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

-------
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

-------
                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

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         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

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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

-------
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.

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                                 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

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                                   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

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         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

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         (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

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         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

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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

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          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

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                                  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

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                                  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

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                                  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

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                                 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

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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

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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

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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

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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

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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

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     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

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                                                      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

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                                 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

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                                                   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

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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

-------
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

-------
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

-------
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

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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

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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)

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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.
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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

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                             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

-------
                                   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

-------
                             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

-------
                              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

-------
                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

-------
                                 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

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                                                     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

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                                                               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

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                                                      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

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                                                       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

-------