/day of tetryl were so processed. Only small amounts of
tetryl-containing wastewater, estimated at 1,500 gallons per week (215 gpd) ,
are generated (3s). This wastewater is transported to a sedimentation
pond for which no estimate of tetryl content is available (2c).
(3) Indiana Army Ammunition Plant (InAAP) . LAP operations con-
sist of fabricating cloth bags and loading mortar and cannon propellant in-
to these bags. The bags are manufactured from purchased cloth and made to
various sizes. Paper tubes are also manufactured for the packaging of pro-
pellant bags before inserting them into a box for shipment. Titanium diox-
ide is purchased and blended with a wax compound for gun tube protection
Cif(D).
Cooling towers are used in the loading plant to condition air. A
closed-loop system is used with a minimum of blowdown. Copper piping is
used in the system, and no corrosion inhibitors or fungicides are required
No appreciable amount of industrial wstewater is generated from
these LAP operations (lf(l)).
144
-------
00 Joliet Army Ammunition Plant (JAAP). LAP operations at
JAAF include loading of medium caliber ammunition and ammunition components
(except small arms) in Group 3 and Group 4 Areas. At the time of the 1973
USAEHA report (lg(3)) the LAP Area operated on a two shift/day, five-day work
week. Roughly .015 mgd of TNT-containing washwater is reported to be gen-
erated in Group 4 Area each day, all of which receives treatment (lg(3))«
The 1974 USAMBRDL report (20 indicates that JAAP currently has
only one LAP line in operation where Composition B is being loaded into 105
mm shells at a rate of 200,000 shells per month. Explosives wastewaters
amount to 6,200 gpd (note that this is less than one half the figure cited
above). These wastewaters are collected in a catch basin, filtered through
diatomaceous earth and then through two granulated charcoal columns prior
to discharge into surface drainage (2c) A recent USAEHA survey (lg(3))
of JAAP included extensive testing of these wastewaters. RDX content was
reduced from a mean value of 145 ppm in catch basin water to 20 ppm in final
carbon column effluent. At a flow of 6,200 gpd this corresponds to a raw
waste discharge of 7.5 Ib/day RDX and a treated waste discharge of approxi-
mately one Ib/day RDX.
(5) Kansas Army Ammunition Plant (KAAP). Explosives, primarily
formulations of TNT and RDX, are loaded into ordnance items in melt-pour
buildings in Areas 900 (81 mm load line), 1,000 (105 mm load line), and
1,100 (CBU line). Steam is used to melt the explosive and for cleaning
forms, trays, and other equipment used in melt-pour operations. Explosives-
bearing watewaters flow or are trucked to evaporative ponds. The residual
sludge from these ponds is either burned or buried. There is no available
data to indicate the extent of RDX intrusion into groundwaters as a result
of ponding procedures. Occasionally, through leaks in pond walls or over-
145
-------
flow in heavy rain, some explosives are introduced into surface streams
(2c). Eventually the treatment system at each of these areas will consist
of sumps follows by anthracite filters. A portion of the waste will then
be recirculated and the remainder treated by diatomaceous earth filter fol-
lowed by a carbon column. This type of recirculation system is currently
being developed in each of these areas (lh(3)).
Detonators for 105 mm howitzer shells are also manufactured at
KAAP. The detonators are loaded with lead azide, lead styphnate, and RDX.
The detonator mixture is blended in this area, and the associated wastes
from floor wash downs and from a scrubber system are collected in sumps.
These wastes are batch treated in a series of reactions to deactivate the
explosives present. Sodium nitrite and acetic acid are used to deactivate
the lead azide. Caustic soda (NaOH) is added to the holding tank at a later
time to assure the killing of lead styphnate. Caustic soda is also used to
deactivate the RDX. In addition, caustic soda is spread on areas adjoining
the sumps and holding vats to eliminate explosives contamination. In the
front line, where the explosive mixture is loaded into the primer cup, ex-
plosive dust is drawn from the machine area and passed through glass jugs
filled with water. These solutions are also "killed" prior to disposal.
After deactivation, water from the sumps drains into ditches and flows to
holding ponds. Sludges from the sumps are collected periodically and taken
to the burning ground for disposal. The approximate daily flow is 2,500
gallons (In(3)).
(6) Lone Star Army Ammunition Plant (LSAAP). Explosive-contam-
inated pink water generated in Area 0 (Melt-Four Line; intermittent flow)
is discharged directly to the Red Water Lakes. This lagoon system acts as
a means of wastewater reduction. Composition-B is the primary raw material
••*• -
146
-------
used in Area 0, and the wastes discharged from this area include raw sewage
and storm-water runoff and may contain 1103, TOC, color, TNT, and extreme pH
(not specified). Pink water generated at Areas C (Melt-Pour; intermittent
flow), E (Melt-Pour; intermittent flow), and G (Melt-Pour; continuous flow)
is passed through a bed of granular anthracite coal to remove suspended
material and reused on a batch basis (lk(2), (l5v)). Composition-B is the
primary raw material in Area C, and thewastewaters from this Area include
raw sewage and storm-water runoff and may contain N(>3, TOC, color, TNT, and
extreme pH (not specified). TNT and Composition-B are the raw materials
used in Area E. Wastes from this Area include storm-water runoff and raw
sewage and may contain NC>3, TOC, color, TNT, and extreme pH (not specified).
Wastewater sources and character for Area G are similar to those from Area
E except that octyl is used as one of the raw materials (lk(2)).
An estimated 20,000 gpd of pink water is generated in Areas C, E,
and G. When TNT concentrations in this wastewater become excessive (about
50 mg/1), this water is removed from recycle and trucked to holding ponds.
Occasionally these ponds flood due to heavy rains, and diluted contents
will flow to an intermittent-stream (lk(l)). It should be noted that this
pink water flow is also likely to contain RDX and octol.
Lead azide, an initiating explosive, is loaded at Areas P (Load
Line; intermittent flow) and Q (Load Line; continuous flow) using a basi-
cally dry operation. Wastewaters generated in this area include treated in-
dustrial sewage, raw sewage, and storm-water runoff, and are reported to
contain no pollutants (lk(2)). Due to the sensitive nature of lead azide,
any waste material must be desensitized. Wasted lead azide is slurried in
stainless steel vats and batch destruction *of the compound is achieved by
the addition of cerric ammonium nitrate. The supernatant from the vats is
147
-------
discharged to an evaporation pond where lead is precipitated as an oxide.
Following heavy rainfall, overflow from the ponds in Areas P and Q may
reach surface waters (lk(2)).
Black powder is loaded in a dry process in Area R (Dry Load; inter-
mittent flow). The only liquid wastes from this area are raw sewage and
stormwater runoff which are reported to contain no pollutants. No process
(industrial) wastewater is generated. Spilled black powder is cleaned up
by a dry method and presently disposed of by dumping into natural surface
waters. The black powder used has the composition: 75 percent potassium
nitrate, 15 percent charcoal, and 10 percent sulfur. Roughly 50 pounds of
black powder are dumped per week. An MCA project, FY 78, will provide an
incinerator for proper destruction of this waste (lk(2)).
(7) Longhorn Army Ammunition Plant (LHAAP). In the M120 Area
at LHAAP, the mixing, processing, and loading of propellants for rocket mo-
tors are conducted. The other areas are primarily assembly areas and gen-
erate little waste. Liquid wastes from all areas flow through sumps and
into surface water. Waste propellants settled out in the sumps are pumped
periodically into trucks and hauled to the evaporation pond at the explosive
burning grounds. These solids consist primarily of polysulfide polymers,
aluminum powder, ammonium perchlorate, and black powder. The ammonium per-
chlorate used as an oxidizer in the rocket propellant is water soluble.
Ammonium perchlorate transport containers are washed at Building 17-D. The
waste-containing wash water is stored in a 35,000 gallon storage tank and
is released to surface drainage at such a time when the flow is enough to
give adequate dilution (lj(2)).
No MCA or modernization effort related to water pollution abatement
is known to be scheduled. Although BOD, COD, manganese, cyanide, nitrate,
148
-------
phosphate, iron, and cadmium may exceed APSA boundary guidelines, biological
indicators of water quality indicate that no waste materials of significant
toxicity to aquatic life are being discharged by LHAAP (lj(2)).
(8) Louisiana Army Ammunition Plant (LAAP). Full capacity
shell-loading operations at LAAP generate approximately 138,000 gpd waste-
water with a TNT content of about 80 mg/1. This water is trucked to leach-
ing ponds on the plant grounds (2b). Some TNT was noted in surface runoff,
probably due to spills (l
-------
figure of 50,000 gallons per 90 days for the effluent from the shell wash-
out facility and presuming this flow to be as concentrated with RDX as
water from the JAAP catch basin (1^5 ppm), about 60 lb/3 month (.? Ib/day)
RDX is discharged from this operation.
Using data from the later USAMHRDL report (2c) and assuming:
o One ppm TNT in all but the shell washout wastewater — where
overall discharge is .k mgd and shell-washout discharge is 555 gpd;
o kQ ppm TNT in the shell -washout water;
o 2 + .7 = 2.7 Ib/day RDX discharge;
then the overall TNT discharge from MAAP is roughly 3-5 Ib/day and the
overall RDX discharge is roughly 2.7 Ib/day.
(10) Ravenna Army Ammunition Plant (RaAAP). RaAAP no longer
engages in LAP operations, and historical data were not available.
(ll) NAD Crane (l5ae). Located in Indiana, NAD Crane is a
Navy LAP plant for explosives only. No propellants are loaded here. Ex-
plosives are loaded by melt-cast and press-load processes. As is the
case at typical LAP facilities, waste water (pink water) from the wash-
ing of equipment and buildings flows through ditches to outside concrete
sumps . At Crane , the overflow from the sumps , goes to the natural water-
shed, rather than lagoons. The sludge from the sumps is removed periodically
and taken to the burning ground for disposal by incineration.
The explosives loaded at Crane include the following: RDX, HMX,
TNT, RaJKL, NENO , and ammonium pi crate.
Active industrial discharges are tabulated below
Cast Loading Area 'A' - Up to three points discharging objectionable
quantities of contaminants. Primarily TNT, RDX
related, from rinses and washdowns. Immediate
ground area heavily saturated with explosive
contaminants .
150
-------
Cast Loading of Area 'B' - Up to three or more points discharging
objectionable, quantities of contaminants.
Primarily TNT, RDX related, from rinses and
washdowns. Immediate ground area heavily
saturated with explosive contaminants.
Bldg. 10l» - Up to four points discharging objectionable
quantities of contaminants. Primarily RDX
and ammonium picrate process and rinse water,
and water from phosphate coating operations.
Bldgs 107 & 107 - One point discharging objectionable effluent,
highly caustic, containing undesirable amounts
of oil, scum, and metals.
Bldg. lQ8k - One point discharging objectionable effluent
from plating operations: flow from rinse tanks,
spills, and washdowns. Primarily oil, scum, and
metals.
Rockeye Loading - Two points discharging effluent containing high
concentrations of contaminants, primarily TNT
and RDX related, from rinses and washdowns.
Immediate ground area heavily saturated with
explosive contaminants.
A large percentage of the airborne and waterborne explosive
wastes generated from the bomb loading areas of Crane are discharged
directly to the surrounding ground and nearby streams. High concentrations
of explosives contaminants are retained in the soil as saturated surface
water percolates through the various layers to the ground water table.
During dry weather when all polluted effluent disappears below the stream
.bed, concentrations ranging from the limits of detection up to several
milligrams per liter are found in nearby groundwater samples. During
normal and wet seasons, contaminated waste water flows farther down the
watershed, and dilution helps to lower the explosive concentrations
significantly. Further natural aeration and stream actions generally lower
explosive concentrations below detectable limits at the point where the
stream leaves the base. Thus present deficiencies in treatment of in-
dustrial effluents at Crane are not greatly affecting the surrounding
areas; but there is occurring a deterioration of the local environment,
151
-------
due to the unacceptable practice of using Boggs Reservoir, the natural
streams, and surrounding land as a big wastewater treatment plant (lUv).
EXPLOSIVES DISCHARGED DAILY TO THE ENVIRONMENT THRU WASTEWATER
-Lb. per Day-
Station
TBCfc
S005
TOlU
B015
B016
BOU2
BOU9
TNT
U.8
12.2
3.7
2.9
.5
1.7
-
RDX
—
U.8
1.0
.5
1.3
HMX
.6
2.2
.5
.1
.1
D
-
•
IDA
9.6
7.3
Loc.
3 inch
it
A Loading
B Loading
B
B
10U
During the period Jan-Aug 1972, fifty points were monitored
during multi-shift operations and high waste water loadings. No explosives
(TNT, TDX, HMX or Ammonium Picrate) were found in detectable amounts in the
waters leaving the military reservation. Only intermittent monitoring has
taken place since 1972.
Three major abatement programs are planned:
o Wet scrubbers for TNT dust,
o Carbon columns for treatment of pink water, and
o Diversion of sump run-off water from the natural watershed to
the sewage treatment plant, through settling basins.
(12) NAD Hawthorne (l5ef ). This is another Navy LAP plant
which loads explosives only, by the melt-pour process. The explosives
include: TNT and RDX, with formulations including A£.
The volume of industrial process water ranges from 1 to 2 mil-
lion gpd. The washings of buildings and equipment flow through ditches
152
-------
to outside sumps, and thence to pits for evaporation and percolation.
Ifalike most other LAP plants, Hawthorne is located in an arid area (Nevada)
of high evaporation (80"/year), and disposal by evaporation is quite prac-
tical. The sludge is disposed of by burning.
The potable water supply is from reservoirs in the mountains
above the reservation. Industrial waste water goes to some thirty pits
for disposal. Essentially no monitoring has been conducted at Hawthorne
of process waters.
NAD Hawthorne has been designated as the site of one of the two
principal Navy demilitarization facilities, which is currently under
development.
(13) NAD McAlester (l5iatg). Like Crane and Hawthorne, NAD
McAlester is involved only in the loading of explosives, including TNT,
RDX, HMX, NH^NO , and ingredients such as A£, CaC-tp, and polymers. Both
melt-pour and press-load processes are used. The waste waters from build-
ings and equipment flow through ditches to sumps, with overflow to evapor-
ative lagoons. McAlester is located in Oklahoma, and the high evaporation
rates make this method of disposal quite feasible.
There is no overflow from the evaporative lagoons. Weekly
monitoring of six farm wells on the military installation and Brown Lake,
as well as tap water result in no detectable levels of TNT, although the
influent to the lagoons varies from 30-80 ppm TNT. The level of TNT in
the lagoons is at 2-3 ppm.
The volume of industrial water in FY 19fU was about 650,000 gpd.
Monitoring of effluent in the depot areas during 1973-7^ gave
the following results
153
-------
Depot Effluents (1973-7*0
Ave.
(ppm)
1*
6
U
9
150
25
15
Min.
(ppm)
0
1
1
3
75
0
5
Max.
(ppm)
6
12
6
12
225
50
1*0
Phosphate
Nitrate
BOD
Diss. Oxy.
TDS
Sulphate
Chloride
Although pink water is currently being treated at some LAP
facilities by carbon columns, the Navy has been developing an "Oxidation
Ditch" for biodegradation of TNT (see Chapter VI). NAD McAlester has been
selected as the site for the installation of the first of these treatment
facilities.
Analyses (ll*w) of Brown Lake, Sewage Effluent and Depot Effluent
in July 1973 gave the following results.
Laboratory No.
Sample
PH
P Alkalinity as
M Alkalinity as
N0_ (Nitrates)
POji; (Phosphates)
BOD
COD
Ammonia Nitrogen
Organic Nitrogen
Total Kjeldahl
Total Suspende
Total Dissolve
Total Solids
Total Volatile
CaCO-
CaCCK
3
I
i
I
Fitrogen
Solids
Solids
lolids
SU37
Brown Lake
7.0
None
21.0 PPM
0.89 PPM
0.10 PPM
0.90 PPM
3.37 PPM
0.08 PPM
1.10 PPM
1.18 PPM
10.50 PPM
158.00 PPM
168.50 PPM
1*8.50 PPM
8U38
Sewage Effluent
7.1
None
36.0 PPM
16.83 PPM
7.00 PPM
1*.80 PPM
3.37 PPM
0.15 PPM
0.90 PPM
1.05 PPM
12.00 PPM
233.00 PPM
21*5.00 PPM
90.00 PPM
81*39
Depot Effluent*
6.9
None
33.0 PPM
1.33 PPM
0.80 PPM
1.
5-
0.03
.50 PPM
.03 PPM
PPM
0.90 PPM
0.98 PPM
17.50 PPM
161.00 PPM
178.50 PPM
56.50 PPM
*Bull Creek
154
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NWS Yorktovm (15ah). The fourth and last Navy LAP
facility is at Yorktovm, Va. Explosives, loaded by the melt-cast process
include TNT, RDX and HMX. In addition to the melt-cast process, PBX formu-
lations (RDX/HMX plus polymers) are filled using propellant-type blenders.
The industrial water volume is around 1*5,000 gal (max) per 8-hour
shift for all of the three plant sites. Wash water from buildings goes to
the usual concrete sumps, with overflow via storm drains to Lee Pond and,
eventually to the York River. Sludge from the sumps goes to the burning
grounds for disposal.
Well-water is monitored, with no detectable levels of explosives.
Essentially no other monitoring data are available.
Plans are in preparation for installation of five waste water
treatment facilities using carbon columns.
b. Summary of Wastewater Character
Table U8 summarizes the available information on LAP wastewater
character presented above. Note that the data presented is insufficient
to allow cross correlation.
c. Data Limitations
There is insufficient data to indicate the complete magnitude of
discharges at LAP plants. The potential for groundwater infiltration of
explosive and propellant wastes from evaporative ponds has not been fully
investigated at every plant, and may be of some concern in some instances,
but not in all.
155
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TABLE 1*7 i j
INDUSTRIAL WASTEWATER LOAD
TYPICAL SHELL/BOMB LOAD LINE 8
CAAP (
Source Volume
(gpd)
Boiler Plant 525
Rod & Pellet Manufacturing 1,000
Explosive Pour Building 3,500
Screen Building 1,000
Cooling, X-ray, Storage 300
Total 6,325
156
-------
TABLE ^8
WASTEWATERS GENERATED IN LAP OPERATIONS
AAP 1
CAAP
IAAP
Activities
Load 8-inch shells
Load 500-,750-,
and 1,000-pound
bombs
Laundry
Overall
Shell loading
Laundry
Mold booster
charges from bulk
explosives
Overall
9
Raw Materials
TNT
Tritonal (80% TNT
and 20% flaked Al)
*
flow
(gpd)
. 1
20.0001
14,500
34,500
90,000
(25,000)
8,000
215
98,000
Pollutants
7
57 mg/1 TNT I
}
2.7 mg/1 TNT
Pink water
1 mg/1 TNT3
145 mg/1 RDX2
20 mg/1 RDX3
10 mg/1 TNT
Tetryl
Discharge
Load
(Ib/day)
«
~ 9.5(TNT)
/^.3(TNT)
9. 8 (TNT)
.75 (TNT) 3
109 (RDX)2
15 (RDX)3 .
•
.67 (TNT) 2
1.42 (TNT)
109 (RDX) 2
15 (RDX)3
Comments
/Disposal in evapor
ration ponds
J
Disposal In dry
streams
Wastes subjected
to diatomaceous
earth filtration
followed by adsorpj-
tion on granular
carbon columns
Discharged to
surface streams
-
01
-q
-------
TABLE U8
WASTEWATERS GENERATED IN LAP OPERATIONS
(continued)
AAP
InAAP
JAAP
KAAP
*.
1
Activities
Fabricate cloth
bags and paper
tubes and load
propel lants into
these containers
for 'shipment
Loading of medium
caliber ammunitioi
and ammunition
components
Load explosives,
primarily formu-
lations of TNT ant
RDX, into ordnance
items
Detonators for
105 mm howitzer
shells
Raw Materials
N.A.4
Composition-B
being loaded into
105 mm shells at
a rate of 200,000
shells per month
TNT, RDX
Lead azide, lead
styphnate, RDX
. . i
Flow
(gpd)
N.A.4
6,200
N.A. 4
N.A.4
Pollutants
N.A.4
TNT
145 mg/1 RDX2
20 mg/1 RDX3
TNT, RDX
N.A.4
i
Discharge
Load
(Ib/day)
N.A.4
7.5(RDX)Z
1.0(RDX)3
N.A.4
Comments
Filtered through
diatomaceous earth
and then through
two granulated
charcoal
Currently waste-
waters are dispose!:
of by trucking thet
to evaporative
ponds
NaNO-j, acetic acidj
and NaOH used to
deactivate the leajc
azide
01
00
-------
TABLE ll-B
WASTEWATERS GENERATED IN LAP OPERATIONS
(continued)
AAP
LSAAP
LHAAP
Activities
Melt-pour (Area 0)
Melt-pour (Area C)
Melt-pour (Area E)
Melt-pour (Area G)
Load Line (Area P)
Load Line (Area Q)
Black-powder load
Mixing, processing
and loading of pro
pellants for rocke
projectiles
I •
Raw Materials
Composition-B
Composition-B
•*
TNT and Composi- /
t ion-B >
Octyl,TNT, and •*
Composition-B
Lead azide
Lead azide
Black powder
N.A.*
t
Flow
(gpd)
N.A.4'5
20.0005
N.A.4'6
18 A 4'6
N.A.
None except
raw sewage
and storm-
water runof
N.A. 4
Pollutants
Pink Water
N03 , TOC , color , TNT ,
pH
» •
Pink Water
l}03 , TOC , color , TNT ,
PH
N.A.4
N.A.4
N.A.4
BOD,COD,Mn,CN-,N03
PO ,Fe,Cd,polysul-
fide polymers,
aluminum powder,
black powder, and
ammonium perchlor-
ate
Discharge
. Load
(Ib/day)
N.A.4
N.A.4
N.A.4 "I
N.A.4 \
N.A.4
N.A.*
i
Comments
Discharged to
lagoon system
Recycled
1
Batch destruction
by use of cerric
ammonium nitrate j
Spilled powder is
dumped into surfaci
waters
i
i
Ammonium perchlor-
ate goes to surface
water. All solids
go to evaporative
ponds and are even-
tually incinerated
Remaining wastes
go to surface wate:
01
CO
-------
TABLE -kQ
WASTEWATERS GENERATED IN LAP OPERATIONS
(continued)
AAP
LAAP
MAAP
RaAAP
Activities
Shell-loading
N.A.4
Shell washout
Overall
N.A.4
Raw Materials
N.A.4
N.A.4
/.
N.A.4
N.A.4
N.A.4
Flow
(gpd)
138,000
400,000
555
400,000
N.A.4
Pollutants
80 mg/1 TNT
\5 mg/1 RDX
1.0 mg/1 TNT
145 mg/1 RDX2
40 rag/1 TNT2
•
N.A.4
•
1
Discharge
Load
(Ib/day)
92 (TNT)
2.0 (RDX)
3.0 (TNT)
'.7 (RDX)
.5 (TNT)
2. 7 (RDX)
3.5(TNT)
N.A.
Comments
Waste is trucked
to leaching ponds
on the plant
grounds
Wastewaters are
discharged to a
drainage canal
which flows to
surface water
i
Oi
O
-------
TABLE U8
(continued)
^Primarily washdown waters
^Before treatment
*After treatment
^N.A. = not available
^Includes raw sewage and storm-water runoff
^Includes treated industrial sewage, raw sewage, and storm-water runoff
161
-------
CHAPTER V
WASTEWATER CHAKACTERIZATIONS
APPENDIX I
DETAILED DATA TABLES
162
-------
TABLE I.A.I
CRDTE ACETIC ANHYDRIDE PRODUCTION. AREA A. HAAP
. , DIRECT DISCHARGE OF COOLING AND PROCESS WASTES TO THE HOLSTON RTVER FROM WTTT.nTwa 7 1.3(21
Parameter
Temperature (°F)
PH
Conductance
Nitrite and Nitrate as
Nitrogen
Kjeldahl Nitrogen as
Nitrogen
Total Filterable
Phosphorus as Phosphon
Acidity as Calcium
Carbonate
Alkalinity as Calcium
Carbonate
Total Solids
Suspended Solids
Dissolved Solids
Chemical Oxygen Demand
Total Organic Carbon
Biological Oxygen
Demand
Sulfates
Phenols
Annf--tn AA-JJ
Minimum
68.0
7.30
163
0.9
< 0.5
< 0.03
s
2.4
75
80
1.0
68
10
4
1.0
16.0
< 0.05
4 n n
Maximum
74.0
8.40
229
1.6
1.1
0.23
4.7
80
165
11.0
164
21
13
3.0
22.0
0.16
Mean
70.8
7.70
187.5
1.2
0.12
0.04
3.86
76.1
122
6.0
116
• 11
6.5
2.0
17.5
0.05
Mean -
Raw Rivei
0.94
44
0.9
43
0.5
2.0**
2.0
Discharge
(Ibs/day)
30.0
1,400
29
1,380
16
64
64
Ibs of discharge *
ton of production
96 x 10~3
t
4,400
92
4,360
50
200
200
Flow = 3.84 mgd; Production - 630,000 pounds acetic anhydride per day
*crude acetic anhydride produced; **no correction for raw rd-ver water
-------
M I
s
TABLE I. A. 2
CRUDE ACETIC ANHYDRIDE PRODUCTION. AREA A. HAAP
DIRECT DISCHARGE OF COOLING AND PROCESS WASTES TO 'THE HOT.STON R VTTO TO AM TmTTTvnro 7 -\f{(9\ — _ — ,
Parameter
Temperature (°F)
pH
Conductance
'Nitrite and Nitrate
as Nitrogen
Kjeldahl Nitrogen as
Nitrogen
Total Filterable
Phosphorus as
Phosphorus
Acidity as Calcium
Carbonate
Alkalinity as Calcium
Carbonate
Total Solids
Suspended Solids
Dissolved Solids
Chemical Oxygen Demand
Total Organic Carbon
Biological Oxygen
Demand
Sulfates
Phenols
Acetic Acid
Flow ='3.55 mgd; Produ(
*crude acetic anhydride
**corrected for Area A
Minimum
69.0
6.70
151
0.5
0.5
0.03
3.0
74
64
3.5
72
< 10
4
< 1.0
15.4
< 0.05
< 2.0
tion - 630, (
! produced
Holston Raw
Maximum
72.0
7.90
260
1.4
2.4
0.67
7.4
85
180
19.5
161.5
18
10
< 1.0
18.9
<0.05
5.1
00 pounds ac
River Water
Mean
70.5
7.34
191
0.93
0.5
0.06
4.6
77.1
126
9.1
117.3
10
5.8
< 1.0
16.8
<0.05
<2.0
etlc anhydrl
Mean -
Raw Rivei
0.02
48
4.0
44.3
1.3
de per day
•
Discharge
(Ibs/day)
0.59
1,400
120
1,310
38.4
Ibs of discharge *
ton of production
o
1.88 x 10-3
1
T
4,600
380
4,160
122
-
-------
OJ'
en!
TABLE I. A. 3
T-«wrrJS£?F:C AHHTOKCDE REFINING AND ACETIC ACID CONCENTRATION. AREA A. HAAP
LIQUID WASTES FROM BUILDINGS 6 AND- 6 A BEFORE ENTERING THE MAIN WASTE STB* AM Id
Parameter
Temperature (°F)
PH
Conductance
Nitrite and Nitrate
as Nitrogen
Kjeldahl Nitrogen as
Nitrogen
Total Filterable
Phosphorus as
Phosphorus
Acidity as Calcium.
Carbonate
Alkalinity as Calcium
Carbonate
Total Solids
Suspended Solids
Dissolved Solids
Chemical Oxygen Demand
Total Organic Carbon
Biological Oxygen
Demand
Sulfates
Phenols
Acetic Acid
Flow =1.15 mgd; Produi
*refined acetic anhydr
**no correction for fii
Minimum
74.0
2.70
156
< 0.5
< 0.5
0.07
2.7
0.0
68
4.0
61.5
10
4
2.0
10.0
<0.05
<2.0
tion = 720, (
de produced
tered raw r:
Maximum
82.0
8.90
3,100
1.4
225
793
625
80
1,695
10.5
213.5
36
27
25.0
127.0
<0.05
3.4
00 refined
ver water
Mean
76.3
7.76
309
1.04
10.5
34.6
82.5
66.3
319
6.7
121.7
17.1
10.5
11.3
31.2
<0.05
1.8
acetic anhyd
Mean -
Raw Rive
10.0
33.9
75,8
243
4.2
47.7
1.2
5.5
11.3**
•
ride per day
1
-
r
0
Discharge
(IbsVday)
> 95.8
325
726
2,330
40
457
11.5
52.7
108
9)
Ibs of discharge *
ton of production
>266 x 10~3
1
902'
2,020
6,460
112
1,270
320
146
300
•
-------
OS
TABLE I. B.I
AMMONIUM NITRATE PRODUCTION. AREA B. HAAP
COOLING WATER FROM AMMONIA NITRATION IN BUILDING 330. ALSO OCCASIONAL RUNOFF FROM NTTKTC AP.Tn STORAGE ANP r>TTMP<; ld(2)
Parameter
Temperature (°F)
PH
Conductance
Ammonia as. Nitrogen
Nitrites and Nitrates
as Nitrogen
Kjeldahl Nitrogen
Acidity
Alkalinity
Total Solids
Suspended Solids
Dissolved Solids
Chemical Oxygen Demand
Total Organic Carbon
Biological Oxygen
Demand
Flow =1.85 mgd; Produc
*NH4N03/HN03 solution I
\
Minimum
6.4
6.6
340
0.62
1.3
0.8
1.0
69
313
4.8
307
21
7
<5
tion = 400, C
roduced
.,
i
\
S
Maximum
79
8.6
740
2.46
7.0
5.8
2.3
80
451
18.0
496
49
40
12
00 pounds NF
Mean
71.9
7.83
540
1.63
2.66
2.40
1.83
73.4
406.4
9.12
397.2
37
16.0
5
4N03/HN03 so
Mean Raw
60
7.43
284
1.02
0.8
1.28
3.4
84.6
207.5
10.2
197
25
13
4
lution/day
Corrected
Mean
0.61
1.86
1.12
198.9
200.2
12
3
1
'
•
Discharge
(Ibs/day)
9.40
28.7
17.2
3,060
3,080
185
46.2
15.4
•
h'
Ibs of discharge
ton of production*
47.0 x ID-3
144 \
~
86
15,300
15,400
924
232
77.0
-------
TABLE I.C.I
AMMONIA RECOVERY. PRODUCT CONDENSER COOLING WATER (1.480 mgd), AMMONIA COLUMN BOTTOMS (0.032 mgd), PUMP SEAL WATER
BUILDING A-l. AREA B. HAAP Id (2)
Parameter
Temperature (°F)
pH
Conductance
Ammonia as Nitrogen
Nitrites and Nitrates
as Nitrogen
•Kjeldahl Nitrogen as
Nitrogen
Orthophosphate as
Phosphorus *
Acidity as Calcium
Carbonate
Alkalinity as Calcium
Carbonate
Total Solids
Suspended Solids
Dissolved Solids
Chemical Oxygen Demand
Total Organic Carbon
Flow = 1.51 mgd; Produi
Minimum
50
7.7
540
1.05
0.9
1.7
0.03
0.5
75
444
5.0
437
53
10
ition = 1200i
*anhydrous NIte produced
Maximum
72
8.2
790
1.98
1.4
2.5
0.05
1.7
80
530
7.2
525
57
12
3 Ib/day anh;
Mean
60
7.95
686
1.34
1.23
1.93
0.03
1.1
77.5
487
6.1
481
55
11
rdrous NH3
Mean Raw
60
7.43
284
Corrected
Mean
1.02 0.32
0.8
1.28
0.03
3.4
84.6
207.5
10.2
197
25
13
0.43
0.65
279.5
284
30
.
Discharge
(Ibs/day)
f
4.02
5.41
8.18
3,520
3,570
377
•
Ibs of discharge*
ton of production
.
.770
.090
1.36
586
596
62.8
-------
TABLE I.C.2
NITRATION (HMX PRODUCTION). .CATCH BASIN
BUILDING D-6 PROCESS WATER. AREA B. HAAP Id(2)
Parameter
Influent
Chemical Oxygen Demand
Total Carbon
Organic Carbon
Inorganic Carbon
Nitrates
Effluent
Chemical Oxygen Demand
Total Carbon
Organic Carbon
Inorganic Carbon
Nitrates
Flow - 18,800 gpd; Pro<
*HMX produced
**not corrected for r<
V
Minimum
uction - 5,i
iw river wati
Maximum
!70 pounds HI
•r concentra
Mean
167
35
22
13
<5.
98
33
19
14
<5
DC/day
ions
Mean Raw
25
0.8
25
0.8
Corrected
Mean
142
35***
22***
13***
<4.2
73
33***
19***
14***
<4.2
•
Discharge
(Ibs/day)
22.2
5.48
3.44
2.04
<0.658
11.4
5.17
2.98
2.19
< 0.658
Ibs of discharge
ton bf production
8.42
2;08
1.31
2.68
.250
4.32
1.96
1.13
.832
.250
•
-------
TABLE I.C.3
NITRATION (RDX PRODUCTION). CATCH BASIN
BUILDING D-6 PROCESS WATER. AREA A. HAAP Id(2)
Parameter
Influent
Biological Oxygen
Demand
Chemical Oxygen Demand
RDX
HMX
Acetic Acid. (100%)
Effluent
Biological Oxygen
Demand
Chemical Oxygen Demand
RDX
HMX
Acetic Acid (100%)
Flow = 50,000 gpd; Pro<
Minimum
Luction = 11
*RDX produced
**not corrected for rai
j river wate
Maximum
!,300 pounds
• cone en tr at
Mean
979
1,177
2.1
0.9
160
878
0.96
0.4
160
RDX/day
.ons
Mean Raw
4
25
4
25
Corrected
Mean
975
1,152
2.1*"
0.9**
160**
874
0.96*
0.4*"
160** .
Discharge
(Ibs/day)
406
480
0.875**
0.35**
66.6**
364
* 0.40**
0.167**
66.7**
Ibs of discharge
ton of production*
.
7.24
8.54
0.015
0.006
1.19
6.48
.007
.003
1.19
M I
o»
to
-------
TABLE I.C.4**
RECRYSTALLIZATION (RDX PRODUCTION). CATCH BASIN
BUILDING G-2 PROCESS WATER. AREA B. HAAP Id(2)
Parameter
Catch Basin Influent
Biological Oxygen
Demand
Chemical Oxygen Demand
Organic Carbon
Inorganic Carbon
Cyclohexanone
Catch Basin Effluent
Biological Oxygen
Demand
Chemical Oxygen Demand
Organic Carbon
Inorganic Carbon
Cyclohexanone
Flow = .0274; Productic
*RDX produced
**no correction for rat
I
Minimum
n - 83,250 j
water concc
,
Maximum
ounds RDX/df
ntrations
Mean
y
•
Mean Raw
896
463
234
22
215
339
403
217
23
206
•
Corrected
Mean
Discharge
(Ibs/day)
204
106
53.4
5.02
49.1
77.4
92.0
49.5
5.25
47.0
Ibs of discharge
ton of production"
4.90
2.54
1.28
0.120
1.08
1.86
2.20
1.19
0.126
1.13
•
i
-------
TABLE I.C.5**
RECRYSTALLIZATION (RDX PRODUCTION). CATCH BASIN
BUILDING G-6 PROCESS WATER. AREA B. HAAP Id(2)
Parameter
Catch Basin Influent
Biological Oxygen
Demand
Chemical Oxygen Demand
Organic Carbon
Inorganic Carbon
HMX
RDX
Acetone
Cyclohexanone
Toluene
Butanol
PH
Catch Basin Effluent
Biological Oxygen
Demand
Chemical Oxygen Demand
Organic Carbon
Inorganic Carbon
HMX
RDX
Acetone
Cyclohexanone
Toluene
Butanol
PH
Flow = .136 mgd; Produc
*many products
**no correction for rav
Minimum
^
tion = not c
water
Maximum
\
\
etermined
Mean
Mean Raw
332
1,240
264
9.7
10.6
5.0
81
587
2.7
81
6.1
323
950
8.0
4.4
5.0
63
220
0.2
63
6.1
Corrected
Mean
•
Discharge
(Ibs/day)
376
1,404
299
11.0
12.0
5.66
91.8
665
3.06
91.8
365
1,080
9.06
4.98
5.66
71.4
• 249
0.226
71.4
Ibs of discharge *
!bs of production
|
i
i
•
-------
TABLE I.C.6*
GRINDING AND DEWATERING (RDX PRODUCTION). CATCH BASIN
BUILDING H-2. AREA B. HAAP Id (2)
Parameter
Catch Basin Influent
Biological Oxygen
Demand
Chemical Oxygen Demand
RDX
HMX
Cyclohexanone
Acetic Acid
Catch Basin Effluent
Biological Oxygen
Demand
Chemical Oxygen Demand
RDX
HMX
Cyclohexanone
Acetic Acid
Flow = .0384 mgd; Prodi
*RDX produced
**no correction for ra\
t
\
Minimum
iction =83,!
j water conci
I
Maximum
50 pounds /d<
ntrations
Mean
2,771
4,292
49
1.5
142
658
33
0.7
ly RDX
Mean Raw
Corrected
Mean
Discharge
(Ibs/day)
886
1,370
15.7
0.480
45.4
210
10.6
0.224
Ibs of discharge*
ton of production
•
21.2
32.8
0.376
0.011
1.09
5.04
254
5.38
• ~» • ,
1 «'^,
to
-------
TABLE I.C.7*
INCORPORATION (COMPOSITON-B PRODUCTION). CATCH BASIN
Parameter
Catch Basin Influent
Chemical Oxygen Demand
RDX
TNT
HMX
Organic Carbon
Inorganic Carbon
Total Carbon
Caitch Basin Effluent
Chemical Oxygen Demand
RDX
TNT
HMX
Organic Carbon
Inorganic Carbon
Total Carbon
.
Flow - .11926 mgd; Pro<
*no correction for raw
*Composition-B producec
Minimum
Maximum
i
i
uction » 55(
water concei
>,000 Ib/day
tr at ions
Mean
Mean Raw
i
384
3.1
6.3
<0.l
9.5
9. '3
17.2
2.7
3.2
<0.06
(275 ton/day
) Compositic
Corrected
Mean
n-B
•
Discharge
(Ibs/day)
381
3.10
6.29
<1.00
9.43
9.24
17.1
2.68
3.17
< 0.060
Ibs of discharge
ton of production ^
1.38
0.011
0.023
4:0.004
0.034
0.034
0.062
0.010
0.012
<0.0003
-3
Cd
-------
TABLE I.C.8*
INCORPORATION: BED DRYING (COMPOSITION-B PRODUCTION)
BUILDING 1-3. AREA B. HAAP ld(2)
Chemical Oxygen Demand
Total Organic Carbon
Nitrites and Nitrates as Nitrogen
Total Kjeldahl Nitrogen as Nitrogen
RDX-insoluble
RDX-soluble
HMX-insoluble
HMX-soluble
Process Catch
Basin No. 1
40 ppm
13
5.5
2.5
0
12.5
0
5.1
Process Catch
Basin No. 2
32 ppm
8.0
4.8
2.3
0
8.5
0
1.0
Process Catch
Basin No. 3
32 ppm
11
4.9
2.0
14.0
18.3
11.2
4.2
Scrubber Effluent
Catch Basin
18 ppm
5.0
2.1
1.7
0
0
0
0
Flow = 0.05 mgd overall; Production = 550,000 Ib/day (275 ton/day) Composition-B produced.
*No correction for raw water concentrations.
-------
TABLE I.C.9*
INCORPORATION: KETTLE DRYING (COMPOSITION-B PRODUCTION)
BUILDINGS L-5 AND M-5. AREA B. HAAP Id(2)
Scrubber Effluent
Catch Basin (L-5)
Main Process
Catch Basin (M-5)
en
Chemical Oxygen Demand
Total .Organic Carbon
(Nitrites and Nitrates as Nitrogen
Total Kjeldahl Nitrogen as Nitrogen
RDX-insoluble
iX-soluble
[-insoluble
[-soluble
25
7.0
1.4
1.4
0
0
0
0
37
10
1.7
1.9
2.8
Flow = 0.0529 mgd overall; Production = 550,000 Ib/day (275 ton/day) Composition-B produced.
*No correction for raw water concentrations.
-------
TABLE I.C.10*
RECEIPT OF TNT (COMPOSITION-B PRODUCTION)
RTTTT.nTW: Tf_l ARWA R WAAP ld(2)
Parameter
Catch Basin No. 1 -
Floor Wash Only
(.00288 mgd)
Chemical Oxygen Demand
Total Organic Carbon
Nitrites and Nitrates
as Nitrogen
Total Kjeldahl Nitroger
as Nitrogen
Soluble RDX
Soluble HMX
TNT
Catch Basin No. 2 -
Floor Wash & Scrubber
Water (.0144 mgd)
Chemical Oxygen Demand
Total Organic Carbon
Nitrites and Nitrates
as Nitrogen
Total Kjeldahl Nitroger
as Nitrogen
Soluble RDX
Soluble HMX
TNT
Flow - .01728 mgd (.002
Minimum
Maximum
i
88 mgd+ .01
44 mgd); Pro
^corrected for raw water concentrations
**TNT produced (process
i
ed)
Mean
31
17
1.9
1.8
36.4
86
40
2.5
3.0
2.8
0
duction = 73
Mean Raw
25
13
0.8
1.28
36.4
25
13
0.8
1.28
.000 pounds
Corrected
^ Mean
6
4
1.1
1.5
0.0
61
27
1.7
1.7 ;
2.8
0
ENT/day
Discharge
(Ibs/day)
.
0.864
0.576
0.158
0.216
5.24
8.78
3.89
0.245
0.245
0.403
•
Ibs of discharge**
ton of production
(x 103)
23.6
15.8
4.32
5.92
144
240
107
6.72
6.72
11.04
-------
TABLE I.C.11
PACKAGING AND LOADING OF EXPLOSIVES (COMPOSITION-B PRODUCTION)
BUILDING N-6. AREA B. HAAP Id(2)
Parameter
Expected Concentration Range
PH
Chemical Oxygen Demand
total Organic Carbon
Biological Oxygen Demand
Nitrites and Nitrates as Nitrogen
Cotal Kjeldahl Nitrogen as Nitrogen
7.0- 7.5
15 - 636 ppm
1.0- 40 ppm
15 -2800 ppm
1.0- 6.0 ppm
•^
1.0- 3.0 ppm
Flow » 74,880 gpd; Production = 550,000 Ib/day (275 ton/day) Composition-B
177
-------
TABLE I.D.I
ACETIC ACID CONCENTRATION. AREA A. HAAP. 42" OUTFALL FROM BUILDING 2
MAIN "ASTF STREAM ld(2)
M~'i
00
Parameter
Temperature (°F)
PH
Conductance
N02 + N03/N
Kjeldahl Nitrogen as
Nitrogen
Total Filterable
Phosphorus as Phosphor
Acidity as Calcium
Carbonate
Alkalinity as Calcium
Carbonate
Total Solids
Suspended Solids
Dissolved Solids
Chemical Oxygen Demand
Total Organic Carbon
Biological Oxygen
Demand
Sulfates
Phenols
Acetic Acid
Minimum
78.0
6.80
160
0.5
0.5
0.03
is
2.0
66
112
3.0
107
79
30
>53
15.0
<0.05
<. 2.0
Maximum
86.0
7.80
228
3.2
8.4
15.9
8.3
76
156
21.0
141
128
50
>79
17.1
<0.05
5.2
Mean
82.1
7.33
192
1.60
0.8
0.72
5.9
68.8
132
7 Jo
124
103
35.0
>67
16.0
<0.05
< 2.0
Mean
Raw
Area A
0.32
0.75
0.68
1.1
54
2.5
51.0
89.0
29.0
> 67**
0.5
•
Corrected
Mean
Discharge
(Ibs/day)
41
96
87
140
6,900
320
6,520
11,400
3,710
>8,566**
•
64
Ibs of discharge *
ton of production
50 x 10~3
120
108
176
8,600
400
8,160
14,200
4,640
10,700
80
Flow = 15.35 mgd; Production = 1,600,000 Ib 99+
*99+ acetic acid produced; ** no correction for
acetic acid per day.
raw river water concentrations.
-------
TABLE I.D.2
ACETIC ACID CONCENTRATION. AREA A. &AAP. 15" OUTFALL FROM BUILDING 2 TO MAIN WASTE STREAM Id(2)
Parameter
Temperature (°F)
PH
Conductance
Nitrites and Nitrates
as Nitrogen-
Kjeldahl Nitrogen as
Nitrogen
Total Filterable
Phosphorus as Phosphort
Acidity as Calcium
Carbonate
Alkalinity as Calcium
Carbonate
Total Solids
Suspended Solids
Dissolved Solids
Chemical Oxygen Demand
Total Organic Carbon
Biological Oxygen
Demand
Sulfates
Phenols
AroHn AMd
Minimum
43.0
6.50
154
0.9
0.5
0.03
IS
2.3
71
90
1.5
87.5
10
4
< 1.0
12.5
< 0.05
< 2.0
Maximum
66.0
8.40
225
1.6
1.2
0.07
7.4
91
191
17.0
189.5
25
11
2.0
16.8
0.13
l&U)
Mean
61.5
7.75
186
1.29
0.5
0.04
3.69
76.0
137
5.4
131.4
. 16
6.4
1.0
15.3
<0.05
1 a^ —
Mean
Raw
River Water
0.01
;59
0.3
58.4
2.0
0.4
1.0**
> 0.0
Corrected
Mean
Discharge
(Ibs/day)
0.03
180
0.90
180
6.0
1.2
3.0
9-=*
Ibs of discharge *
ton of production
0.04 x 10~3
220
1.12
220
7.4
1.48
3.8
. — *-* .
Flow = .36 mgd; Production = 1,600,000 Ib 99+ acetic acid per day.
*99+ acetic acid produced; **no correction for raw river water concentrations.
-------
TABLE I.D.3
PRIMARY DISTILLATION. AREA B. HAAP. PRINCIPAL EFFLUENT FROM BUILDING B-ll Id(2)
Parameter
Temperature (°F)
PH
Conductance
Ammonia as Nitrogen
Nitrites and Nitrates
as Nitrogen
Kjeldahl Nitrogen as
Nitrogen
Orthophosphate as
Acidity as Calcium
Carbonate
Alkalinity as Calcium
Carbonate
Total Solids
i Suspended Solids
Dissolved Solids
Chemical Oxygen Demand
Total Organic Carbon
l
Flow = 11.18 mgd; Prod
*60% acetic acid produi
, - -*
\
Minimum
65
6.8
340
0.73
0.7
0.9
< 0.03
0.8
74
230
Maximum
72
8.2
675
1.98
5.6
3.5
0.07
2.0
91
411
2.5 20.0
223
20
6
ic t ion = 1,5
ed
. — *.-'.-;
397
56
19
)6,667 poundi
-
Mean
68.9
7.68
461.1
1.24
1.72
1.73
<0.03
1.6
79
319
11.7
307
32
10
i 60 percent
Mean Raw
60
7.43
284
1.02
0.8
1.28
<,0.03
3.4
84.6
207.5
10.2
197
25
13
acetic acid
Corrected
Mean
0.22
0.92
0.45
111.5
1.5
110
7
per day.
Discharge
(Ibs/day)
20.5
85.7
41.9
10,400
140
10,200
650
Ibs of discharge *
ton of production
*
27.2 x 10-3
114 -V
^w
55.6
13,800
184 i
13,500
862
«*
'
-------
TABLE I.E.I
WASTEWATER FROM TWO CONDENSATE QUENCH POTS AND FOUR BAROMETRIC SEAL TANKS
BUILDING 334. AREA B. HAAP Id(2)
Parameter
Ammonia as Nitrogen
Nitrites and Nitrates.
as Nitrogen
Kjeldahl Nitrogen as
Nitrogen
Orthophosphate as
Phosphorus
Acidity as Calcium
Carbonate
Alkalinity as Calcium
Carbonate
Total Solids
Suspended Solids
Dissolved Solids
Chemical Oxygen Demand
Total Organic Carbon
Biological Oxygen
Demand
Flow = 1.79 mgd; Produ<
* 99% HN03 produced
**not corrected for fi!
Minimum
0.22
12.0
0.5
0.03
3.1
0
480
4.0
473
16
6
<5
tion = 307, (
tered raw w;
Maximum
1.60
60.0
1.6
0.10
24
65
876
12.7
866
51
8
15
00 Ib/day (i
.ter - Area I
Mean
0.53
29.2
1.14
0.03
9.2
21.1
603
7.1
596
36
6.8
5
54 ton/day)
, Holston R]
Mean
Raw
100% HN03
ver
Corrected
Mean
28.4
6.3
379
6.3
373
17.7
<5**
•
Discharge
(Ibs/day)
423
94
5,650
94
5,560
264
<75**
•
Ibs of discharge
tori of production*
2.75
0.61
36.6
0.610
36.1
1.71
<0.49**
•
00
-------
TABLE I.E.2*
ACID AREAS 1 & 2. JAAP (3f)
Parameter
Average Flow
PH
Acidity as Calcium Car
Sulfates
Nitrates as Nitrate
Color (PCU)
Minimum
>onate
Maximum
Mean
14,700 gpm
7.2
23
373
26
5
Mean Raw
Corrected Mean
Discharge
(Ibs/day)
4,060
65,800
4,580
Ibs of discharge
ton of production
Si
to
Flow =21.168 mgd; Production3 not available
*No correction for raw water values
-------
TABLE I.E.3*
ACID 3 OUTFALL. JAAP (3f)
Parameter
• V
Average Flow
pH Range
Acidity as Calcium Car
Acidity Range
Sulfates
Nitrates as Nitrate
Color . (PCU) •
i
Minimum
>onate
Maximum
Mean
7,800 gpm
2.6-9.7
168
0-2389'
320
30
30
Mean Raw
Corrected Mean
•
Discharge
(Ibs/day)
15,700
29,900
2,810
Ibs of discharge
ton of production
Flow= 11.232 mgd; Production = not available
*No correction for raw water concentrations
-------
TABLE I.F.I*
ACID AREAS 1 & 2, JAAP • (3f)
Parameter
Average Flow
PH
Acidity as Calcium Car
Sulfates
Nitrates as Nitrate
Color (PCU)
•
Minimum
>onate
Maximum
Mean
14,700 gpm
7.2
23
373
26
5
Mean Raw
Corrected Mean
Discharge
(Ibs/day)
4,060
65,800
4,580
Ibs of discharge
ton of production
*
-•
Flow =21.168 mgd; Production80 not available
*No correction for raw water values
-------
TABLE I.F.2*
ACID 3 OUTFALL. JAAP (3f)
Parameter
Average Flow
pH Range
Acidity as Calcium Car
Acidity Range
Sulfates
Nitrates as Nitrate
Color . (PCU) •
Minimum
>onate
• ••
Maximum
Mean
7,800 gpm
2.6-9.7
168
0-2389'
320
30
30
Mean Raw
Corrected Mean
•
Discharge
(Ibs/day)
15,700
29,900
2,810
Ibs of discharge
ton of production
Flows 11.232 mgd; Production« not available
*No correction for raw water concentrations
-------
TABLE I.I.I
ACID NEUTRALIZATION PLANT EFFLUENT
"C" NITROCELLULOSE LINE. BAAP. la(l)
Parameter
Flow
Temperature (°F)
PH
Conductance
Total Kjeldahl
Nitrogen
Ammonia
Nitrates
Total Phosphates
Sulfates
Chemical Oxygen
Demand
Turbidity (JTU)
Color (Platinum-Cobalt
Total Organic Carbon
Total. Solids
Suspended Solids
Dissolved Solids
Iron
Minimum
1.20
65
1.7
510
1.3
0.8
50
<0.5
275
57
2.5
15
22
396
9.6
386.4
0.5
Maximum
1.93
120
12.2
18,000
3.4
2.35
600
0.85
3,000
111
150
40
78
9,141
646
8,500
7.60
Mean
1.64
84.9
7.01
8,884.3
2.17
1.51
434.1
0.593
1,605.7
83.1
60.57
26.4
37
5,516
286.7
5,229.3
4.23
Mean Raw
27.2
7.36
2.28
0.74
0.63
0.63
38
45
6.1
77
27
200
13.7
186
1.04
Corrected
Mean
0.77
434
1.570
38.1
10
5,316
273
5,040
3.19
Discharge
(Ibs/day)
10.5
5,930
21,400
520
137
72,600
3,730
68,800
43.6
Ibs of discharge
ton of production
.233
132
476
11.6
3.04
1,610
82.9
1,530
.969
Flow =1.64 mgd; Production = 90,000 lb/ctey (45 ton/day) NC
-------
TABLE I.I.2
ACID NEUTRALIZATION PLANT EFFLUENT
"B" NITROCELLULOSE LINE. BAAP. lc(l)
Parameter
Flow
Temperature
PH
Conductance
Total Kjeldahl
Nitrogen
Ammonia
Nitrates
Total Phosphates
Sulfates
Chemical Oxygen Demand
JTU
Color (Platinum-Cobalt^
Total Organic Carbon
Total Solids
Suspended Solids
Dissolved Solids
Iron
Minimum
2.54
60
0.9
760
0.8
0.38
70
<0.5
103
40
44
10
21
1,162
149
1,013
0.23
Maximum
3.55
>120
12.4
> 18, 000
2.8
1.4
680
0.95
2,175
925
300
45
50
10,024
948
9,246
7.46
Mean
3.12
75
11.7
10,205
1.73
0.89
378.3
0.625
1,103.8
237.2
164.7
32.5
34.7
6*522.1
571.7
5,950.5
T.57
Mean Raw
27.2
7.36
2.28
0.74
0.63
0.63
38
45
6.1
77
27
200
13.7
186
1.04
Corrected
Mean
0.15
378
1,066
192
7.7
6,322.1
558
5,760
0.53
Discharge
(Ibs/day)
3.90
9,820
27,700
4,990
200
164,000
14,500
150,000
13.8
Ibs of discharge
ton of production
.087
218
616
111
4.44
3,640
322
3,330
.307
Flow =3.12 mgd; Productions 90,000 Ib/day (45 ton/day) NC
-------
00
00
TABLE 1. 1 . 3
POACHER PIT EFFLUENT
"C" NITROCELLULOSE LINE.. BAAP la(l)
Parameter
Flow
Temperature
PH
Conductance
Total Kjeldahl
Nitrogen
Nitrates
Total Phosphates
Sulfates
Chemical Oxygen Demand
JTU
Color (Platinum-Cobalt]
Total Organic Carbon
Total Solids
Suspended Solids
Dissolved Solids
i
Minimum
0.45
70
1.5
410
1.2
7.1
<0.5
63
64
43
0
35
340
63.5
276
Maximum
1.75
>120
6.9
4,100
4.4
31.8
2.3
195
112
75
10
66
542
138
412
Mean
1.29
83.6
5.43
932.9
2.1
14.8
0.83
128
90
61
1.43
48.5
440.7
'104.6
336
Mean Raw
27.2
7.36
2.28
0.63
0.63
38
45
6.1
77
27
200
13.7
186
Corrected
Mean
<
14.2
0.20
90
45
21.5
240.7
91
150
Discharge
(Ibs/day)
152
2.15
967
484
231
2,590
978
1,610
Ibs of discharge
ton of t>*ol*i&tion
i
3.38
.048
21.5
10.8
5.13
57.6,.
21.7
35.8
Flow = 1.29 mgd; Production^ 90,000 Ib/da^ (45 ton/day) NC
-------
•B'
TABLE X.I.4
POACHER PIT EFFLUENT
NITROCELLULOSE LINE. BAAP
Parameter
Flow
Temperature (°F)
PH
Conductance .
Total Kjeldahl
Nitrogen
Nitrates
Total Phosphates
Sulfates
Chemical Oxygen Demand
JTU
Color (Platinum-Cobalt
Total Organic Carbon
Total Solids
Suspended Solids
Dissolved Solids
Minimum
0.13
82
5.3
450
0.1
3.8
^0.5
69
43
5.0
10
29
249
0
241
Maximum
2.34
>120
8.4
900
2.6
12.5
27.2
122
2,100
12
65
720
441
13.6
441
Mean
1.02
93.4
7.01
584.3
1.36
7.6
4.81
95
750.9
8.13
27.9
318.7
294.4
7.6
338.9
Mean Raw
27.2
7.36
2.28
0.63
0.63
38
45
6.1
77
27
200
13.7
186
Corrected
Mean
7,0
4.2
57
706
292
94.4
153
Discharge
(Ibs/day)
59.5
35.7
484
6,000
2,480
802
1,300
Ibs of discharge
ton of production
1.32
.793
10.8
133
•
55.1
17.8
28.9
00
-------
TABLE 1.1.5
SOLVENT RECOVERY
STILL BOTTOMS. BAAP
Parameter
Temperature
PH
Conductance
Total Kjeldahl Nitrogen
Nitrates
Total Phosphates
Sulfates
Chemical Oxygen Demand
JTU
MBAS
Total Organic Carbon
Total Solids
Suspended Solids
Dissolved Solids
Minimum
57
6.0
380
1.0
2.0
0.8
126
48
102
0.50
31
612
40.9
476
Maximum
> 120
11.5
> 18, 000
19.4
425
15.3
1,050
1,560
520
0.90
1,160
4,639
427
4,212
Mean
110
8.95
2,315.8
5.57
143.7
4.99
316.3
347.2
. 261
0.70
516.8
1,885
251
1,634
Mean Raw
7.36
2.28
0.63
0.63
38
45
6.1
0.16
27
200
13.7
186
Corrected
Mean
3.29
143.07
4.36
278.3
302.2
0.54
489.8
1,685
237.3
1,448
Discharge
(Ibs/day)
Ibs of discharge
ton of production
-,:-- • '
Flow= not determined; Production =not determined
-------
TABLE I.I.6*
NC PRODUCTION
BOILING TUB HOUSE. LINE A. DRAIN WHILE TUB IS FILLING. BLDG. 1019. RAAP In(3.)
• Parameter
pH
Specific Conductance
.Suspended Solids
Total Organic Carbon
Fil-Chemical Oxygen
Demand
N02-N03/N
. f
Minimum
Maximum
•
Mean
1.40
36,700
22.00
20.00
56.00
460.00
Mean Raw
•
Flow = .0193 mgd; Production = 4500 pounds HG-LG/NC/day Fil=F
*No correction for raw water concentrations
Corrected
Mean
Discharge
(Ibs/day)
3.54
3.22
9.00
84.0
Ibs of discharge
ton of production
1.57
1 1.43
4.00
37.4
Lltered
-------
TABLE I.I.7*
NC PRODUCTION
BOILING TUB HOUSE. LINE A. DRAIN AFTER ACID BOIL. BLDG 1019. RAAP In(3)
Parameter
pH
Specific Conductance
Suspended Solids
Total Organic Carbon
Fil Chemical Oxygen
Demand
N02-N03/N
Minimum
Maximum
Mean
1.60
13,300
< 1.00
98.00
270.00
160.00
Mean Raw
Corrected
Mean
Discharge
(Ibs/day)
< 0.085
8.33
22.9
13.6
Ibs of discharge
ton of production
•< .037
3.70.
10.2
6.04
CD
to
Flow = .0102 mgd; Production = 4500 pounds HG-LG/NC/day
*Uo correction for raw water concentrations
-------
TABLE I.I.8*
NC PRODUCTION
BOILING TUB HOUSE. LINE A. DRAIN AFTER NEUTRAL BOIL. BLDG 1019. RAAP In(3)
Parameter
PH
Specific Conductance
Suspended Solids
Total Organic Carbon
Total Chemical Oxygen
Demand
N02-N03/N
Minimum
Maximum
Mean
3.10
620.00
<1.00
18.00
32.00
7.10
Mean Raw
Corrected
Mean
Discharge
(Ibs/day)
< 0.085
1.53
2.72
0.603
Ibs of discharge
ton of production
<37.8
.680
1.21
.268
Flow = .0102 mgd; Production = 4500 pounds HG-LG/NC/day
*No correction for raw water concentrations
-------
TABLE I.I.9*
NC PRODUCTION
BOILING TUB HOUSE. LINE A. DRAIN AFTER NEUTRAL BOIL. BLDG 1019. RAAP In(3)
Parameter
PH
Specific Conductance
Suspended Solids
Total Organic Carbon
Fil Chemical Oxygen
Demand
N02-N03/N
IT
Minimum
Maximum
.
Mean
3.20
800.00
9.00
22.00
56.00
1,000.00
Mean Raw
Corrected
Mean
Discharge
(Ibs/day)
0.765
1.87
4.76
85.0
*
Ibs of discharge
ton of production
.340
.832
2.12
37.8
-
Flow - .0102 mgd; Production = 4500 pounds HG-LG/NC/day
*No correction for raw water concentrations
-------
TABLE I.I.10*
NC PRODUCTION
WASTEWATER DRAIN LINE AT NORTHEAST END OF BOILING TUB HOUSE. LINE B. DRAIN WHILE TUB IS BILLING. BLDG 2019. RAAP ln(3)
Parameter
pH
Specific Conductance
Suspended Solids
Total Organic Carbon
Fil Chemical Oxygen
Demand
Total Chemical Oxygen
Demand
N02-N03/N
Minimum
1.10
37,900.00
11.60
0.00
151.00
245.33
946.67
Maximum
3.93
65,891.67
62.53
148.00
151.00
464.00
1,000.00
Mean
2.24
53,930.56
34.88
90.56
151.00
354.67
982.22
Mean Raw
Corrected
Mean
Discharge
(Ibs/day)
135
350
583
1,370
3,790
Ibs of discharge
toit of production
2.12
5.52
9.20
21.6
59.8
Flow = .4636 mgd; Production = 126,667 pounds NC/day
*No correction for raw water concentrations
-------
TABLE I.I.11*
NC PRODUCTION
WASTEWATER FROM BOILING TUB HOUSE. LINE B. DRAIN AFTER ACID BOIL. BLDG 2019. RAAP ln(3)
Parameter
PH
Specific Conductance
Suspended Solids
Total Organic Carbon
Total Chemical Oxygen
Demand
N02-N03/N
t
Minimum
1.30
11,500
<1.00
500.00
1,280.00
9.00
Maximum
2.00
16,100.00
2.80
767.00
1,984.00
220.00
Mean
1.70
13,200.00
<1.77
655.67
1,661.33
79.33
Mean Raw
Corrected
Mean
Discharge
(Ibs/day)
<5.10
1,890
4,780
228
Ibs of discharge
ton of production
< .080
29.8
75.4
3.6
-f- :
Flow = .3458 mgd; Production = 126,667 pounds NC/day
*No correction for raw water concentrations
-------
TABLE I.I.12*
NC PRODUCTION
WASTEWATER FROM BOILING TUB HOUSE. LINE B. DRAIN AFTER NEUTRAL BOIL. BLDG 2019. RAAP In(3)
• Parameter
pH
Specific Conductance
Suspended Solids
Total Organic Carbon
Fil Chemical Oxygen
Demand
Total Chemical Oxygen
Demand
N02-N03/N
Minimum
2.60
375.00
0.00
34.00
152.00
72.00
11.00
Maximum
3.30
1,210.00
6.00
91.00
152.00
120.00
80.00
Mean
3.00
721.33
2.33
59.00
152.00
96.00
35.00
Mean Raw
•
Corrected
Mean
Discharge
(Ibs/day)
6.71
170
438
276
101
Ibs of discharge
ton of production
.106
2.68
6.92
4.36
1.59
Flow = .3458 mgd; Production = 126,667 pounds NC/day
*No correction for raw water concentrations
-------
TABLE I.I.13*
NC PRODUCTION
BOILING TUB HOUSE. LINE B. DRAIN AFTER NEUTRAL BOIL. BLDG 2019. RAAP In(3)
Parameter
pH
Specific . Conductance
Suspended Solids
Total Organic Carbon
Fil Chemical Oxygen
Demand
Total Chemical Oxygen
Demand
N02-N03/N
?
Minimum
2.90
378.00
1.00
39.00
105.00
140.00
12.00
Maximum
3.40
750.00
1.80
58.00
105.00
140.00
13.60
Mean
3.15
564.00
1.40
48.50
105.00
140.00
12.80
Mean Raw
Corrected
Mean
Discharge
(Ibs/day)
4.03
140
302
403
36.9
Ibs of discharge
ton of production
.064
2.20
4.76
6.36
.582
Flow = .3458 mgd; Production = 126,667 pounds NC/day
*Uo correction for raw water concentrations
-------
TABLE I.I.14*
NC PRODUCTION
DRAINLINE FROM TANK 4. BLDG 1022. JORDAN BEATER HOUSE. A-LINE. RAAP In(3)
Parameter
PH
Specific Conductance
Suspended Solids
Total Organic Carbon
Total Chemical Oxygen
Demand
Minimum
Maximum
Mean
7.20
798.00
140.00
7.0
144.00
Mean Raw
Corrected
Mean
Discharge
(Ibs/day)
1.75
0.087
1.80
Ibs of discharge
ton of production
.778
.038
.800
Flow = .0015 mgd; Production = 4500 pounds NC/day
*No correction for raw water concentrations
-------
TABLE I.I.15*
NC PRODUCTION
DRAINLINE FROM TANK 4. BLDG 2022. JORDAN BEATER HOUSE. B-LINE. RAAP In(3)
• Parameter
PH
Specific Conductance
Suspended Solids
Total Organic Carbon
Fil Chemical Oxygen
Demand
Total Chemical Oxygen
Demand
N02-N03/N
t
Minimum
7.63
179.00
290.00
10.00
31.00
272.00
0.60
1 ;
Maximum
9.10
480.00
1,053.67
10.33
31.00
544.00
4.03
Mean
8.41
279.67
579.89
10.11
31.00
416.00
2.21
Mean Raw
Corrected
Mean
Discharge
(Ibs/day)
613
10.7
32.8
440
234
Ibs of discharge
ton of production
9.68
.169
.518
6.94
3.70
...
Flow = .127 mgd; Production = 126,667 pounds NC/day (HG & LG)
*No correction for raw water concentrations
-------
TABLE I.I.16*
NC PRODUCTION
POACHER BLENDER HOUSE. A-LINE. BLDG 1024. DECANT LINE FROM POACHER TUBS. RAAP In(3)
Parameter
PH
Specific Conductance
Suspended Solids
Total Organic Carbon
Total Chemical Oxygen
Demand
N02-N03/N
Minimum
Maximum
Mean
9.00
218.00
52.00
13.00
128.00
1.10
Mean Raw
Corrected
Mean
Discharge
(Ibs/day)
0.412
O.o03
1.01
0.0087
Ibs of discharge
ton of production
.183
.046
.448
.004
Flow - .00095 mgd; Production = 4500 pounds NC/day
*No correction for raw water concentrations
-------
TABLE I.I.17*
NC PRODUCTION
POACHER BLENDER HOUSE. A-LINE. BLDG 1024. SECOND DECANT FROM POACHER TUBS. RAAP ln(3)
Parameter
PH
Specific Conductance
Suspended Solids
Total Organic Carbon
Total Chemical Oxygen
Demand
N02-N03/N
Minimum
Maximum
Mean
9.80
208.00
147.50
13.00
192.00
1.00
Mean Raw
Corrected
Mean
Discharge
(Ibs/day)
1.17
0.103
1.52
0.0079
Ibs of discharge
ton of production
.520
.046
.676
.004
Flow = .00095 mgd; Production = 4500 pounds NC/day
*Uo correction for raw water concentrations
-------
TABLE I.I.18*
NC PRODUCTION
POACHER BLENDER HOUSE. A-LINE. BLDG 1024. TERTIARY DECANT FROM POACHER TUBS. RAAP In(3)
• Parameter
PH
Specific Conductance
Suspended Solids
Total Organic Carbon
Total Chemical Oxygen
Demand
N02-N03/N
Minimum
!
Maximum
•
Mean
9.80
224.00
125.00
24.00
128.00
•
Mean Raw
•
Corrected
Mean
Discharge
(Ibs/day)
0.739
0.142
0.757
•
Ibs of discharge
ton of production
.328
• .063
.336
10
g ,
Flow = .00071 mgd; Production = 4500 pounds/day (LG & HG)
*No correction for raw water concentrations
-------
TABLE I.I.19*
NC PRODUCTION
POACHER BLENDER HOUSE. A-LINE. BLDG 1024. DECANT AFTER 4 HOUR SODA BOIL. RAAP ln(3)
Parameter
PH
Specific Conductance
Suspended Solids
Total Organic Carbon
Total Chemical Oxygen
Demand
N02-N03/N
V
Minimum
Maximum
i
Mean
6.80
826.00
632.00
92.00
600.00
60.00
Mean Raw
Corrected
Mean
Discharge
(Ibs/day)
3.74
0.544
3.55
0, 355
Ibs of discharge
ton of production
1.66
.242
1.58
.158
V. ..
Flow = .00071 mgd; Production = 4500 pounds NC/day
correction for raw water concentrations
-------
TABLE I.I.20*
NC PRODUCTION
POACHER BLENDER HOUSE. A-LINE. BLDG 1024. DECANT.AFTER ONE HOUR WATER BOIL. RAAP In(3)
Parameter
PH
Specific Conductance
Suspended Solids
Total Organic Carbon
Total Chemical Oxygen
Demand
N02-N03/N
Minimum
Maximum
I
6.60
550.00
318.00
53.00
536.00
34.00
6.70
550.00
558.00
57.00
560.00
51.00
Mean
6.65
550.00
438.00
55.00
548.00
42.50
Mean Raw
Corrected
Mean
Discharge
(Ibs/day)
2.11
1.68
0.211
0.163
Ibs of discharge
ton of production
.938
.746
.094
.072
to
o
en
Flow - .00046 mgd; Production = 4500 pounds NC/day
*No correction for raw water concentrations
-------
TABLE 1.1.21*
NC PRODUCTION
POACHER BLENDER HOUSE. A-LINE. BLDG 1024. DECANT AFTER ONE HOUR WATER BOIL. RAAP In(3)
Parameter
PH
Specific Conductance
Suspended Solids
Dissolved Solids
Total Organic Carbon
Total Chemical Oxygen
Demand
N02-N03/N
Minimum
6.60
450.00
463.00
0.00
41.00
456.00
30.00
Maximum
6.60
550.00
495.00
0.00
45.00
552.00
34.00
Mean
6.60
450.00
479.00
0.00
43.00
504.00
32.00
Mean Raw
Corrected
Mean
Discharge
(Ibs/day)
Ibs of discharge
ton of production
•
to
o
05
Flow = not available; Production = 4500 pounds NC/day
correction for raw water concentrations
-------
TABLE I.I.22*
NC PRODUCTION
POACHER BLENDER HOUSE. B-LINE. BLDG 2024. DECANT DRAINLINE FROM POACHER TUBS. RAAP In(3)
Parameter
PH
Specific Conductance
Alkalinity
Suspended Solids
Total Organic Carbon
Fil Chemical Oxygen
Demand
Total Chemical Oxygen
Demand
N02-N03/N
Minimum
7.30
148.00
0.00
23.93
14.00
72.00
192.00
<0.10
'•
Maximum
9.00
263.33
0.00
258.00
27.00
72.00
240.00
2.37
i
Mean
7.92
'200.44
0.00
142.98
18.67
72.00
216.00
0.86
Mean Raw
Corrected
Mean
Discharge
(Ibs/day)
94.6
12.5
48.2
144
0.575
Ibs of discharge
ton of production
1.51
.197
.760
2.28
.009
Flow
*No correction
-------
TABLE I.I.23*
NC PRODUCTION '
POACHER BLENDER HOUSE. B-LINE. BLDG 2024. SECONDARY DECANT FROM POACHER TUBS. RAAP ln(3)
Parameter
PH
Specific Conductance
Suspended Solids
Total Organic Carbon
Fil Chemical Oxygen
Demand
Total Chemical Oxygen
Demand
.*
Minimum
7.70
150.00
63.83
12.00
485.33
160.00
0.57
Maximum
8.50
264.00
203.00
386.00
485.33
184.00
1.10
Mean
8.63
190.33
153.11
137.00
485.33
172.00
0.86
Mean Raw
Corrected
Mean
Discharge
(Ibs/day)
102
91.6
325
115
0.575
Ibs of discharge
ton of production
1.61
1.45 '
5.12
1.82
.009
- V ,.
Flow = .0803 mgd; Production = 126,667
*No correction for raw water concentrations
-------
TABLE I. I. 24*
NC PRODUCTION
POACHER BLENDER HOUSE. B-LINE. BLDG 2024. DECANT AFTER FOUR HOUR BOIL. RAAP In (3
• Parameter
PH
Specific Conductance
Suspended Solids
Total Organic Carbon
Fil Chemical Oxygen
Demand
Total Chemical Oxygen
Demand
N02-N03/N
Minimum
6.50
484.00
287.00
77.00
685.00
424.00
11.00
Maximum
7.93
1,020.00
430.00
456.67
685.00
704.00
40.00
Mean
Mean Raw
•
Corrected
Mean
Discharge
(Ibs/day)
215
229
343
352
20.0
Ibs of discharge
too of production
3.4
3.64
5.42
5.56
.316
Flow = .0681 mgd; Production = 126,667 pounds NC/day
*No correction for raw water concentrations
-------
TABLE I.I.25*
NC PRODUCTION
POACHER BLENDER HOUSE. B-LINE. BLDG 2024. DECANT AFTER TWO HOUR WATER BOIL. RAAP In(3)
Parameter
PH
Specific Conductance
Suspended Solids
Total Organic Carbon
Total Chemical Oxygen
Demand
N02-N03/N
V
• 'V
Minimum
5.80
567.00
56.50
81.00
248.00
47.00
Maximum
6.70
917.00
526.00
140.00
688.00
70.00
Mean
6.13
734.33
258.33
103.67
464.00
55.33
Mean Raw
Corrected
Mean
Discharge
(Ibs/day)
129
569
232
27.7
Ibs of discharge
ton of production
2.04
.820
3.66
.438
Flow = .0601 mgd; Production = 126,667 pounds NC/day
*JSo correct ion for raw water concentrations
-------
TABLE I.I.26*
NC PRODUCTION
POACHER BLENDER HOUSE. B-LINE. BLDG 2024. DECANT AFTER TWO HOUR WATER BOIL. RAAP ln(3)
Parameter
PH
Specific Conductance
Suspended Solids
Total Organic Carbon
Total Chemical Oxygen
Demand
N02-N03/N
Minimum
5.60
575.00
78.00
82.00
212.00
40.00
Maximum
6.90
647.00
363.00
91.00
512.00
50.00
Mean
6.10
614.00
195.33
86.33
334.67
43.67
Mean Raw
Corrected
Mean
Discharge
(Ibs/day)
97.8
43.2
168
21.9
Ibs of discharge
ton of production
1.54
.682
2.66
.346
Flow = .0601 mgd; Production = 126,667 pounds NC/day
*No correction for raw water concentrations
-------
TABLE I.I.27*
NC PRODUCTION
POACHER BLENDER HOUSE. B-LINE. BLDG 2024. DECANT AFTER ONE HOUR WATER BOIL. RAAP
ln(3)
• Parameter
PH
Specific Conductance
Suspended Solids
Total Organic Carbon
Total Chemical Oxygen
Demand
N02-N03/N
V
,*»
Minimum
5.50
343.00
69.50
58.00
216.00
25.00
Maximum
6.50
500.00
314.50
85.00
268.00
43.00
Mean
6.13
407.67
180.67
68.67
236.00
33.00
Mean Raw
•
Corrected
Mean
Discharge
(Ibs/day)
57.9
22.0
75.7
10.6
•
Ibs of discharge
ton of production
.914
.348*
1.20
.168
SZ
Flow = .0385 mgd; Production = 126,667 pounds NC/day
*No correction for raw water concentrations
-------
FINAL WRING HOUSE. A/B LINE.
TABLE I.I.28*
NC PRODUCTION
BLDG 1026. DRAINLINE FROM WRINGER HOUSE. RAAP ln(3)
Parameter
PH
Specific Conductance
Total Solids
Suspended Solids
Dissolved Solids
Total Organic Carbon
Fil Chemical Oxygen
Demand
Total Chemical Oxygen
Demand
M-tn-Jtinim
7.40
114.00
442.00
343.00
59.00
10.00
135.00
284.00
Maximum
8.20
140.00
1,462.00
828.00
534.00
30.00
135.00
784.00
Mean
7.73
129.67
794.00
518.00
242.67
18.33
135.00
534.00
Mean Raw
Corrected
Mean .
Discharge
(Ibs/day)
Ibs of discharge
ton of production
\ Flow = not available; Production = 131,167 pounds NC/day (HG & LG)
*No correction for raw water concentrations
-------
TABLE I.I.29*
ALCOHOL RECTIFICATION
STILLHOUSE. BLDG 1502. WASTE "SLOP" FROM SAMPLING SPIGOT OF STILL. RAAP In(3)
• Parameter
PH
Specific Conductance
Acidity
Alkalinity
Total Solids
Suspended Solids
Dissolved Solids
Total Volatile Solid§
Color
Total Organic Carbon
Total Chemical
Oxgen Demand
Biological Oxygen
Demand
Kjeldahl Nitrogen
Nitrite and Nitrate-
Nitrogen
Sulfates
Minimum
6.70
10.00
2.00
27.00
25.00
3.00
14.00
25.00
28.00
15.00
32.00
24.00
2.00
3.00
.00
Maximum
7.40
20.00
•
12.00
465.00
98.00
12.00
68.00
68.00
28.00
40.00
144.00
78.00
2.00
3.00
.00
Mean
7.10
15.00
7.00
246.00
49.67
7.17
34.67
39.67
28.00
29.67
104.00
44.67 •
2.00
3.00
.00
Mean Raw
•
Corrected
Mean
Discharge
(Ibs/day)
1.23
43.2
8.73
1.26
6.09
6.97
5.21
18.3
7.85
.351
.527
-0-
Ibs of discharge
ton of production
* .008
.298
.060
.008
.042
.048
.036
.126
.054
.002"
.004
-0-
Flow = 21,100 gpd; Production = 290,356 pounds weak alcohol processed/day
*No correction for raw water concentrations
-------
TABLE I.I.30*
ALCOHOL RECTIFICATION
^ST-ILEHdUSE. BLDG 1502. COOLING WATER. FROM COOLING WATER DISCHARGE LINE AT BOTTOM OF STILL IN BLDG 1502. RAAP ln(3)
Parameter
PH
Secific Conductance
Total Solids
Suspended Solids
Dissolved Solids
Total Organic Carboi
Filtered Chemical
Oxygen Demand
Kjeldahl Nitrogen
Nitrite and Nitrate-
Nitrogen
Minimum
8.20
110.00
111.00
<1.00
98.00
5.00
13.00
.70
2.10
Maximum
9.70 -
189.00
129.00
15.00
129.00
6.00
14.00
.70
2.10
Mean
8.73
143.67
117.67
<6.50
111.33
5.67
13.67
.70
2.10
Mean Raw
Corrected
Mean
Discharge
(Ibs/day)
421
<23.3
399
20.3
49.0
2.51
7.52
Ibs of discharge
ton- of production
2.90
< .160
2.74
.140
.338
.017
.052
Flow = .43 mgd; Production = 290,356 pounds weak alcohol processed
*No correction for raw water concentrations
-------
TABLE I. I. 31*
ALCOHOL RECTIFICATION
STILLHQUSE. BLDG 1502. WASTE SLOP FROM SPIGOT AT BOTTOM OK STTT.T. TN STTT T.wnnsi? PAAP in^l
Parameter
PH
Specific Conductance
Acidity
Alkalinity
Total Solids
Suspended Solids
Dissolved Solids
Total Organic Carbon
Filtered Chemical
Oxygen Demand
Biological Oxygen
i
Minimum
6.50
1,000.00
0.00
175.00
4,060.00
2,264.00
1,796.00
500.00
,#•-
3,400.00
185.00
Maximum
9.00
2,140.00
12.00
700.00
5,997.00
2,545.00
3,452.00
1,240.00
3,640.00
> 350. 00
Mean
7.40
1,396.67
7.33
371.67
5,146.67
2,451.33
2,695.33
824.33
3,520.00
295.00
Mean Raw
Corrected
Mean
Discharge
(Ibs/day)
0.528
26.7
370
176
194
59.3
253
21.2
• i
Ibs of discharge
ton of production
.004
.187
2.58
1.23
1.36
.414
1.77
.148
.;•
Flow - .00864 mgd; Production - 286,216 pounds weak alcohol processed/day
correction for raw water, concentrations
-------
TABLE I.I.32*
ALCOHOL RECTIFICATION
COOLING WATER DISCHARGE LINE IN BLDG 1503,' RAAP In (3)
Parameter
PH
Specific Conductance
Total Solids
Suspended Solids
Dissolved Solids
Total Volatile Solids
Color
Total Organic Carbon
Filtered Chemical
Oxygen Demand
Kjeldahl Nittogen '
Nitrite and Nitrate-
Nitrogen
Min inmnr
8.80
109.00
112.00
<1.00
110.00
28.00
5.00
5.00
14.00
0.50
3.10
Maximum
9.60
150.00
215.00
3.80
211.00
77.00
28.00
6.00
17.00
0.50
3.10
Mean
9.17
131.33
164.00
<2.20
161.67
52.50
12.67
5.67
15.67
0.50
3.10
Mean Raw
Corrected
Mean
Discharge
(Ibs/day)
587
<7.88
579
188
45.4
20.3
56.1
1.79
39.8
Ibs of discharge
ton of production
4.38
< .005
4.32
1.40
.340
.151
.418
.013
.296
Flow - .43 mgd; Production = 268,216 pounds weak alcohol processed/day
*No correction for raw water concentrations
-------
TABLE
NITROGLYCERIN
BAAP
I.J.I
PLANT EFFLUENT
Parameter
Flow
Temperature
PH
Conductance
Total Kjeldahl Nitroge
Ammonia
Nitrates
Total Phosphates
Sul fates.
Chemical Oxygen Demand
Total Organic Carbon
Lead
Iron
Minimum
0.06
50
1.7
400
i 1.1
0.85
0.5
<0.5
62
18
19
0.05
0.24
Maximum
0.17
67
9.5
8,000
5.1
3.05
200
2.0
415
340
56
1.29
0.55
Mean
0.11
58.3
4.74
2,720
2.54
1.66
116.6
1.21
242.6
109.1
35.3
0.73
0.40
Mean Raw
27.2
7.36
2.28
0.74
0.63
0.63
38
45
27
1.04
Corrected
Mean
0.26
0.92
115.97
0.58
204.6
64.1
8.3
0.73*
Discharge
(Ibs/day)
0.238
0.843
106
0.531
187
58.7
7.60
0.669*
-
Ibs of discharge
ton of production
.018
,066
8.28
,041
14.6
4.58
.594
.052
,.:• ; ,' ~
Flow= 0.11 mgd; Production = 25% capacity = 25,600 Ib/working day (12.8 ton/day) NG
*not corrected for raw water concentrations
-------
TABLE I.J.2*
NG PRODUCTION
COMBINED FLOW OF NITRATOR BLDG AND COOLING WATER. RAAP In(3)
Parameter
Temperature (°F)
pH
Specific Conductance
Acidity
Alkalinity
Total Solids
Suspended Solids
Dissolved Solids
Color
Total Organic Carbon
Fil Chemical Oxygen
Demand
Kjeldahl Nitrogen
N02-N03/N
Sulfates
Nitroglycerin
Minimum
62.0
8.8
182.0
0.0
99.0
111.0
<1.0
111.0
5.0
5.0
<10.0
<0.5
0.3
14.0
0.0
Maximum
80.0
9.9
11,500.00
0.0
6,900.0
25,358.0
39.0
25,351.0
80.0
420.0
195.0
6.0
1,920.0
466.0
315.0
Mean
71.6
9.4
4,732.0
0.0
2,100.7
8,149.5
<6.4
8,143.0
19.0
86.0
< 81.7
-<1.6
458.2
145.4
105.7
Mean Raw
Corrected
Mean
Discharge
(Ibs/day)
936
3,630
< 2.85
3,630
38.3
<36.4
< 0.713
204
64.8
47.1
Ibs of discharge
ton of production
226
874
< .686
874
9.22
< 8.78
^ .172
49.2
15.6
11.3
Flow =.0535; Production = 8300 pounds/day (4.15 ton/day) NG
*No correction for raw water concentrations
-------
TOE
TABLE I.J.3*
NG PRODUCTION
PIPE ENTERING CATCH TANK NO. 12 CARRYING AMMONIA COMPRESSOR WATER. RAAP In(3)
• Parameter
PH
Specific Conductance
Acidity
Alkalinity
Total Solids
Suspended Solids
Dissolved Solids
Fil Chemical Oxygen
Demand
Biological Oxygen
Demand
Kjeldahl Nitrogen
N02-N03/N
Nitroglycerin
L
Minimum
7.70
170.00
0.00
55.00
273.00
2.60
267.00
4> 10.00
0.00
0.00
5.20
0.00
Maximum
10.70
583.00
2.00
233.00
491.00
5.50
488.00
27.00
6.00
0.50
5.20
0.00
Mean
9.03
386.00
0.67
124.00
382.00
4.05
377.50
15.67
3.33
0.25
5.20
0.00
Mean Raw
•
Corrected
Mean
Discharge
(Ibs/day)
•
Ibs of discharge
ton of production
»
i
-•
Flow = not available; Production = not available
*Ko correction for raw water concentrations
-------
TABLE I.J.4*
NG PRODUCTION
EFFLUENT FROM CATCH TANK RECEIVING WASTES FROM NITRATION BLDG 9463. NO. 2 AREA. RAAP ln(3)
Parameter
PH
Specific Conductance
Acidity
Alkalinity
Total Solids
Suspended Solids
Dissolved Solids
Filtered Chemical
Oxygen Demand
Kjeldahl Nitrogen
Nitrite and Nitrate-
Nitrpgen
Sulfates
Nitroglycerin
Minimum
8.40
1,650.00
0.00
410.00
2,041.00
<1.00
2,033.00
41.00
<0.50
250.00
15.20
0.00
Maximum
9.30
31,000.00
0.00
15,100.00
70,775.00
63.30
70,712.00
1,400.00
<0.50
250.00
535.00
32.00
Mean
8.97
13,550.00
0.00
6,310.00
25,028.33
<24.20
25,004.67
567.00
^0.50
250.00
238.40
12.33
Mean Raw
Corrected
Mean
Discharge
(Ibs/day)
93.3
370
< 0.358
370
8.38
<.0. 00739
3.70
3.52
0.182
Ibs of discharge
ton of production
22.4
89.2
.086
89*2
2.02
< .002
.892
.848
.044
Flow = .001775 mgd; Production - 8300 pounds/day (4.15 ton/day) NG
*No correction for raw water concentrations
-------
TABLE I.J.5*
NG PRODUCTION
BOTTOM PIPE IN CATCH TANK NO. 12 CARjyiNG COOLING WATER FROM AIR COMPRESSOR BLDG 9467. NG NO. 2
AREA. RAAP ln(3l
Parameter
pH
Specific Conductance
Acidity
Alkalinity
Total Solids
Suspended Solids
Dissolved Solids
Filtered Chemical
Oxygen Demand
Kjeldahl Nitrogen
Nitroglycerin
i
Minimum
8.20
210.00
0.00
80.00
127.00
^ 1.00
124.00
r " 24.00
<0.50
0.00
Maximum
9.20
465.00
0.00
107.00
628.00
4.50
628.00
148.00
<0.50
0.00
Mean
8.77
305.67
0.00
91.33
337.67
^.2.83
335.00
68.67
<0.50
0.00
Mean Raw
Corrected
Mean
Discharge
(Ibs/day)
Ibs of discharge
ton of production
•si
Elow = not available; Production = not available
*T3o coirrectioti for taw water concentrations
-------
TABLE I.J.6*
NG PRODUCTION
EFFLUENT FROM FINAL CATCH TANK OF NITROGLYCERIN STOREHOUSE BLDG 9472. PREMIX NO. 2 AREA. RAAP In(3)
**" Parameter
PH
Specific Conductance
Acidity
Alkalinity
Total Solids
Suspended Solids
Dissolved Solids
Total Organic Carbon
Filtered Chemical
Oxygen Demand
Kjeldahl Nitrogen
Nitrite and Nitrate-
Nitrogen
Nitroglycerin
Minimum
10.40
1,280.00
0.00
952.00
1,304.00
3.30
1,301.00
31.00
74.00
0.50
19.00
0.00
Maximum
11.00
8,100.00
0.00
11,700.00
8,006.00
16.30
7,998.00
630.00
815.00
0.50
19.00
83.00
-
Mean
10.63
5,393.33
0.00
6,717.33
4,088.33
9.20
4,079.33
330.50
449.67
- 0.50
19.00
48.00
Mean Raw
Corrected
Mean
Discharge
(Ibs/day)
48.1
29.3
0.0660
29.2
2.37
3.22
•" 0.00359
0.136
0.344
Ibs of discharge
ton °f production
34.8
21.2
.048
21.2
1.71
2.34
. 003
.098
.248
Flow =.000861; Production = 2765 pounds/day (1.38 ton/day) NG processed
*No correction for raw water concentrations
-------
TABLE I.J.7*
NG PRODUCTION
EFFLUENT FROM FINAL CATCH TANK OF NG MIXHOUSE BLDG 9473. PREMIX NO. 2 AREA. RAAP ln(3)
Parameter
PH
Specific Conductance
Acidity
Alkalinity
Total Solids
Suspended Solids
Dissolved Solids
Color
Total Organic Carbon
Filtered Chemical
Oxygen Demand
Nitrite and Nitrate-
Nitrogen
Nitroglycerin
*
Minimum
7.70
271.00
.00
112.00
375.00
<1.00
374.00
8.00
83.00
64.00
13.00
72.00
Maximum
8.90
295.00
1.00
210.00
623.00
24.30
615.00
8.00
83.00
400.00
13.00
72.00
Mean
8.40
282.00
.33
153.67
494.33
<10.93
483.33
8.00
83.00
221.33
13.00
72.00
Mean Raw
Corrected
Mean
Discharge
(Ibs/day)
.00550
.256
.824
.0182
.805
.138
.369
.0216
.120
Ibs of discharge
ton of production
< .001
.254 '
.820
.018
.802
.137
.368
.021
.120
=5
1
Flow = .0002 mgd; Production = 2008 pounds/day (1.00 ton/day) NG
*No correction for raw water concentrations
-------
TABLE I.J.8*
NG PRODUCTION
EFFLUENT FROM PREMIX BLDG 9303-3 AND 9303-4, SOUTHEAST. PREMIX NO. 2 AREA. RAAP In(3)
Parameter
PH
Specific Conductance
Acidity
Alkalinity
Total Solids
Suspended Solids
Dissolved Solids
Total Volatile Solid*
Total Organic Carbon
Filtered Chemical
Oxygen Demand
Total Chemical
Oxygen Demand
Biological Oxygen
Demand
Kjeldahl Nitrogen
Nitrite and
Nitrate-Nitrogen
Nitroglycerin
Minimum
7.30
90.00
.00
53.00
145.00
17.50
69.00
101.00
18.00
60.00
88.00
25.00
^.50
1.60
.00
Maximum
9.40
509.00
3.00
265.00
941.00
76.40
923.00
221.00
43.00
60.00
152.00
37.00
«<.50
6.00
40.00
Mean
8.23
316.33
1.33
158.33
518.00
44.40
473.67
168.33
33.00
60.00
120.00
31.00
<.50
3.80
13.33
Mean Raw
Corrected
Mean
Discharge
(Ibs/day)
.000665
.0791
.259
.0222
.237
.0841
.0165
.0300
.0600
.0155
<. 000250
.00190
.00667
Ibs of discharge
ton of production
(x 103)
. ,200
24.0
78.4
6,74
72.0
25.6
5.00
9,10
18.2
4.70
< ,076
.576
- .2,04
Flow = .00006 mgd; Production = 6592 pounds/day (3.30 ton/day) NG
*No correction for raw water concentrations
-------
TABLE I.L.I
OLEUM PRODUCTION
OLEUM DITCH NORTH OF PLANT. JAAP lg(3)
Parameter
Temperature (°F)
pH
Specific Conductance
Acidity
Alkalinity
Sulfates
T Hexane Extract
t
Minimum
82.0
6.2
337.0
0.0
148.0
109.0
19.3
Maximum
90.0
8.4
2,625.0
28.0
348.0
168.0
29.6
Mean
(A)
86.3
7.8
911.3
s'.o
224.3
133.4
25.4
Mean Raw
(B)
60
8.2
475
4.0
124.0
Corrected Mean
(A-B)
4.0
100.3
133.4*
25.4*
•
Discharge
(Ibs/day)
33.7
846
1,120*
214*
Ibs of discharge
ton of production
.112
2.82
3.73
,713
^ifc.
It*
Flow = ^1.012 mgd; Production = 600,000 Ib/day (300 ton/day) 40% oleum
*No correction for raw water concentrations; **100% oleum (40% actually produced)
-------
TABLE I.L.2
OLEUM DITCH
Parameter
Average Flow
pH Range
Acidity as Calcium .Car
Acidity Range
Sulfates
Nitrates as Nitrate
Color (PCU) •
Minimum
>onate
Maximum
Mean
7,340 gpm
2.3-9.8
17
0-275
153
31
5
Mean Raw
Corrected Mean
Discharge
(Ibs/day)
1,500
13,500
2,730
Ibs of discharge
ton of production
Flow = 10.570 mgd; Production = not available
*No correction for raw water concentrations
-------
TABLE I.L.3
WASTEWATER FROM ACID TANK CAR DRAINING AS IT ENTERS OLEUM DITCH lg(3)
Parameter
PH
Specific Conductivity
Acidity
Alkalinity
Total Solids
Suspended Solids
Dissolved Solids
Volatile Suspended
Solids
j Total Organic Carbon
Kjeidahl Nitrogen
Sulfates
t,
-•V
\
Minimum
7.3
6,144.0
.0
2,840.0
6,412.0
54.0
6,358.0
Maximum
i
7.9
6,144.0
.0
2,840.0
6,637.0
93.0
6,444.0
i
105.6
88.0
17.0
5,000.0
105.6
88.0
711.0
6,750.0
Mean
7.6
6,144.0
.0
2,840.0
6,474.0
73.5
6,401.0
105.6
88.0
364.0
5,875.0
Mean Raw
Corrected
Mean
i
Discharge
(Ibs/day)
Ibs of discharge
Ibs of production
==
to
to
00
-------
TABLE I.N.I*
SINGLE BASE
INDUSTRIAL WASTE SEWER NORTH OF A-LINE SINGLE BASE
PROPELLANT AREA. RAAP ln(3)
Parameter
Temperature (°F)
PH
Specific Conductance
Acidity
Alkalinity
Total Solids
Suspended Solids
Dissolved Solids
Total Volatile Solids
Color
Total Organic Carbon
Filtered Chemical
Oxygen Demand
Kjeldahl Nitrogen
Nitrite and Nitrate-
Nitrogen
Sul fates
Diethyl Ether
Ethyl Ether
Minimum
60.0
7.6
70.0
0.0
47.0
10.0
-------
TABLE I.N.2*
SINGLE BASE
SUMP TANK FOR HOLDING WASHDOWN WATER FROM DEHYDRATION BLDG J.500 - A-LINE SINGLE BASE PROPELLANT
AREA. RAAP ln(3)
Parameter
PH
Specific Conductance
Acidity •-?',: -_,
Alkalinity **"*
Total Solids
Suspended Solids
Dissolved Solids
Total Volatile Solids
Color
Total Organic Carbon
Filtered Chemical
Oxygen Demand
Biological Oxygen
Demand
Kjeldahl Nitrogen
Nitrite and Nitrate-
Nitrogen
Diethyl Ether
•t
Ethyl Ether
Minimum
Maximum
-• c \
n:.
Mean
7.50
70.00
7.00
59.00
78.00
17.00
61.00
23.00
28.00
39.00
89.00
118.00
0.50
0.70
^ 1.00
22.00
Mean Raw
Corrected
Mean
Discharge
(Ibs/day)
•
Ibs of discharge
ton of production
Flow= .000061 mgd; Production = 59,320 pounds/day (29.7 ton/day) Single Base processed
*TSo correct-ion for raw water concentrations
-------
TABLE I.N.3*
SINGLE BASE
EFFEEffiNt PJPE. CARRYING MIXHOUSE. WASHDOWN WATER AS IT ENTERS SEWER LINE NORTHWEST OF MIXHOUSE BLDG 1508. A-LINE. RAAP lr
• Parameter
PH
Specific Conductance
Acidity
Alkalinity.
Total Solids
Suspended Solids
Dissolved Solids
Total Volatile Solids
Color
Total Organic Carbon
Filtered Chemical
Oxygen Demand
Total Chemical
Oxygen Demand
Biological Oxygen
Demand
Kjeldahl Nitrogen
Nitrite and Nitrate-
Nitrogen
Diethyl Ether
Ethyl Ether
Minimum
6.70
510.00
23.00
250.00
1,572.00
324.00
1,116.00
27.00
130.00
268.00
2,000.00
1,200.00
> 350. 00
6. 90
1.00
43. 0(
54.00
A W
Maximum
6.90
683.00
169.00
550.00
3,493.00
606.00
2,887.00
8,828.00
600.00
1,700.00
2,000.00
Mean
6.80
603.67
88.67
370.00
2,223.67
473.33
1,750.33
968.00
410.00
853.33
2,000.00
1,440.00) 1,320.00
> 350. 00
11.80
6.00
189.00
1,853.00
frr-^fl
> 350. 00
8.90
3.67
116.00
953.00
A qn
Mean Raw
.
Corrected
Mean
.
•
Discharge
(Ibs/day)
*
Ibs of discharge
ton of production
i
(3)
<
Dinitrotoluene 0.20 0.23 0.21
Flow= .000091 mgd; Production= 70,000 pounds/day (35 ton/day) NC processed
*No correction for raw water concentrations
-------
TABLE I.N.4*
SINGLE BASE
EFFLUENT PIPE FROM WASHDOWN WATER COLLECTION-AS THE PIPE ENTERS THE CATCH TANK. SERVES BLDGS 1510, 1511, 1512, A-LINE,
SINGLE BASE PROPELLANT AREA. RAAP In(3)
Parameter
PH
Specific Conductance
Acidity
Alkalinity
Total Solids
Suspended Solids
Dissolved Solids
Color
Total Organic Carbon
Filtered Chemical
Oxygen Demand
Total Chemical
Oxygen Demand
Biological Oxygen
Demand
Kjeldahl Nitrogen
Nitrite and Nitrate-
Diethyl Ether
Ethyl Ether
Dinitrotoluene
Minimum
7.80
89.00
0.00
63.00
75.00
2.30
73.00
10.00
9.00
27.00
112.00
100.00
0.40
0.10
<1.00
<3.00
0.94
Maximum
8.00
215.00
2.00
200.00
831.00
435.00
396.00
80.00
31.00
27.00
112.00
100.00
2.20
1.00
<1.00
<.3.00
0.94
Mean
7.90
152.00
1.00
131.00
453.00
218.65
234.50
45.00
20.00
27.00
112.00
100.00
1.30
0.55
<1.00
<3.00
0.94
Mean Raw
Corrected
Mean
Discharge
(Ibs/day)
Ibs of discharge
ton of production
fc
. • ••*••
to
CO
to
Flow - .000038 mgd; Production = 46,420 pounds/day (23.2 ton/day) single base processed
*TSo correction for raw water concentrations
-------
TABLE I.N.5*
SINGLE BASE
EFFLUENT FROM CATCH TANK FOR WASHDOWN WATER NORTH OF PRESS AND CUTTING BLDG 1513, A-LINE. RAAP- ln(3)
Parameter
PH
Specific Conductance
Acidity
Alkalinity
Total Solids
Suspended Solids
Dissolved Solids
Color
Total Organic Carbon
Filtered Chemical
Oxygen Demand
Total Chemical
Oxygen Demand
Biological Oxygen
Demand
Kjeldahl Nitrogen
Nitrite and Nitrate-
Nitrogen
Diethyl Ether
Ethyl Ether
Acetone
Dinitrotoluene
Minimum
6.70
121.00
4.00
79.00
191.00
50.00
0.00
14.00
114.00
122.00
480.00
> 140. 00
0.90
< 0.10
3.00
52.00
1.20
0.19
Maximum
8.40
327.00
28.00
303.00
1,275.00
1,275.00
583.00
105.00
940.00
122.00
1,000.00
> 140. 00
5.10
5.00
341.00
994.50
3.25
0.23
Mean
7.40
196.67
15.00
156.33
699.67
463.33
236.33
73.00
494.67
122.00
740.00
> 140. 00
. 2.87
<1.80
155.67
514.83
2.22
0.21
Mean Raw
Corrected
Mean
Discharge
(Ibs/day)
Ibs of discharge
ton of production
to
CO
w
Flow =.000091 mgd; Production. 33,259 pounds/day (16.6
*No correction for raw water concentrations
ton/day) single base processed
-------
to
00
*>•
WASHDOWN WATER AS IT ENTERS THE CATCH
Parameter
PH
Specific Conductance
Acidity
Alkalinity
Total Solids
Suspended Solids
Dissolved Solids
Total Volatile Solids
Color
Total Organic Carbon
Filtered Chemical
Oxygen Demand
Biological Oxygen
Demand
Kjeldahl Nitrogen
Nitrite and Nitrate-
Nitrogen
Nitroglycerin
Minimum
8.10
115.00
0.00
71.50
317.50
20.00
297.50
128.50
5.00
7.00
17.00
15.00
0.90
0.25
0.00
Maximum
8.40
165.00
1.00
77.00
1,677.00
67.00
1,610.00
1,136.00
5.00
188.00
268.00
15.00
270.00
17.30
0.00
TABLE I.O.I*
MULTIBASE
PANK SOIJTH OF BLDG 4906
Mean
8.25
140.00
0.50
74.25
997.25
43.50
953.75
632.25
5.00
97.50
142.50
15.00
135.45
8.77
0.00
Mean Raw
MTXHOIISF.1 , r.-T.TNF.. MITT TTHACIT APWA BAAP ln(3)
Corrected
Mean
Discharge
(Ibs/day)
0.000833
0.124
1.66
0.0725
1.59
1.05
0.162
0.237
0.0250
0.226
0.0146
0
Ibs of discharge
ton of production
(x 103)
.276
79.4
548
24
526
348
53.6
78.2
8.26
74.8
4.82
0
Flow = .0002 mgd; Production = 6050 pounds/day (3.02 ton/day) M-30
*No correction for raw water concentrations
-------
TABLE 1.0.2*
MULTIBASE
EFFLUENT FROM CATCH TANK SOUTH OF BLDG 4906 (MIXHOUSE) C-LINE, MULTIBASE AREA. RAAP ln(3)
Parameter
PH
Specific Conductance
Acidity
Alkalinity
Total Solids
Suspended Solids
Dissolved Solids
Total Volatile Solids
Color
Total Organic Carbon
Filtered Chemical
Oxygen Demand
Biological Oxygen
Demand
Kjeldahl Nitrogen
Nitrite and Nitrate-
Nitrogen
Minimum
8.00
110.00
1.00
60.00
347.00
28.00
319.00
273.00
5.00
24.00
31.00
14.00
39.00
4.90
Maximum
8.70
145.00
2.00
76.00
624.00
28.00
596.00
409.00
10.00
46.00
40.00
35.00
66.00
7.00
Mean
8.35
127.50
1.50
68.00
485.50
33.00
457.50
341.00
7.50
35.00
35.50
24.50
52.50
5.95
Mean Raw
Corrected
Mean
Discharge --
(Ibs/day)
0.00250
0.113
0.809
0.0550
0.762
0.568
0.0583
0.0591
0.0408
0.0875
0.00991
Ibs of discharge
Con of production
(x 103)
.826
37.4
268
18.2
252
188
19.3
19.5
13.5
19.0
3.28
to
CO
en
Flow ^'.0002 mgd; Production - 6050 pounds/day (3.02 ton/day) M-30
*No correction for raw water concentrations
-------
TABLE 1.0.3*
MULTIBASE
WASHDOWN WATER ENTERING THE CATCH TANK SERVING THE HIGH ENERGY MIXHOUSE. BLDG 3692. C-LINE. MULTIBASE AREA. RAAP Intt
Parameter
PH
Specific Conductance
Acidity
Alkalinity
Total Solids
:,..,•*>.
Suspended Solids
Dissolved Solids
Total Volatile Solids
Color
Total Organic Carbon
Filtered Chemical
Oxygen Demand
Biological Oxygen
Demand
Kjeldahl Nitrogen
Nitrite and Nitrate-
Nitrogen
Minimum
Maximum
Mean
7.30
285.00
3.00
67.00
350.00
31.00
319.00
155.00
150.00
300.00
510.00
> 140.00
16.00
2.00
Mean Raw
Corrected
Mean
Discharge
(Ibs/day)
Ibs of discharge
ton of production
Flow =not available; Productions not available
*No correction for raw water concentrations
-------
TABLE 1.0.4*
MULTIBASE
EFFLUENT CATCH TANK RECEIVING WATER FROM PRESS AND CUTTING BLDG 3514, C-LINE, MULTIBASE AREA. RAAP In(3)
Parameter
PH
Specific Conductance
Acidity
Alkalinity
Total Solids
Suspended Solids
Dissolved Solids
Total Volatile Solids
Total Organic Carbon
Filtered Chemical
Oxygen Demand
Biological Oxygen
Demand
Kjeldahl Nitrogen
Nitrite and Nitrate-
Nitrogen
Nitroglycerin
Minimum
7.70
33.00
2.00
27.00
57.00
12.50
44.00
26.00
23.00
43.00
49.00
1.50
0.70
0.00
Maximum
8.00
75.00
5.00
40.00
57.00
25.00
44.00
26.00
32.00
137.00
49.00
1.60
0.80
0.00
Mean
7.85
54.00
3.50
33.50
57.00
18.75
44.00
26.00
27.50
90.00
49.00
1.55
0.75
0.00
Mean Raw
>•
Corrected
Mean
Discharge
(Ibs/day)
0.0105
0.100
0.171
0.056
0.132
0.0780
0.0825
0.270
0.147
0.00465
0.00225
0
Ibs of discharge
ton of production
(x 103)
.726
6.92
11.8
3.88
9.12
5.40
5.70
18.7
10.2
.322
.156
0
Flow* .0029988; Production - 28,930 pounds/day (14.5 ton/day) M-30
*No correction for raw water concentrations
-------
to
w
CD
TABLE 1.0.5*
MULTIBASE
INFLUENT TO SAND FILTER NORTH OF AP CHEMICAL ^ GRIND, BLDG 3670, MULTIBASE AREA. RAAP In (3)
Parameter
PH
Specific Conductance
? i
Minimum
7.90
205.00
Maximum
8.70
12,500.00
Mean
8.37
4,306.67
Mean Raw
•
Corrected
Mean
Discharge
(Ibs/day)
•
Ibs of ^discharge
ton of production
•
Flow= not available; Production = not available
*No correction for raw water concentrations
-------
TABLE 1.0.6*
MULTIBASE
WASHDOWN WATER FROM HE SLURRY MIXHOUSE., BLDG 3671, AS IT LEAVES CATCH TANK, C-LINE. MULTIBASE AREA. RAAP In(3)
Parameter
pH
Specific Conductance
Color
Total Organic Carbon
Minimum
7.50
8,300.00
15.00
3,500.00
Maximum
7.70
13,500.00
r 25.00
5,300.00
Mean
7.57
10,633.00
20.00
4,600.00
Mean Raw
Corrected
Mean
Discharge
(Ibs/day)
13.8
Ibs of discharge *
ton- of production
9.72
to
GO
CD
Flow - .00036 mgd; Production - 2835 pounds/day (1.42 ton/day) Sprint ABL 2901 DQ/D
*No correction for raw water concentrations
-------
FLOW IN GENERAL PURPOSE SEWER SERVING PREROLL,
TABLE I.P.I
ROLLED POWDER
ETC., IN-THE SOUSTHTROLLED POWDER AREA PRIOR TO DISCHARGE TO SETTLING BASIN
RAAP in(3)
Parameter
Temperature (°F)
PH
Specific Conductance
Acidity
Alkalinity
Total Solids
Suspended Solids
Dissolved Solids
Total Volatile Solids
Color
Total Organic Carbon
Filtered Chemical
Oxygen Demand
Biological Oxygen
Demand
Kjeldahl Nitrogen
Nitrite and Nitrate-
Nitrogen
Sulfates
Minimum
59.0
7.8
109.0
0.0
91.0
115.0
- 1.0
96.0
-*. 10-0
5.0
6.0
14.0
1.0
0.5
^ 0.1
14.0
Maximum
78.0
10.0
636.0
2.0
369.0
1,047.0
18.6
1,039.0
443.0
40.0
40.0
102.0
34.0
4.0
7.9
37.0
Mean
68.2
8.9
383.3
0.1
223.2
468.6
6.9
461.9
148.5
12.0
13.5
31.4
7.9
1.0
1.6
22.5
Mean Raw
Corrected
Mean
t
Discharge
(Ibs/day)
0.0332
74.2
156
2.29
154
49.4
4.49
10.4
2.62
0.332
0.532
7.48
Ibs of discharge
ton of production
.012
27.4 -
57,8
.848
57.0
18.3
1.66
3.84
,970
.123
.197
2.76
Flow = .0399 mgd; Production = 5400 pounds/day (2.70 ton/day) propellant
-------
EFFLUENT CHANNEL FRC
Parameter
Temperature (°F)
pH
Specific Conductance
Acidity
Alkalinity
Total Solids
Suspended Solids
Dissolved Solids
Total Volatile Solids
Total Organic Carbon
Biological Oxygen
Deaand
Kjeldahl Nitrogen
Sulfates
TABLE I.P.2
ROLLED POWDER
m FINAL CATCHBASIN SERVING THE BLENDING BLDG NO. 6304 IN THE FIRST ROLLED POWDER AREA. RAAP ln(3]
Minimum
Maximum
-
Mean
56.0
8.4
130.0
0.0
61.0
128.0
9.5
. 118.0
92.0
11.0
6.0
1.1
16.8
nean Raw
•
Corrected
Mean
Discharge
(Ibs/day)
21.7
45.6
3.39
42.0
32.8
3.92
2.14
0.392
5.99
Ibs of discharge
ton of production
8.68
18.2
1.36
16,8
13.1
1.56
.856
.157
2.40
Flow - .0428 mgd; Production = 5000 pounds/gay (2i5 ton/day) M-8 propellant
-------
TABLE I. P. 3
ROLLED POWDER
DISCHARGE GUTTERS ENTERING CATCHTANK SOUTH OF PREROLL BLDG 9309-4, FOURTH ROLLED POWDER AREA (INDIVIDUAL BAY WASHDOWNS SAMPLE
RAAP ln(3) -
Parameter
PH
Specific Conductance
Total Solids
Suspended Solids
Total Organic Carbon
Filtered Chemical
Oxygen Demand
%
•?'
Minimum
8.70
135.00
280.00
29.00
11.00
38.00
Maximum
11.60
3,690.00
5,462.00
. 402.00
566.00
731.00
Mean
10.36
1,085.43
1,761.71
179.29
137.14
197.14
Mean Raw
Corrected
Mean
Discharge
(Ibs/day)
16.7
1.70
1.30
1.87
Ibs of discharge
ton of production
18.6
1.89
1.44
Flow » .00114 mgd; Production = 1800 pounds per day (.9 ton/day) propellant
-------
TABLE I.P.A
ROLLED POWDER
WASHWATER TROUGH LEADING IN FROM BLENDER BLDG 6304, FIRST CATCH BASIN, FIRST ROLLED POWDER AREA. RAAP ln(3)
Parameter
PH
Specific Conductance
Total Solids
Suspended Solids
Dissolved Solids
Total Organic Carbon
Filtered Chemical
Oxygen Demand
Biological Oxygen
Demand
Nitrite and Nitrate-
Nitrogen
Mil* •><""»"
7.40
115.00
109.00
1.30
108.00
4.00
10.00
1.00
0.10
•
Maximum
8.90
136.00
174.00
23.00
151.00
11.00
16.00
12.00
0.10
Mean
7.87
127.50
127.00
6.90
120.25
7.25
11.50
4.50
0.10
Mean Raw
Corrected
Mean
Discharge
(Ibs/day)
3.24
0.176
3.07
0.185
0.294
0.115
0.00255
Ibs of discharge
ton of production
(x 10J)
432
23.4
410
24.6
39.2
15.3
.34
Flow - .003066 ragd; Production - 15000 pounds/day (7.5 ton/day) rolled powder
CO
-------
EFFLUENT FROM CLEANOUT
TABLE I.P. 5
ROLLED POWDER
OF BOTTOM OF ROTOCLONE AS IT EMPTIES INTO FIRST CATCH TANK, BLDG 6304, FIRST ROLLED POWDER AR1:
RAAP ln(3T
Parameter
PH
Specific Conductance
Total Solids
Suspended Solids
Dissolved Solids
Total Organic Carbon
Filtered Chemical
Oxygen Demand
Biological Oxygen
Demand
Nitrite and Nitrate-
Nitrogen
Minimum
7.50
131.00
129.00
3.50
122.00
9.00
10.00
1.00
1.20
Maximum
8.10
138.00
398.00
98.50
299.00
13.00
22.00
40.00
1.20
Mean
7.80
134.67
221.00
38.67
182.00
11.33
17.67
18.33
1.20
Mean Raw
•
Corrected
Mean
Discharge
(Ibs/day)
4.97
0.870
4.09
0.255
0.397
0.412
0.0270
•
Ibs of discharj
ton of product:
(x 103)
662
116
t
246
34
52.8
55.0
3.6
•
Flow = .0027 mgd; Production = 15000 pounds/day (7.5 ton/day) rolled powder
-------
TABLE I,P.6
COMBINED WASTEWATER FROM THE BALL POWDER AREA. BAAP la/2)
Parameter
Temperature (°F)
PH
Conductance
Total Kjeldahl Nitrogei
Ammonia
Nitrates
Total Phosphates
Sulfates
Chemical Oxygen Demand
JTU
Color (Platinum-Cobalt)
MBAS
Total Organic Carbon
Total Solids
Suspended Solids
Dissolved Solids
Minimum
53
5.7
300
1.0
0.50
- 0.5
~~'0.5
36
42
0.64
0
0.00
20
242
0.6
241
Maximum
83
9.2
13,500
5.2
2.45
31.3
0.7
361
102
56
.10
0.10
130
724
15.4
715
Mean
62
7.3
1,220
2.1
1.31
5.8
0.63
247
72
11.10
2.86
0.03
63
531
8.2
523
Mean Raw
7.36
2.28
0.74
0.63
0.63
38
45
6.1
77
0.16
27
200
13.7
186
Corrected
Mean
0.57
5.17
209
27
36
331
337
Discharge
(Ibs/day)
Ibs of discharge
ton of production
to
I*.
Ut
Flow = not determined; Production = 50% of capacity
-------
TABLE I.Q.I*
NITRATOR DITCH. JAAP lc(l)
Parameter
Average Flow l\ "fv
PH
Acidity as Calcium Car
Sulfates
Nitrates
Color (PCU)
Minimum
tonate
Maximum
Mean
450 gpm
1.6
2,983
2,783
560
263
Mean Raw
Corrected Mean
•
Discharge
(Ibs/day)
16,100
15,000
3,020
Ibs of discharge
ton of production
N>
*«.
as
Flow = .648mgd; Production =not available
*N# correction for raw water concentrations
-------
TABLE I.Q.2
REFINING DITCH. JAAP (3f)
Parameter
Average Flow
PH
Acidity as Calcium Car
Sulfates .as Sulfate
Nitrates as Nitrate
Color (PCU)
Minimum
>onate
Maximum
Mean
350 gpm
2.5
165
260
55
313
Mean Raw
Corrected Mean
Discharge
(Ibs/day)
693
1,090
231
Ibs of discharge
ton of production
•
Flow = .504 mgd; Productions not available
*No correction for raw water concentrations
-------
TABLE I.Q.3*
DRY HOUSE DITCH. JAAP (3f)
Parameter
Average Flow
PH
Acidity as Calcium Car
Sulfates
Nitrates
Color (PCU)
Minimum
>onate
Maximum
Mean
40
12.5
0
137
33
1,000
Mean Raw
Corrected Mean
Discharge
(Ibs/day)
0
65.7
15.8
Ibs of discharge
ton of production
Flow» .0576 mgd; Production* not available
*No correction for raw water concentrations
-------
TABLE I.Q.4
TETRYL PRODUCTION
DITCH A BETWEEN HALF TILE DRAIN AT BLDG 1002-7 AND FOOT BRIDGE ACROSS DITCH. JAAP lg(3)
Parameter
Temperature (°F)
PH
Specific Conductance
Acidity
Alkalinity
Color
Total SolidS
Suspended Solids
Total Dissolved Solids
Total Volatile Solids
Total Organic Carbon
Total Kjeldahl Nitrogei
Sulfates
Sulfides
Minimum
75.0
2.2
727.0
162.0
0.0
30.0
941.0
4.0
866.0
165.0
10.3
1.6
580.0
0.0
Maximum
84.0
6.6
3,150.0
430.0
0.0
>100.0
3,012.0
96.0
3,007.0
1,004.0
14.4
5.5
1,220.0
0.0
Mean
78.1
3.1
8,875.4
314.3
0.0
70.0
1,565.1
-<36.7
1,528.4
458.9
12.5
2.6
778.6
0.0
Mean Raw
60.0
8.2
475.0
4.0
124.0
25.0
748.0
28.0
720.0
7.6
1.0
Corrected Mean
310.3
817.1
< 8.7
808.4
458.9*
4.9
1.6
778.6*
0*
Discharge
(Ibs/day)
3,748
9,869
^.106
8,764
5,543*
59.2
9.3
9,404*
0*
Ibs of discharge**
ton of production
797
2100
<. 22.6
1860
1180
12.6
1.98
2000
0*
Flow =1.45 mgd; Production - 9,404 Ib/day (4.70 ton/day) tetryl
*No correction for raw water concentrations; **Tetryl produced
-------
TABLE I.Q.5
TETRYL PRODUCTION
DITCH B APPROXIMATELY 45 FEET EAST OF THE MAIN TETRYL DITCH. JAAP lg(3)
Parameter
Temperature (°F)
PH
Specific Conductance
Acidity
Alkalinity
Color
Total Solids
Suspended Solids
Total Dissolved Solids
Total Volatile Solids
Total Organic Carbon
Total Kjeldahl Nitrogei
Sulfates
Sulfides
Minimum
73.0
6.9
269.0
0.0
56.0
10.0
149.0
*U..O
142.0
61.0
15.0
1.3
97.0
0.0
Maximum
77.0
8.4
490.0
20.0
128.0
90.0
790.0
78.0
790.0
677.0
19.8
4.3
133.0
0.0
Mean
(A)
75.1
7.4
381.4
13.7
98.3
50.0
485.3
-------
TABLE I.Q.6*
NITRATING & REFINING HOUSES. JAAP lg(3)
Parameter
Tetryl
Chemical Oxygen Demand
Dissolved Solids
Nitrates as Nitrate
Sulfates as Sulfate
PH
Acidity as Calcium Car
(pH = 7.0)
t
Minimum
>onate
Maximum
Mean
415
370
21,800
2,700
18,500
0.9
19,900
Mean Raw
Corrected Mean
•
Discharge
(Ibs/day)
847
755
44,500
5,510
37,800
40,600
Ibs of discharge
ton of production
Flow = 120 gpm = .245 mgd; Production = not available
*No correction for raw water concentrations
-------
TABLE I.R.I**
TNT PRODUCTION
SCRUBBER WATERS FROM NITRATION BLDG 9500 BEFORE FLOWING TO THE RED WATER DESTRUCTION FACILITY. RAAP In(3)
Parameter
PH
Specific Conductance
•Acidity
Alkalinity
Total Solids
Suspended Solids
Dissolved Solids
Color
Total Organic Carbon
Fil Chemical Oxygen D
Total Kjeldahl Nitrog
N02-N03/N
Sulfate
TNT
Minimum
3.00
175.00
13.00
0.00
167.00
^1.00
166.00
45.00
9.00
emand 12.00
en 2.20
2.00
24.00
2.00
Maximum
7.20
750.00
101.00
42.00
274.00
2.80
271.00
720.00
13.00
24.00
3.10
12.70
146.00
5.80
Mean
5.43
391.67
44.67
28.00
221.83
1.70
220.00
278.33
11.33
17.00
2.73
6.80
73.33
3.90
Mean Raw
Corrected Mean
Discharge
(Ibs/day)
5.21
91.43
25.81
0.20
25.66
32.46
1.98
0.32
0.79
8.55
0.45
Ibs of discharge
ton of production
.108
1.89
.533
.004
.530
.670
.041
.007
.016
.176
•&*
.009
*TNT produced
**Nq correction for raw water concentrations
Flow » .0014 mgd; Production = 96,893 Ib/day (48.4 ton/day) TNT
-------
TABLE I.R.2**
TNT PRODUCTION
DRAINAGE FROM OLEUM TANK CARS. RAAP
ln(3)
Parameter
pH
Specific Conductance.
Acidity
Alkalinity
Total Solids
Suspended Solids
Dissolved Solids
N02-N03/N
Sulf ate
Minimum
8.90
10,300.00
0.00
3,820.00
942.00
23.00
919.00
0.50
7,600.00
Maximum
10.40
15,600.00
0.00
28,300.00
31,709.00
134.00
31,665.00
5.00
13,000.00
Mean
9.83
13,700.00
0.00
13,123.33
18,180.33
67.00
18,113.33
2.00
LO.633.33
Mean Raw
Corrected Mean
'
Discharge
(Ibs/day)
1,169.70
1,620.43
5.97
1,614.46
0.18
947.76
Ibs of discharge
ton of production
8.07
11.2
.041
11.1
.001
6.54
CO
en
03
*TNT produced .
**No correction for raw water concentrations >
Flow = .0107 mgd; Production^ 291,000 Ib/day (145 ton/day) TNT
-------
EFFLUENT FROM SETTL
Parameter
Temperature
PH
Specific Conductance
Acidity
Alkalinity
Total Solids
Suspended Solids
Dissolved Solids
Color
Total Organic Carbon
Fil Chemical Oxygen D
Total Kjeldahl Nitrog
N02-N03/N
Sulfate
TNT
Minimum
69.0
7.6
90.0
0.0
48.0
22.0
1.0
13.0
5.0
16.0
amand 11.0
an 0.3
0.2
12.6
1.8
Maximum
108.0
9.3
135.0
2.0
79.0
619.0
41.7
577.0
760.0
43.0
33.0
3.7
45.0
26.4
75.4
TABLE I.R.3**
TNT PRODUCTION
ENG TANK (FLOOR WASH WATER). BLDG 9503. RAAP ln(3)
Mean
89.1
8.7
112.5
0.2
65.3
172.5
7.4
164.8
110.9
23.9
16.3
1.0
2.7
15.7
46.7
Mean Raw
Corrected Mean
Discharge
(Ibs/day)
0.01
3.86
10.2
0.44
9.75
1.41
0.96
0.06
0.16
0.93
2.76
Ibs of discharge*
ton of production
< .001
.080
.211
.009
.201
.029
.020
.001
.003
.019
052
*TNT produced
**No correction for raw water concentrations
Flow = .0071 mgd; Production = 96,893 Ib/day (48.4 ton/day) TNT
-------
TABLE I.R.4**
TNT PRODUCTION
SCRUBBER WATER IN TANK OF FINSIHING BLDG 9503. RAAP
Parameter
PH
Specific Conductance
Acidity
Alkalinity
Total Solids
Suspended Solids
Dissolved Solids
Color
Total Organic Carbon
Fil Chemical Oxygen
Demand
Total Kjeldahl Nitrog
N02-N03/N
Sulfate
TNT
Minimum
6.90
132.00
1.00
63.00
93.00
2.00
91.00
260.00
63.00
118.00
m 2.00
2.40
19.50
145.00
Maximum
7.70
144.00
4.00
75.00
286.00
2.30
284.00
520.00
69.00
280.00
3.20
6.60
35.00
1,525.00
Mean
7.37
137.00
2.00
68.33
158.33
2.10
156.33
358.33
65.67
173.67
2.67
4.37
25.00
608.33
Mean Raw
Corrected Mean
Discharge
(Ibs/day)
0.023
0.797
1,85
0.024
1.82
0.766
2.02
0.031
0.051
0.292
7.09
Ibs of discharge
ton of production*
< .001
.016
.038
^ .001
.038
.016
.042
< .001
.001
.006
.146
Flow = .0014 mgd; Production = 96,893 Ib/day (48.4 ton/day) TNT
*TNT produced
**No correction for raw water concentrations
-------
TABLE I.R.5**
TNT PRODUCTION
YELLOW WATER AS IT ENTERS THE CATCH TANK IN THE RED WATER DESTRUCTION AREA. RAAP In(3)
Parameter
PH
Specific Conductance
Acidity
Alkalinity
Total Solids
Suspended Solids
Dissolved Solids
Color
Total Organic Carbon
Fil Chemical Oxygen
Demand
i
Total Kjeldahl '
Nitrogen
N02-N03/N
Sulf ates .
TNT
Minimum
0.50
110,000.00
63,000.00
0.00
52,238.00
52.50
52,185.00
560.00
1,700.00
2,700.00
101.00
1,210.00
56,000.00
740.00
Maximum
1.00
185,000.00
171,200.00
0.00
137,696.00
131.00
137,595.00
720.00
10,000.00
10,000.00
215.00
6,000.00
99,999.00
1,600.00
Mean
0.77
136,666.67
101,533.33
0.00
82,930.67
94.77
82,835.67
633.33
4,476.67
5,133.33
140.33
3,770.00
85,332.67
1,113.33
Mean Raw
Corrected Mean
.
Discharge
(Ibs/day)
1,220
995
1.14
994
53.7
61.6
1.68
45.2
1,020
13.4
Ibs of discharge
ton of production*
8.41
6.86
.008
6.86
.370
.425
.012
.312
7.03
.092
Flow = .00144 mgd; Production = 291,000 Ib/day (145 ton/day) TNT
*TNT produced
**No collection for raw water concentrations
-------
TABLE I.R.6**
TNT PRODUCTION
INFLUENT TO WASTE ACID NEUTRALIZATION FACILITY. RAAP In(3)
Parameter
Temperature
pH
Specific Conductance
Acidity
Alkalinity
Total Solids
Suspended Solids
Dissolved Solids
Color
Total Organic Carbon
Fil Chemical Oxygen
Demand
Total Kjeldahl
Nitrogen
N02-N03/N
Sulfate
TNT
Sodium
Mipimynn
75.0
1.6
1,320.0
30.0
0.0
352.0
3.0
349.0
100.0
31.0
22.0
1.4
12.0
135.0
48.0
14.0
Maximum
96.0
7.3
20,000.0
5,020.0
760.0
8,260.0
609.5
8,122.0
1,200.0
120.0
220.0
10.1
610.0
5,500.0
175.0
1,700.0
Mean
86.2
3.4'
4,485.4
1,056.0
59.7
2,304.5
87.0
2,217.5
574.6
57.2
57.3
4.2
63.3
1,554.0
91.2
464.2
Mean Raw
Corrected Mean
Discharge
(Ibs/day)
1,430
80.9
3,120
118
3,000
77,52
77.7
5.69
85.8
2,160
123
629.13
Ibs of discharge
toff of production*
9.86
.558
21.5
.814
20.7
.534
.536
.039
.592
14.9
.848
.4.34
Flow .- .1627 mgd; Production * 291,000 Ib/day (145 ton/day) TNT
*TNT produced
**No correction for raw water concentrations
-------
TABLE I.R.7**
TNT PRODUCTION
WASTES GENERATED IN THE SAR AREA, INCLUDING SOME ACID SPILLS, BEFORE FLOWING TO THE ACID NEUTRALIZATON FACILITY FOR TREATMENT
RAAP ln(3)
Parameter
Temperature
PH
Specific Conductance
Alkalinity (as CaC03>
Acidity (as CaC03>
Total Solids
Volatile Solids
Suspended Solids
Dissolved Solids
Color
Total Kjeldahl
Nitrogen
Nitrites as Nitrogen
Nitrates as Nitrogen
Sulfates
Chemical Oxygen
Demand
.4
Minimum
80
5.2
16
35.4
0
90
24
45
40
5
0.5
< 0.2
< 2.0
<25.Q
5.0
Maximum
93
8.3
76
101.0
4.4
634
102
130
504
50
2.9
3.5
150
1,000
67.0
Mean
88
7.1
27
48.9
1.9
229
62
68
161
17
1.1
< 0.2
5.8
52.8
23.0
Mean Raw
Corrected
Mean
Discharge
(Ibs/day)
990
38.4
4,640
1,250
1,380
3,260
22.3
4.05
117
1,070
466
Ibs of discharge
ton, of productiort*
6; 83
.265
32.0
8.62
9.52
22.5
.154
.028
.807
7.38
3.21
Flow - 2.4299 mgd; Production = 291,000 Ib/day (145 ton/day) TNT
*TNT produced; **No correction for raw water concentrations
-------
TABLE I.R.8
TNT PRODUCTION
TNT DITCH BELOW MAIN COOLING WATER DISCHARGE FROM TNT BATCH LINE 10, AREA 5. JAAP lg(3)
Parameter
Temperature (°F)
PH
Specific Conductance
Acidity
Alkalinity
Color
Total Solids
Suspended Solids
Total Dissolved Solids
Total Organic Carbon
Total Kjeldahl Nitrogei
Nitrate-Nitrogen
Sulfates
TNT
Minimum
80.0
6.4
425.0
0.0
84.0
5.0
594.0
1.0
465.0
12.4
i 0.9
15.4
113.0
0.0
Maximum
88.0
7.6
1,388.0
20.0
304.0
25.0
925.0
84.0
844.0
17.3
8.0
17.0
178.0
1.3
Mean
84.0
7.2
688.6
5.0
154.3
13.3
753.4
43.9
702.0
15.1
3.0
16.5
153.1
0.8
Mean Raw
60.0
8.2
475.0
4.0
124.0
25.0
748.0
28.0
720.0
7.6
1.0
Corrected Mean
13.1
30.3
5.4
15.9
7.5
2.0
16.5*
153.1*
0.8*
Discharge
(Ibs/day)
165
283
68.0
200
94.5
25.2
208*
1,930*
10.0*
Ibs of discharge
ton of production
3.28
7.58
1.35
3.96
1.87
.500
4.12*
38.2*
.198*
Flow = 1.512 mgd; Production = 100,831 Ib/day (50.4 ton/day) TNT
*No correction for raw water; **TNT produced
-------
TABLE I.R.9
TNT PRODUCTION
RED WATER ENTERING SETTLING TANK OUTSIDE WASH HOUSE, LINE 10. JAAP lg(3)
Parameter
Temperature (°F) ^^h
Minimum
_ 72.0
pH ^BF 7.2
Specific Conductance
Acidity
Alkalinity
Color
Total Solids
Suspended Solids
Dissolved Solids
Total Volatile Solids
Total, Organic Carbon
Kjeldahl Nitrogen
Nitrate-Nitrogen
Sulfates
24,000.0
0.0
2,700.0
5.0
25,170.0
20.0
25,135.0
9,690.0
3,050.0
89.2
7.9
8,600.0
Maximum
149.0
9.5
37,500.0
20.0
4,000.0
5.0
30,220.0
58.0
30,168.0
13,700.0
4,500.0
163.7
8.6
9,000.0
Mean
128.2
8.6
28,200.0
5.0
3,620.0
5.0
27,225.0
41.2
27,183.7
11,856.7
3,612.5
120.5
8.2
8,900.0
Mean Raw
60.0
8.2
475.0
4.0
124.0
25.0
748.0
28.0
720.0
7.6
1.0
Corrected Mean
1.0
3,496
26,477
13.2
26,464
11,856.7*
3,605
120
8.2*
8,900.0*
Discharge
(Ibs/day)
0.50(
1,747
13,233
6.60
13,227
5,926*
1,802
60.0
4.10*
4,450*
Ibs of discharge
tour of production
.010
34.6
262
.131
262
118*
35.7
1.19
.081*
88.3*
*
e*
Flow- .06 mgd; Production =100,831 pounds/day. (50.4 ton/day) TNT
*No correction for raw water concentrations; **TNT produced
-------
TABLE I.R.10
TNT PRODUCTION (SELLITE PRODUCED)
SELLITE DITCH ABOUT 20 FEET BELOW EARTH DAM. JAAP lg(3)
Parameter
Temperature (°F)
PH
Specific Conductance
Acidity
Alkalinity
Total Solids
Suspended Solids
Total Dissolved Solids
Total Organic Carbon
Sulfates
Sulfides
T Hexane Extract
Minimum
65.0
2.1
692.0
9.0
0.0
824.0
^ 1.0
784.0
6.0
530.0
10.0
10.5
Maximum
79.0
7.8
4,800.0
720.0
382.0
2,030.0
40.0
2,015.0
10.2
1,400.0
1,600.0
31.4
Mean
(A)
72.0
5.3
1,886.7
209.7
125.0
1,453.2
17.1
1,438.2
8.5
928.6
330.0
21.1
Mean Raw
(B)
60
8.2
475.0
4.0
124.0
748.0
28.0
720.0
7.6
Corrected Mean
(A-B)
204.7
1.0
705.2
718.2
0.9
928.6*
330.0*
21.1*
Discharge
(Ibs/day)
295
1.44
1,020
1,030
1.30
1,340*
476*
30.4*
Ibs of discharge
ton- of production*
13.9
.068
47.8
48.4
.060
63.0*
22.4*
1.43*
Flow -.173 mgd; Production -42,509 pounds 100% sellite/day
*No correction for raw water concentration; **Sellite produced
-------
TABLE I ,S . 1
AOP
WASTEWATER FROM: 2 CONDENSATE QUENCH POTS (BUILDING 33); 4 BAROMETRIC SEAL TANKS (BUILDING 334); 3 CONDENSATE COOLERS
(BUILDING 302); BUILDING 302-B; AND BUILDING 300. AREA B. HAAP ld(2)***
Parameter
Ammonia as Nitrogen
Nitrites and Nitrates
as Nitrogen
Kjeldahl Nitrogen as
Nitrogen
• Orthophosphate as
Phosphorus
Acidity as Calcium
Carbonate
Alkalinity as Calcium
Carbonate
Total Solids
Suspended Solids
Dissolved Solids
Chemical Oxygen Demand
Total . Organic Carbon
Biological Oxygen
Demand
Flow = 6.04 mgd; Produi
*61% HN03 produced
**not corrected for fii
***assume all pollutan
.4
Minimum
0.70
1.6
0.7
<0.03
1.2
63
83
0.2
82
18
5
<5
:tion = 400,
tered raw w
discharge
Maximum
1.93
6.1
2.2
0.03
8.9
78
346
137
346
31
12
11
)00 Ib/day (
iter - Area :
Ls a result
«.
Mean
00 ton/day)
, Holston R:
f ammonia o:
Avg. ppm R
1.27
3.17
1.53
<0.03
3.4
69
244
0.7
236.6
22
8
<5
61% HN03
ver
idatioh
ppm R -
ppm filtere
raw water
2.40
0.5
20
13.6
3.7
<5**
.
Discharge
d (Ibs/day)
121
25
1,000
684
190
<300**
.
Ibs of discharge
ton of production*
0.605
0.125
5.00
3.42
0.95
1.5**
i
-------
TABLE I.S.2
AOP
COOLING WATER FROM 2 CHICAGO PNEUMATIC CENTRIFUGAL PRECOMPRESSORS LOCATED IN THE SOUTHWEST CORNER OF BUILDING 302-B AND
A PORTION OF THE COOLING WATER FROM THE OTHER BUILDING 302-B PRECOMPRESSORS. AREA B. HAAP ld(?)
Parameter
Ammonia as Nitrogen
Nitrites and Nitrates
as Nitrogen
Kjeldahl Nitrogen as
Nitrogen
Orthophosphate as
Phosphorus
Acidity as Calcium
Carbonate
Alkalinity as Calcium
Carbonate
Total Solids
Suspended Solids
Dissolved Solids
Chemical Oxygen Demand
Total Organic Carbon
Biological Oxygen
Demand
Flow = .31 mgd; Produc
*61% HN03 produced
**not corrected for fi
Minimum Maximum
;
0.50
1.9
1.0
<0.03
0
71
96
0.5
93
19
7
<5
:ion = 400, q
1.90
65.0
3.4
0.17
5.9
91
762
3.8
759
23
26
9
00 Ib/day (2
.tered raw w
iter - Area
Mean
00 ton/day)
J, Hols ton R:
I
Avg. ppm S
1.29
13.9
1.83
<0.03
1.96
79
243
1.9
315
21
3
<5
61% HN03 (as
ver
ppm S - ppn
filtered n
water
13.1
0.17
3.7
19
1.1
92
2.7
4.2
<5**
100% HN03)
.
Discharge
w (Ibs/day)
33.8
0.439
9.6
49.1
2.8
238
7.0
11
-------
TABLE I .S . 3
AOP
WASTEWATER FROM AMMONIA TRANSFER OPERATION FLOWING DIRECTLY TO ARNOTT BRANCH CREEK. AREA B. HAAP Id(2)
Parameter
Ammonia as Nitrogen
Nitrites and Nitrates
as Nitrogen
Kjeldahl Nitrogen as
Nitrogen
Orthophosphate as
Phosphorus
Alkalinity as Calcium
Carbonate
Total Solids
Suspended Solids
Dissolved Solids
j Chemical Oxygen Demand
; Total Organic Carbon
Biological Oxygen
Demand
i
Minimum
4.6
0.6
6.0
v. 0.03
95
125
0.25
119
19
7
Maximum
i
115.0
2.9
162
0.07
172
277
59.3
262
30
26
<5 15
i
i
Flow = .0134 mgd; Production = 400.
000 Ib/day
*6l% HN03 produced
**not corrected for fi
.tared raw w
ater - Area
*
Mean
200 ton/day)
J, Hols ton R
Avg. ppm T tpm T - ppm
filtered
25.7
1.51
30.6
0.03
121.5
199.4
14.3
185.2
25.2
14.2
<5
61% HN03 (t
Lver
raw water
24.2
0.74
28.9
46.2
13.5
0.2
<5**
s 100%. HN03
Discharge
(Ibs/day)
2.70
0.08
3.23
5.16
1.51
0.02
<0.6**
)
Ibs of discharge
ton of production*
.014
.0004
.016
.026
.008
.0001
^ .003
•
to
OJ
-------
TABLE I.S.4
AOP
MINOR COOLING WATER FLOWS FROM AMMONIA UNLOADING OPERATIONS AND BUILDING 300, AND CONDENSATE RECEIVER TANK AND CONDENSATE
COOLER WATER FROM BUILDING 334. AREA B. HAAP ld(2)
Parameter
Ammonia as Nitrogen
Nitrites and Nitrates
as Nitrogen
Kjeldahl Nitrogen as
Nitrogen
Orthophosphate as
Phosphorus
Acidity as Calcium
Carbonate
Alkalinity as Calcium
Carbonate
Total Solids
Suspended Solids
Dissolved Solids
Chemical Oxygen Demand
Total Organic Carbon
Biological Oxygen
Demand
Grease and Oil
Flow =2.86 mgd; Produ
*corrected for filtere<
**61% HN03 produced
***assume all pollutan
Minimum
Maximum
i
0.3
6.0
0.7
1.0
26
329
3.8
1.6
24.0
3.3
6.3
54
573
13.7
I
19 1 56
6.0
ction = 400,
raw water
t discharge
19
000 Ib/day (
Ls the resul
Mean
200 ton/day)
t of ammonia
Avg. ppm W
0.9
10.4
1.4
2.5
45
467
7.7
43
9.8
61% HN03 (a
oxidation (
ppm W - ppn
filtered
raw water
9.6
243
6.9
236
25
1.0
: 100% HN03
>roduction <
Discharge
(Ibs/day)
.
230
5,790
164
5,620
600
24
if weak HN03> oper
Ibs of discharge
ton of production *
1.15
29.0
0.820
28.1
3.00
0.12
it ions
-------
TABLE I.S.5*
ACID AREAS 1 & 2. JAAP (3**)
Parameter
Average Flow
PH
Acidity as Calcium Car
Sulfates
Nitrates as Nitrate
Color (PCU)
Minimum
>onate
•• -# ,
Maximum
Mean
14,700 gpm
7.2
23
373
26
5
Mean Raw
Corrected Mean
Discharge
(Ibs/day)
4,060
65,800
4,580
Ibs of discharge
ton of production
Flow =21.168 mgd; Production31 not available
*No correction for raw water values
-------
TABLE I.S.6*
ACID 3 OUTFALL. JAAP (3f)
Parameter
Average Flow
pH Range
Acidity as Calcium Car
Acidity Range
Sulfates
Nitrates as Nitrate
Color (PCU)-
t
Minimum
>onate
Maximum
Mean
7,800 gpm
2.6-9.7
168
0-2389'
320
30
30
Mean Raw
Corrected Mean
•
Discharge
(Ibs/day)
15,700
29,900
2,810
Ibs of discharge
ton of production
Flow = 11.232 mgd; Production = not available
*No correction for raw water concentrations
------- |