Report to
Department of Health
State of Hawaii
Honolulu
Evaluation of Waste Control and Treatment Systems
for
Hawaiian Petroleum Refinery and Other Hajor Hawaiian Industries
January 23 to February 3t
By
Hnyse H. Black
Sanitary Engineer Director
Industrial Wastes Consultant
S. DEPARTMENT 07 HZAIffH. EDUCATION, AttD WBJJTAHS
Public Health Service
Rooert A. Taft Sanitary Engineering Center
Cincinnati, Ohio
March 196!
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18716
Report to
Department of Health.
State of Hawaii
Honolulu
Evaluation of Waste Control and Treatment Systems
for
Standard Oil Co., Hawaiian Refinery (Petroleum)
fhe Flint koto Company, Canec Division (Bagasse)
Hakalau Sugar Company, Ltd. (Sugar)
Hawaiian Agricultural Company (Sugar)
American Jactors, Ltd,, Eona Branch (Coffee)
Hawaiian Trult Packers* Ltd* (Pineapple)
.January 23 to Pebruary 3» 1961
By
Hayse H, Black
Sanitary Engineer Director
Industrial Wastes Consultant
S«- DBPARfMSHT 07 HEALTH, EDDGATIOH, AHD WELTAHE
Puolic Health Service
Hooert A* Taft Sanitary Engineering C enter
Cincinnati, Ohio
March 196!
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DEPARTMENT OF HEALTH, EDUCATION, AND WELFARE
PUBLIC HEALTH SERVICE
DIRECTOR Jebruary 15, 1961.
icrt A. Taft Siniury Engineering Center
4676 Columbii Parkway
Cincinnati 16. Ohio
To: RECORD
from: Hayse H. Blade
Industrial Wastes Consultant
Subject! Report on Trip to Hawaiian Islands
January 22 - February 6, 196!
Dr. Richard K* C* Lee, Director, Havalian Department of Health, in a letter
dated August 5, 1960 to Dr. Charles ?• Blankenshlp, Regional Medical Director,
Region 9, PHS, San Tranclsco, officially invited technical assistance from the
writer and an Engineer from the Region 9 Office* The August 5 comonnicatioa
specifically requested evaluation of the vaste control and treatment facilities
of the new Hawaiian petroleua refinery located at Barbers Feint and to "be placed
in operation "by Standard Oil Company of California in Hovember 1960* Subsequent
to. this initial request, Mr* McMorrow broadened the assignment to include obser-
vations at two sugar mills, one wallboard mill, and one coffee processing plant*
Observations were made on the Islands of Oahu, Hawaii, Maul, and Kauai.
HAWAIIA5 RWIHBHT STUDIES
Mr. Va. B, Schreeder and the writer arrived in Honolulu: at 1:00 PM, January
23, 1961* We conferred later in the afternoon with Messrs* McMorrow, Lam, and
Hekoaoto* A tentative work schedule (Appendix A) was discussed* Preliminary
studies at the refinery, Initiated by Mr* Hekomoto, provided effluent data as
basis for discussion* These analytical results are included in this memorandum
as Appendix B*
January 2», 1961 (Tuesday)
The first conference with Standard Oil Company representatives was held
Tuesday, January 24, 1961, at 10t30 AM, in the office of the Plant Manager. The
following men who participated in this conference are listed by organization
represented!
STANDARD OIL COMPACT 07 CALITOHHIA, IBS., HAWAIIAN BEFIHERY
R. H* Rowland, Manager
¥• B* Scarborough, Project Engineer
Lee Morris, Plant Superintendent
Al Hanson, loreman Crude Unit, Hydrogenation Unit, and Effluent Treater
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** 2 ••«
EAWAIIAH BHPAHBflnre 07 HEAIflH
Robert lekomoto, Chemist
Mr* Xakahara
FOBLIC HEAIffH SERVICE
tim. B, Schreeder, Senior Sanitary Engineer, Region 9
Hayse H. Black, Industrial Wastes Consultant, Robert A.Taft
Sanitary Tingl Peering Center, Cincinnati 26, Ohio
i
Mr. Boger Bell, Chief Chemist at the refinery, was unable to participate
in this aeeting. Mr. Bell was incapacitated during the entire period of the
survey because of a bur sit is condition*
Mr* Rowland advised that the refinery was presently processing 22,000
'barrels per day Arabian crude* tthen the catalytic cracking unit is placed in
operation in Hevember 1961, the refinery capacity will be Increased to some
4*2,000 barrels erode per day* In addition to the fluid catalytic cracking
unit, an Isomerisation unit and an alkylation unit are being added* It has
also been decided to construct a sulfurlc acid plant* A considerable amount
of sea vater will be used for cooling* It is planned to use this cooling water
for dilation of effluent.
Mr* Bovland expressed satisfaction with the refinery waste treatment sys-
tem. It was pointed out that variations in the preliminary data (Appendix B)
might be explained in part by the fact that grab samples were analyzed. It also
was pointed out that weighted composite samples were desired for the survey*
Mr. Rowland offered full cooper at ion in this work*
Following a general discussion of the proposed survey and the analytical
work required, Mr* Rowland conducted a tour of the refinery waste treatment
facilities* She surge pond appeared to be in a satisfactory condition, but
considerable oil had collected at the outlet end of the retention pond. In
fact, design of the retention pond oil skimmer allowed collection of a pocket
of oil immediately above the outlet from this basin* This condition would seem
to invite carryover of oil from the retention pond to the surge pond* There
was a telltale film of oil on the rock at the water line in the surge pond*
A row boat was tied up at the inlat end of the surge poad to facilitate
ski inning of oil, if necessary*
Some oil was escaping over the API separator effluent weir. The separator
effluent weir was not level* which aggravated this condition* Oily wastes were
being pumped from a receiving sump to the API separator by a small centrifugal
motor driven pump* This centrifugal pump was reported to have a capacity of
200 CTH. However, the name plate Indicated 100 G-PH at 3*t6*0 HPM. This centri-
fugal pump was operating continuously*
Our comments on this refinery waste treatment system cited the tendency
to emulsify oil-water mixtures by pumping* It was stated that high ground water
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«* 3 **
level in the coral formation precluded deep construction for the API separator*
Accordingly, the separator was constructed above ground and provision had been
Bade for putting the oily wastes* A special Blackmer pomp, operated by a float-
controlled steam turbine, was installed* This Blackmer pump was rated at **50
GPM when running at 230 RPM. Because of the low flow, the Blackmer pump was
soldo* operating, being activated only when the centrifugal allowed sufficient
accumulation in tho surap. Inasmuch as the Blackmer pump was designed to mini"*
adze emulsification, it was decided to shut down the centrifugal and to operate
the Blackmer at a low speed consistent with present waste flow*
In the afternoon, details of the survey were discos sed with the following
men who were assigned to this project!
Herbert Tor it a, Assistant Cheaist, Hawaiian Refinery
Shiro Higakl, Assistant Chemist, Hawaiian Refinery
Lester Muramoto, Chemist, Hawaiian Department of Health
Tom Maeda, Marine Biologist, Hawaiian Department of Health
January 25» 1961 (Wednesday)
Vm. B. Schreeder and the writer met with Mr* McMorrov and Dr. Lee at 3:00
AM. Dr. Lee welcomed us to Hawaii and expressed satisfaction in the industrial
developments on Oahxu She James Campbell Industrial Park was cited as an ex-
cellent solution te the refinery development and the satellite industries which
may be eapected. Attention was called te the Hawaiian Cement Company plant and
to the Hawaiian Western Steel Rolling Mill.
Standard Oil Company of California purchased some 300 acres from the James
Campbell Bstatei The present refinery will occupy about 200 acres of this
Barbers Point site* The additional 100 acres will be held in reserve for ex*
pension*
following our meeting with Dr. Lee, we went directly to the Hawaiian Re-
finery with Mr* Vekomoto* We spent some time with Lee Morris and Al Hanson.
Mr* Morris was critical of the preliminary data and particularly the oil re~
suits* It was his opinion that these high oil values were not consistent with
the qppearance of the refinery effluent, especially since there was no visible
oil film.
Messrs* Morris, Hansen, and Torita held a short private conference and
shortly advised that Al Hansen would represent Standard Oil on this survey*
Mr. Hansen introduced us to Lou Basklns, Shift Supervisor, who was designated
as the contact man on any questions pertaining to sampling* Mr. Basking pro**
mised to handle the sampling each morning until representatives of the Hawaiian
Department of Health reached the refinery. Mr* Hekomoto designated Tom Maeda
as the Hawaiian Department of Health representative who would assist in
sampling*
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It vas decided to sample regularly at five points. These sampling points
and their corresponding number designation vere:
1, API separator influent
2, API separator effluent
3« Retention pond effluent
4. Surge pond effluent
5* Waste pump discharge to sea
It was decided to collect eight horn- composite samples "beginning at 8100
AM. The sailing interval vas thirty minutes* Because of variations in prop**
ing, it vas deeaed advisable to collect weighted composite saaples at Stations
Ho.l and Ho .2. Accordingly, the API separator influent and API separator eff-
luent portions vere determined froa a chart prepared from the steam turbine
speed and the corresponding Blackmer pump discharge* The steam turbine speed
vas determined by a Tram tachometer* This tachometer converted vibration of
the steam turbine to BPK. The Blackmer pump vas considered to give direct dis
placement vith no slippage*
Mr* Eansen furnished the following Blackmer pump charaeteristlcst
Liquid pumpef*-oll and water
Flev temperature •» 75* F
Specific gravity *» 0.8 - 1*0
GPM- *»50
Suction pressure - 10.8 FSIA
Discharge pressure - 21,8 PSIA
Differential pressure - 11 PSIA
Overall efficiency - - 65$ at rating
BPM pump/driver - 230/1800
Gear ratio « ?•& to 1
Two samples vere collected on January 25, 1961* These vere weighted com-
posite samples of the API separator influent and the API separator effluent.
Sampling vas started at 12:00 noon and stopped at 3:00 FH*
After sampling vas initiated, a reconnaissance tour vas made of Industrial
Park. Industries observed included:
1. Hawaiian Western Steel Boiling Mill and Electric Furnace
2* Hawaiian Cement Company
3. Southern Pipe Division, TT. S. Industries, Inc.
fc* Island Lumber Company, Ltd.
5* Texaco - Barbers Point Terminal «- Oahu
Oil vas in evidence in the receiving stream below the steel rolling mill. The
cement plant vas not operating,' It vas reported that some time ago, an electro**
static precipitator blew up at this cement plant* This cement plant has a csg>*
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•* 5 **»
acity of one million "barrels cement per year (3?6 Ibs. per barrel). The
Hawaiian Cement Company is competing with the Permanente Cement Company, which
is owned and operated by Zalser Industries.
Waste flows at the refinery were increased some by storm water. It
started to rain about 3?00 AM, Wednesday morning, January 25. There was a very
heavy rain in the Walklki area Wednesday evening. This rainstorm continued
through Wednesday night and until about mid forenoon on Thursday. A consider-
able amount of water was noted entering the refinery storm water pond; some
was being pumped and some overflowed the pond banks.
January 26, 196! (Thursday)
Sampling was started for oil at 8:00 AM at sampling points 1, 2, 3, ^, and
5* At lOtOO AM we added sample bottles for phenol, sulf ids, and a second oil
sample at sampling points 1, 2, and 5» Hence, fourteen samples were collected
on this date*
Remarks by the sampler Indicated that there was no flow from the API sepa-
rator at 11:30 AM. Sludge was being withdrawn from the separator to the sludge
holding ponds. Accordingly, samples were not collected at sampling points Ho.l
and Ho.2 at 11:30 AM.
Opportunity was afforded to talk briefly with Jim McClellan, sampler and
student trainee at the refinery. Mr* McClellan advised that they were presently
running 20,000 barrels per day Arabian crude. He advised that they were changing
over Thursday afternoon from Arabian crude to Minas crude, which comes from
Sumatra* They can change from one crude to another in six hours*
The asphalt content of the three crudes run at the Hawaiian Hefinery was
reported as follows!
Mlnas (Sumatra) 75/6 asphalt
Sayphiena (Sumatra) lOOJjg asphalt
Arabian «... • 15$ asphalt
The Arabian crude is high in sulfur whereas the Mlnas crude is almost sulfur free,
Mr. McClellan advised that the following products were being produced from
the Arabian erodes
Butane Cjt
Pentane « 05
Light straight run gasoline ...(C$ to CQ)
Heavy straight run gasoline
Commercial jet fuel
Military fuel
Diesel « 4° J change
Marine diesel
XL-aid catalytic cracking feed
He sid - Asphalt
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Preducts from the Mines crude will be the same as those from the Arabian
crude but less of the higher fractions* Mr* McClellan Indicated that when the
cat cracker went into eperatlon, the refinery input will probably range between
30,000 and 35*000 barrels per day.
Mr* McClellan indicated that slop oil skimmed from the API separator was
heated to l60» 7 before pumping through the pipe line to the slop oil tank. It
is understood that crude oil is likewise heated before pumping from the tankers
through the submarine pipe line*
In the afternoon we drove along the west coast of Oahu from Barbers Point
to a point where the highway terminates near Kaena Point. Mr* Nekomoto pointed
out the Permanente Cement Company, which was constructed by Kaiser Industries*
Observations made at the API separator during the afternoon revealed two
Irregularities, namely:
1. Operation of the Blackmer pump was erratic. At 3:05 Hi,
the Blackmer pump suddenly increased speed to 216 HPM,
which meant that the steam turbine increased to 1685
2. Samples of the API separator Influent and effluent con-
tained excessive oil. The sample bottles were coated
with a thick brown film of oil
Opportunity was afforded to discuss mercaptan with Hawaiian Befinery labor-
atory representatives* It was reported that Jet fuel contained less than 0.0001
per cent mercaptan. This means less than 1 part per million.
January 2?, 1961 (Friday)
Mr. Hekomoto and the writer conferred with Al Hans en regarding the obvious
high oil concentration in the API influent and effluent samples of the previous
day. Mr. Hansen advised that on January 26 some 600 barrels of sludge from a
bunker fuel at or age tank had been pumped into slop oil tank So. 302. It was re-
ported that this bunker fuel sludge came from Hawaiian Electric. Bunker fuel is
used for ships and boilers. The stated purpose in putting this bunker fuel
sludge through the refinery waste treatment system was to recover some oil and
to dispose of the sludge in the API separator sludge ponds.
Some of this bunker fuel oil has about the same specific gravity as water*
Accordingly, the API gravity oil-water separator was not effective in removing
oil from the water drawoff from slop oil tank Ho. 302. This condition was the
cause for the high oil concentration in the API separator influent and effluent
on January 26. Rising globules of oil were observed on the separator effluent
at 3:00 PM, January 26.
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Slop oil tanks Ho. 301 and Ho. 302 each have a capacity of 10,000 "barrels.
Effective water depth was reported to be 4-0 ft,, which gives a capacity of 250
barrels per ft. depth. Measurements made at midnight January 26-Jsmary 27 in**
dicated that tank Ho. 301 contained 585 barrels of ''oil and tank Ho. 302 contained
4-200 barrels of oil. This totals 4800 barrels of oil, of which some 600 barrels
were bunker fuel sludge. This Is not water free oil. However, this indicates
that the slop oil accumulated since start up of the refinery in October I960
amounts to only 4200 barrels.
Observations made at the Ho. 1 sampling point on the discharge line from
the Blackmer punp indicated that discharge from the sampling line was alternately
gas, oil, and water. The sampling line came off the top of the discharge line.
It was evident that a representative sample could not be taken from the discharge
of the Blackmer pump with the existing arrangement. Sampling was discontinued at
sample point Ho. 1 for the reasons indicated*
January 28, 1961 (Saturday)
Mr. Hekomoto and the writer spent the day at the Hawaiian Refinery making
observations, working up flow data, and conferring with laboratory and operating
personnel at the refinery. The surge pond was distinctly brown in color, indica-
tive of the carry through of oil from the bunker fuel sludge which was pumped
into slop oil tank Ho. 302 on Thursday, January 26. It is believed significant
that this bunker fuel oil showed up in the surge pond within 48 hours. This in-
cident demonstrates actual retention in the refinery waste treatment system. Ref-
erence is made to the June 1, 1960 report on Proposed Waste Water Treating Facil-
ities for Hawaiian Eefinery, submitted by Standard Oil Company of California. On
page 12 of this report, retention periods are given as 4-2 hours for the retention
pond and 84- hours for the surge pond at a flow rate of 400 G3>M. Computed flows
for January 26, 27, and 28 were 230 GPM, 210 GJM, and 125 GPM, respectively. These
results Indicate that actual retention in the retention pond 10 only about one-
half of theoretical*
At 10:00 AM, estimates were made of discharge from the surge pond and from
the storm water pond. Measurements with a bucket and watch indicated a surge
pond discharge of 150 GEM. By comparison, the storm water pond discharge was
estimated at 50 GPM. Accordingly, at the time of these observations, discharge
to the ocean was estimated at 200 GPM. The valve on the pump discharge line was
partially closed, with only seven threads showing above the valve wheel. One
pump was operating and the discharge pressure was 25 pel.
The Blackoer pump, discharging to the API separator, was checked at 10:00
AM and again at 3:30 Hi. In the morning, the steam turbine was running at 4yo
EPM aad In the afternoon, at 560 EPM. Converting these rates to pump discharge,
It can be estimated that waste flow was 125 ®?M at the times measurements were
made*
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Examination was made of the facilities to handle storm water drained
from the main process areas and plpeways. These facilities are described on
pages 3 and **• of the June 1, 1960 Standard Oil Company report previously re-
ferred to* This storm water is collected in a sump near the north boundary
of the retention pond* This sump is presently equipped vith two pumps; one
pump is rated at 9,000 GBI and the other is rated at JfOO GPM. Provision has
been made for installation of a second 9.000 GPM pump during phase 2 construc-
tion. These are both Peerless pumps and the following information was taken
from the name plates:
Peerless Pumps
Peerless Pump Division
food Machinery & Chemical Corporation
Los Angeles, California
Serial Ho* 188206 Serial Ho. 188211
Model Ho* 20MF GPM 400
6PM 9,000 BPM 1760
BPM 8?0 Head 20.8 feet
Head 20 feet
These two primps discharge to the inlet end of the surge pond through a J6 inch
diameter force main*
Attempt was made to adjust the float control on the steam turbine driving
the Blackmer pump. Inasmuch as the Blackmer pump was designed to handle oily
water mixtures without emulslf ication, it was desired to use this pump daring
the test, even though the flow was less than that for which the pump was in-
tended*
Based on tachometer readings made by the sampler, oily water pumped to
the API separator for the sampling periods averaged as follows*
January 25, 196! 350 GPM
January 26, 1961 230 GPM
January 27, 1961 210 0PM
January 28, 196! 125 GSR
Space had been provided for a second motor driven centrifugal pump at the
oily wator sump ahead of the API separator* Refinery representatives gave the
sump pump capacities as)
Blackmer *50 GPM
Centrifugal pump (each) 200 GPM
Total 850 GPM
Inasmuch as the name plate on the centrifugal pump gave 100 GPM instead of 200
GPM as reported* it is believed that the combined capacity of these oily water
sump pumps will bear checking. The total capacity provided appears to be 650
GFM rather than 850 GPM which was reported.
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•* 9 **
It was pointed out that the Hawaiian Department of Health laboratory
should "be equipped to run all analytical tests recommended for the Hawaiian
Refinery. This will pendt check analyses and comparison of techniques. Mr.
lekomoto requested that the Sanitary Engineering C enter prepare a list of lab-
oratory equipment and chemical reagents required to make these analytical de-
terminations on petrolem refinery wastes* This list should include quantities,
unit prices, and the name and address of suppliers* The writer agreed to under-
take this work, which will necessitate cooperation of the Center Purchasing
Department •
February 3, 1961 fmdayl
Robert lem made arrangements for the writer and R. H. Rowland to observe
the ocean over the refinery outfall at 9:00 .AM on this date* It was proposed
to make these observations from a helicopter* It was planned to Introduce
fluorescein dye into the sump from which the ocean outfall pumps took suction*
It was thought that the dispersion pattern could be photographed.
Robert Vekomoto and the writer reported to the International Airport, heli-
copter area, at 8:30 AM as planned* Mr* Rowland could not make this trip, but
he was represented by V* B. Scarborough. Unfortunately, magneto troubles de-
veloped in the engine of the helicopter and it became necessary to cancel the
flight.
Tluoresceln dye was added to the pump well leading to the ocean outfall
at 8:15 AM. Mr. Hekomote called Standard Oil Company officials at 8:30 AH end
requested that the ocean outfall pump be stopped* At that tiw>, it was expected
that the helicopter flight would be made later in the morning* When the hell-
copter flight was canceled, the ocean outfall pump was started and this was
about 9100 AM.
The fluorescein dye showed up over the outfall about 9:10 AM. In other
words, total pumping time was about 25 minutes Instead of the computed time of
47 minutes* The outfall is 16 Inches in diameter and 1125 feet long. Based OB
a discharge rate of 250 GPH, theoretical displacement in this outfall sewer
would require 4? nlnutes*
The fluorescein dye was distinctly visible from shore* Photographs were
taken, but it was not possible to photograph from a high enough level to give
a distinct lint of demarkation between the dye and the blue ocean water* It
was observed that the green dye dispersed very slowly and it floated to the
southeast* Travel to the southeast was not expected, inasmuch as float studies
had Indicated that ocean surface currents in this region were in a northerly
direction along the west coast of Oahu*
COHFEBEHCB WITH STABDARD OIL CO*
Mr. B* J* McMorrow requested a conference with representatives of Standard
Oil Company for discussion of industrial waste survey results and the overall
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•» 10 **
refinery waste problem. Ihis conference was held at 10:30 AM, February 3,1961,
In the office of Mr* H. E. Rowland. The following sen who participated in this
conference are listed by organisation represented!
STAEDABD OIL COMEAHT 0? CALIFORNIA, HAWAIIAH BBFIKERT
R. E. Rowland, Manager
V. B. Scarborough, Project Engineer
HAVAIIAI DBPARBCEHT 07 HEALTH
B. J. McMorrow, Director, Division of Sanitation
Robert Hekomoto, Chemist
Robert L* Lam, Chief, Bureau of Sanitary Engineering
PUBLIC ggATMT SERVICE
William £. Schreeder, Senior Sanitary Engineer, Region 9
Hayse E, Blade, Industrial Wastes Consult ant, Robert A. Taft
Sanitary Engineering Center
Mr* McMorrow outlined the objectives of the conference, which were!
1* Discuss additional waste treatment which nay be needed
for phase 2 of the refinery operation
2* Reappraise effluent criteria*
3. Consider the monitor ing program to be employed at the
Hawaiian Refinery
Mr* Hekomoto was asked to comment on the industrial waste survey that was
started January 25, 1961. Mr. Hekomoto presented a tabulation of analytical
results for this work. These data are reproduced as Appendix C*
Mr, Hokomoto described the five sampling points and briefly reviewed the
problems experienced at sampling point Ho.l. As previously mentioned, gas, oil,
and water were Intermittently discharged from the Hb.l sampling cock. Mention
was made of the problems resulting from the bunker oil sludge from Hawaiian
Zlectrie Company* Mr* Rowland stated that this was thermally cracked oil.
Mr.Hekomoto called attention to the phenol results for the Ho.2 sample, which
were reported greater than 1.0 ppm. Actually, dilutions Indicated that these
phenol results were of the order of 6.8 ppm. Refinery representatives were TUP*
able to account for this phenol*
Phenol data are still not available from Standard Oil's new Irving, Hew
Brunswick, Canada Refinery* At the time of the May 18, I960 conference in San
Francisco, we were advised that, at the Irving Refinery, the steam condensate
in the overhead receivers at the catalytic cracking unit was taken off at a tern-*
perature below the boiling point of phenol. She objective was to hold the phenol
in the petroleum products, from which it was subsequently removed by caustic
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treatment* Mr. Scarborough reported that the success of this design feature
at the Irving Refinery had neither been confirmed nor disproved*
Farther discussion of .the surrey analytical results "brought out the fol-
lowing significant point st
1, Irregularities in operation interfered with the orderly conduct
of this surrey* Reference was nade to the introduction of
"bunker fuel sludge into the oily water system and to Irregular
operation of the sump pumps discharging into the API separator
2. Even though the waste data are Halted, It is "believed that
they will serve for preliminary evaluation of the waste control
and treatment system
3» Sulflde and mercaptan were not detecti"ble in the refinery efflux
eat pumped to the oceam
*U Phenol was found in the refinery effluent when the samples were
preserved with copper sulfate. The absence of phenol in the
preliminary effluent study may be attributed to biological
degradation in the unpreserved staples
5* She survey results Indicate that nonvolatile oil concentration
In the refinery effluent meets effluent criteria* It should be
pointed out that the volume of oily wastes was less than half
ef the anticipated flow for second phase operation. There is
reason to believe that the second phase operations may overload
the waste treatment system and that total oil in the refinery
effluent may exceed 15 ppm when the refinery is in full opera*
tion
6. Based on available information, it appears that oil and phenol
are the most significant determinations to be made on the
Hawaiian Refinery effluent
There was some discussion of seepage In and out of the waste water ponds*
It was stated that the retention pond apparently leaked because trouble was
experienced in bringing the water level to the 7*5 *** operating level* Mr*
Schreeder Galled attention to throttling of the ocean outfall pump, *hlch was
obviously Increasing the cost of pumping effluent to the ocean* He suggested
closing outlet valves on the pond and putting the ocean outfall pumps on sato-*
oatic float control in order to take full advantage of seepage* There was
some discussion of this proposal and It was the concensus that advantage should
be taken of seepage so long as concentration of refinery wastes In the pond did
not Increase to the extent that the receiving waters would be deleteriously
affected from purging of the surge pond following storms*
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~ 12-
Considerable time was devoted to discussion of the point where effluent
criteria should lift applied* Because of discharge into the ocean, refinery rep*
resentatives expressed the opinion that effluent criteria should "be applied to
the effluent after dilation, whlchmeans discharge from the ocean outfall pump*
It was pointed out that protection of the beaches was mandatory and that efflu**
ant criteria in terms of pounds of pollutants would preclude the effluent dllu**
tlon controversy. Cognisance was taken of the fact that the API separator efflu-
ent could not "be expected to meet all criteria and further treatment is obviously
"being achieved in the retention and surge ponds* By the same reasoning, effluent
dilution Bust be reasonable If the "beaches are to be protected*
fhe writer briefly discussed bio-assays for industrial effluent control*
It was pointed out that the bio-assays fora of monitoring system provided a con**
tinuous accurate record of the effluent quality* Mention was made of observations
In Germany and in England, where bio-assays were successfully used in monitoring
complex industrial effluent* Success is being achieved by the Ssso Standard Oil
Refinery at Baton Rouge, Louisiana, where fish are maintained in the diluted re~
finery effluent*
The writer specifically Inquired as to the thinking of refinery represents^
tives on the size and capacity of the API oi2f*water separator* It was pointed out
that this design departs from previous API separators and that the capacity of the
existing separator appears inadequate for phase 2 operation* Refinery representa-
tives contended that the retention pond was an integral part of the oil recovery
system and that the existing system should be adequate* Space has been provided
for construction of another API separator If the present unit proves inadequate
when the refinery is In full operation*
At the close of the conference, Mr* Rowland summarized our discussion as
follows*
1* the Hawaiian Refinery officials wished to compare the effluent
of the refinery at Barbers Point with the effluent of other
refineries on the mainland* Mr* Rowland offered to contact
John Easthagen, who is the Standard Oil Company of California
representative on the API Waste Disposal Committee* It is pro**
posed to compare effluent characteristics from the standpoint
of concentration and volume reduced to production basis* This
Investigation will Include consideration of the oil determina-
tion, that is, total oil vs» nonvolatile oil* Phenol concen**
trations and quantities in the refinery effluent will likewise
bo checked*
2. Zfflxusnt sampling will bo on a weekly basis and using different
days each week* It was agreed that the API separator Influent
sampling point should be Improved so that a representative
sample can be collected and the efficiency of this unit can be
determined*
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3* Interest was expressed in use of bio-assays for refinery effluent
control* In addition to providing a continuous record, it was
agreed that this system of monitoring should reduce the load on
the laboratory• This system of monitoring will "be explored*
*U Mr* Bovland was agreeable to exploring the suggestion that the
waste water ponds be used as seepage pita* This Investigations!
•work will be carefully checked to assure that damage does not re**
suit te the receiving waters*
Mr* Rowland expressed Appreciation for assistance given on the recent in*»
dust rial waste survey and for the opportunity to discuss these refinery waste
problems which are of mutual interest* Mr* McMorrow likewise expressed grati-
tude for the splendid cooperation received from representatives of the Hawaiian
Refinery*
January JO, l$6l (Monday)
Mr. Schreeder and the writer traveled to Hilo via Aloha Airlines, arriving
at 8:55 AM. Shlngi Soneda met us at the airport and we promptly embarked on a
heavy two day schedule* We visited two sugar cane mills, one coffee processing
plant, and one mill producing Insulation board from bagasse and paper*
Our first visit was to the Eakalau Plantation Company sugar cane mill. This
mill Is located on the coast some 30 miles northwest of Hilo. The mill is lo-
cated in a deep ravine and only a few feot above high tide.
Mr* Clinton Chock, Industrial Engineer, Hakalau Plantation Company, served
as our host. He advised that the mill had been shut down for approximately one
month. They were in process of starting the plant up and because of special work
in connection with this operation, he thought it best that we not take a walk
through the plant.
Mr. Chock reported that this mill had a rated capacity for processing 60
tons net sugar cane per hour. In the year I960, this mill produced 23,000 tons
of cane sugar (96° Baums sugar). We were advised that the Hawaiian Sugar Plan-
ters' Association, Honolulu, had a brochure on sugar production*
la an effort to obtain maximum sugar yield, there is a tendency at the
Hakalau Plantation to harvest much of the finer material. Sometimes trucks de-
livering cane to the mill will be half filled with sugar cane leaves and trash.
It is understood that this practice is common for the sugar cane plantations on
the island of Hawaii.
The Fftfa»ln" Plantation Company mill discharges bagasse to the ocean. Loca-
tion of this mill In a deep ravine at the ocean level would make return of bagasse
to the land a very expensive operation. Daring our visit bagasse was being re«
moved from the ravine by means of a power shovel and trucks. A bulldozer was be-
ing used to push bagasse within reach of the shovel. Presumably much of this
-------
"bagasse was carried "back into the ravine at high tide. This tonnage of bagasse
la the ravine gives some Indication of the ocean teach in the immediate vicinity
of the mill.
It is •understood that a considerable tonnage of "bagasse is "burned as fuel
•under the toilers at Hawaiian sugar cane mills* Inasmuch as we were not per-
mitted to inspect the HaTcalttii Plantation Hill, we did not determine whether all
the "bagasse was wasted or some was consumed aa fuel. It is evident that use of
the "bagasse to produce power is a desirable method of recovering some value from
this material i as well as an economical system for keeping it out of the ocean*
la the afternoon, we visited the Canec Division of The Plintkote Company
located in Hilo. This plant has a rated capacity of one hundred million square
feet per year of insulation "board 1/2 inch thick. MairlBim production of 150
tons per day was reported. We conferred with Ken Mclerty, Plant Manager, and
Kenneth A. Wong, Par chasing Agent. Mr. William Machado, Quality Control Engi-
neer, conducted a tour through the plant.
The finished product is Insulation board, varying in thickness from 3/8"
to 3". The thicker "board is produced "by lamination.
Mr. Wong reported the following raw materials which -were used in various
quant it le si
Bagasse
Caustic soda
Fezol (rosin)
Paracol wax
Bituslze
Calcium carbonate
Alum
Arsenic (powdered)
Borax •* granular form
Boric add
Corn starch
Eydrated lime
Carbon bisulfide
Carbon tetrachloride
Dowicide - C
Casein laotln
Stover clay
Titanium dioxide
Tetra sodium pyro phosphate
Mica
Absentine talc
Polyco resin
1. WL
2. 505
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® 15 *»
Mr. Wong advised that The Flintkote Company used one million gallons of
Hilo city water per month. Three wells provide saline water for process. In-
formation on water consumption at the mill was not immediately available. Mr.
Machado referred to a fourth well which apparently is a standby.
Fuel oil is burned to produce power. It was reported that some of the steam
was consumed in a steam turbine* There were numerous details with which Mr.Wong,
as Purchasing Agent, either was not familiar with or was not at liberty to report.
Our discussion with Plant Manager Mclarty brought out some interesting infor-
mation in connection with processing bagasse. He pointed out that bagasse aver-
aged about 60$ moisture. Shrinkage normally ranges between 13$ and 15$, but may
be as high as **0$. Mud and gravel which is loaded with the sugar cane is included
in this shrinkage* Some 25$ of the weight of bagasse is pith. This pith is either
burned as fuel or fed to cattle.
Mr. Mclarty reported a change in the bagasse cook which should reduce the
concentration of the digester liquor. He indicated that they were presently using
heat softening In the digesters for 30 minutes at 40 psi. Formerly, it was cus-
tomary to cook bagasse after adding 50 Ihs. soda ash for each 3 1/3 tons bagasse
(dry basis). Mr. Machado was not familiar with this detail, indicating that the
change in cooking bagasse is fairly recent*
It was pointed out that Gelotez Corporation used bagasse in their process at
Marrero, Louisiana. la this instance, bagasse is used along with wood fibre. In-
asmuch as sugar cane is a seasonal crop in Louisiana, It is necessary to store the
bagasse* Storage Introduces problems which may eventually eliminate bagasse as a
raw material for Celotex.
OrownrZellerbach, Camas, Washington, in cooperation with Hawaiian Sugar Plan-
ters' Association, has conducted research on production of news print from bagasse*
A joint patent on this process has been Issued to Crown—Zellerbach and Hawaiian
Sugar Planters' Association. It was reported that Crown-Zellerbach had made a
study of the economic feasibility of constructing and operating a bagasse news
print mill on one of the Hawaiian islands. This development was abandoned because
of Insufficient demand for news print* Instead, it IB understood that Crown-
Zellerbach now plans to install a mill in India for production of news print from
bagasse, using this new patented process*
The Tlintkote Mill operates five days a week, starting up at 3:00 PM on Mon-
day and shutting down at 3*00 PM on Saturday. Even though they were in process
of starting up the mill* Mr* McLarty authorized a tour through the plant* Mr*
Machado was most gracious with his tine and explained each step from the beginning
of the process to the finished insulation board*
The principal materials going into the finished board are bagasse and waste
papers* Formally the board is composed of 92$ bagasse and 8$ paper* Bagasse is
cooked In one of six rotary digesters. Paper is worked in two paper beaters,
batch type, operating in parallel. It was noted that fresh water was being sup-
plied to the beaters*
Cooked bagasse is broken down into short length fibre by passing through 11
-------
-16-
grinders operating in parallel. It was interest ing to note that each, grinder
was covered as a safety measure in case a large rock carried through this far in
the process* Ground bagasse was pumped to stock tanks, from which it was fed to
Claflin and then Jordan refiners In series. There were three Claflln and two
Jordan refiners* Paper stock was Introduced into the system and mixed with
bagasse in the head box supplying the Jordan refiners*
Refined stock entered a large "IT" tank along with return white water. Di-
luted stock was then pumped to the board machine, the first unit of which was an
Oliver filter 12» 9" in diameter. Board formed on the Oliver was passed through
press rolls and driers similar to a paper machine* The dried board, containing
1% to Jf> moisture, was cut in lengths varying from l6« to 20'.
The Flintfcote Mill is an excellent example of converting a waste material
or an inexpensive raw material into a usable product. Unfortunately, the demand
for insulation board is limited in the Hawaiian islands. It would seem that the
finished insulation beard would be too bulky to ship to the mainland for competi-
tion with other building materials*
January 31» 19&1 (Tuesday)
On this data, we traveled by automobile from Eilo to Kailua-Kona* We spent
most of the afternoon at the Hawaiian Agricultural Company sugar cane mill at
Pahala* En route to Pahala, we inspected waste treatment facilities at another
sugar mill and we visited the Thar at on lava tube*
The first sugar mill visited was located near Olaa, south of Hilo. A Dorr
clarifier was being used as an integral part of the process water system. Water
that had been used to wash the cane, and laden with mod, was clarified and returned
to wash more cane. Bffluent from the clarifier was still high in turbidity, but it
was pointed out that this was a closed system and that the effluent was satisfac-
tory for reuse* This clarifier was approximately 100 ft. in diameter, 12 ft. deep
at thecenter, and it had an earthen bottom*
It was reported that clarifiers of similar design and dimensions were being
used to clarify waste water at other sugar mills in the Hawaiian islands. It is
understood that these clarifiers permit reuse of water in those areas where the
supply is limited* These installations demonstrate the feasibility of primary
treatment for liquid wastes from these sugar mills and it would appear that gen**
era! application might not prove a hardship on the sugar cane industry in Hawaii.
Our first contact with representatives of Hawaiian Agricultural Company at
Pahala was Joe Hackett, Industrial Relations. We later met Paul R. Tate, Plan-
tation Manager* Most of our time was spent with R. H* Mott-Smith, Factory Super-
intendent, who conducted a tour of the plant*
The Hawaiian Agricultural Company sugar cane mill was constructed about 1900.
Although some of the equipment has necessarily been replaced, it appeared that
out* of the equipment had received good maintenance and actually was the original
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«•» 1? **
equipment* This mill operates continuously with a shutdown of a month to six
weeks the Christmas season for essential maintenance.
Sugar cane in Hawaii enjoys a continuous growing season. It takes approx**
Imately 18 months to nature. Some plantations hare been affected "by recent
strikes, which have influenced planting of sugar cane, The effect of these
strikes is now being felt and some of the mills have been forced to shut down
for lack of sugar cane to process*
The Hawaiian Agricultural Company sugar cane mill is rated at 80 net tons
of sugar cane per hour. It was reported that the mill processed an average of
85 tons per hour, indicating slight overload* Sugar cane contains about 12$ dry
fibre and 88$ water and sugar. It takes 11 tons of sugar cane at the Fahala Hill
to produce one toa of raw sugar*
fhe plantations owned and operated by the Fahala Sugar Cane Hill do not ir-
rigate* It was reported to be common practice to shut off the water on irrigated
cane fields in order for the cane to dry out. Hoisture level in the cane may
thus be reduced sufficiently that 8 tons of sugar cane will produce one ton of
raw sugar* Other plantations may produce a sugar cane which will require as much
as 13 to 14- tons of cane per ton of raw sugar*
Ve observed collection and transportation of trash and rock. Hr.Kott-Smith
advised that they discarded as much as 30 truck loads per day of trash and ten
truck loads per day of rock. These are ten ton trucks*
The Fahala Sugar Cane Kill produces roughly 500 tons per day of bagasse.
The moisture content of this bagasse usually runs 48$ to ^, with a minimum of
4l£. Host of this bagasse at the Pahala Hill is burned under the boilers to
produce power* If the moisture content of bagasse goes above 50$, combustion
problems develop* The moisture content of trash may run as high as 70$.
When dirty case slows -up grinding, it is necessary to supplement bagasse
with fuel oil for the boilers* A balance has been developed at this sugar cane
mill between available bagasse and power requirements* In fact, Mr. Hott^Smlth
Indicated that operation of this sugar cane mill would not be economically sound
if the bagasse was not available as a low cost fuel* Mr. Hott-Smith reported
that the Pahala Hill burned 98$ to 99$ of the bagasse produced*
Hill operations require 3,000 GPM fresh water. The principal source is one
600 ft* well from which 2,000 <2)H water are pumped* The remaining 1,000 GFH
comes from a mountain reservoir*
Hr* XottHSmith pointed out some Interesting features about the Fahala Hill*
After the cane Is cleaned and trash has been removed* it is ground and then
pressed by five presses in series* These are two-high presses and the last press
applies 500 Ibs/B&.ia, A countercurrent wash is applied to the cane as It passes
through the presses*
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** 18 ~
Accurate control is maintained throughout the eager cane mill and 99$ of
the sugar can "be accounted for* In processing, the first operation is to weigh
the Juice in a large tank mounted on a scale. After weighing, each "batch is
nade alkaline "by addition of milk of lime. The alkaline Juice is then heated
to boiling. The next step is clarification of the hot Juice In a multiple tray
(5 trays) Dorr Clarifier, with the temperature "being maintained at 212° T.
Clarified Juice is decanted from the Dorr unit.
The clarified alkaline Juice is then evaporated in a system of evaporators,
The first evaporator is referred to as a pre-evaporator, which concentrates the
Juice to 10$ solids. The pre-evaporator is followed "by a quadruple effect evap-
orator, which further concentrates the Juice to 60$ sugar*
Crystallization of the sugar is accomplished in finishing pans. There are
three finishing pans operating in parallel for production of the regular grade
raw sugar. There is one finishing pan operating on low grade sugar. A fifth
unit referred to as a seed pan, is used to develop sugar crystals of a specified
size, starting with a very fine C-H seed sugar.
The evaporation system handles 100 tons of Juice per hour. Evaporation of
water amounts to 80 tons per hour. This leaves a normal production of 20 tons
per hour syrup containing 90$ raw sugar.
After the proper size sugar crystals have teen formed, the syrup containing
sugar crystals is centrifuged. The high grade raw sugar is removed from the syrup
in 5 minutes using five centrifuges. The low grade sugar requires one hour cen~
trifuglng in ten centrifuges operating In parallel. These are Hep worth centri-
fuges, manufactured by S. S. Hepworth Company, Long Island, Hew York.
Haw sugar is hauled in special tank trucks from each mill on the island to
Eilo for temporary storage and shipment to the mainland. About 95$ of Hawaii's
sugar is refined and marketed on the mainland. The remaining $% is refined
locally for Hawaiian consumption.
Cane wash water, process wastes, and cooling water are collected in a common
open conduit and drained to bottom land between the mill and the ocean* A small
quantity of excess bagasse is discharged to the waste water flume and conveyed to
the low ground along with process wastes* Mr. Mott—Smith indicated that bagasse
could not be fed to cattle because of the sand it contained and its effect on the
animals teeth. It was reported that these wastes seeped Into the ground and did
not reach the ocean. It is understood that few sugar cane mills in the Hawaiian
Islands are as favorably located with respect to handling of liquid and solid
wastes*
February 1. 1961
Mr. Soneda, with the approval of Mr* McMorrow, arranged for Henry C. Helson,
Area Sanitarian, Hawaiian Department of Health, Zona, and the writer, to visit the
coffee processing plant operated by American Factors, Ltd., Kona Branch, Eailua-
Ebna. The following representatives of American Factors, Ltd., were contacted:
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- 19 «
Janes K. Takauye, Manager, Building Materials Department
Toshio Hakamoto, Manager, Agricultural Deportment
Clarence Komo, Mill Hand
American Factors, Ltd., started pulping and drying of coffee In July 1958.
Prior to that time, this company received dried coffee "beans from the farms and
operated only the deparchnent, classifying, and bagging departments* Green
coffee cherries are received at the mill in bags weighing 115 to 130 Ibs. Daring
the peak of the season, this Kona coffee mill is operated from 6x00 AM to 1:00
AM dally.
Equipment employed In processing green coffee at the Xona mill is listed
"below In the order in which each unit is used}
1. Two receiving vats for coffee cherries
2. fwo vibrating screens for removal of water and stones
3» Bucket elevator to convey coffee cherries to hopper above pulpers
k. Six combination pulpers and washers (5 Puerto Rico-1 Japan)
5» Conveyor from pulpei—washer to drier
6* One circular pre-drler (four hours)
7» Two tunnel driers (12 to 15 minutes)
8. Two Coluaar (finishing) driers (14 to 16 hours)
9* Three storage bins for dry coffee
10. Blower to supply air for pneumatic system
11. Deparchment and finishing departments (not Inspected)
The principal difference between American Factors, Ltd. coffee mill and
other coffee mills with which the writer is familiar Is the combination pulper-
washer. The pulper removes the skin and a large portion of the flesh from the
coffee bean. The bean is surrounded by a thin parchment and a coating of muci-
lage. The pulped coffee bean is usually held in a tank for 12 to 2k hours for
natural fermentation of this mucilage, which converts this substance to water
soluble materials readily washed from the bean parchment. Pulpers at the Ebna
mill are followed directly by a washer that provides agitation by a number of
transverse pins on a vertical shaft which revolves within the washer. This
washer was said to be effective In removal of the mucilage.
She five pulpers manufactured in Puerto Rico bear the name "Morovis". The
following name and address were taken from the name plate on one of these Puerto
Hican pulperst
Morovls
Fabricada Por
Maquinaria Cafetalera, Inc.
Bayamon, Puerto Eico
BSD - 381
Diesel oil was being used in the burners for the driers. The following in*
formation was taken from the name plate on the small Columar drier:
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« 20 -
American Drying Systems, lac,
Burlingame, California
Model 2X-3
Serial Ho. 1502
Process water is taken from two sources, namely: Brackish water from a
shallow well and fresh water from the county line. Brackish water is used to
hydraulically more coffee cherries from the receiving vats to the tucket ele-
vator which conveys cherries to the hopper above the pulpers. Fresh water is
used in the pulpers and for equipment washup*
Water consumption was reported as:
Fresh water ...... 145,000 (JED (19 hours)
Brackish water ... 55»000 gallons per week
Brackish water is pumped to a 55tOOO gallon storage tank which constitutes a
seven day supply* Tanks are located "beneath the vibrating screens for colleo*
tlon of brackish water, which is returned to the receiving vats for reuse* If
fermentation in the receiving vats "becomes excessive, the quantity of brackish
water may be doubled*
Liquid wastes from the coffee mill are disposed of in two covered cesspools*
One cesspool is used for brackish water wastes and the second cesspool for fresh
water wastes from the pulpers. The fresh water waste cesspool had been Inspected
by Kr. Nelson* He reported this cesspool to be 6 ft. in diameter and 8 ft* deep*
Normally the water level in this cesspool Is 3 ft. deep but during peak operation
at the mill, the water level will rise to a depth of 6 ft. 3 in* When operations
are suspended, the water level returns to the 3 ft. depth in a few minutes. There
is a scum layer approximately 2 ft* thick on this fresh water waste cesspool*
It le believed significant that this volume of waste water drains readily
from these two cesspools* Inasmuch as this property is located within a few hun-
dred feet of the ocean, it is entirely possible that lava tubes permit prompt
release to the ocean* It is understood that fluoresceda dye placed in one of
these cesspools during the early part of the coffee season failed to show up in
the ocean water* It is probable that solids in the coffee wastes would adsorb
some of the fluoresceln dye and might prevent its detection in receiving waters*
It Is understood that consideration has been given to use of radioactive isotopes
as tracers* Although this method possesses unusual possibilities, its applica-
tion necessarily remains in the hands of a specialist*
During the 196CKL961 season, American Factors, Ltd*, expects to pulp 55$000
bags of cherries* This should produce 10,000 bags of finished coffee, or one
million pounds* This represents roughly 10$ of the total finished coffee pro-
duced in Hawaii. American Factors, Ltd*, will alee receive dry coffee from the
farms for deparchment, classifying, and bagging*
It was reported that the Csptaln Cook Coffee Company expected to process
125,000 bags of green cherries this season, uaieh should give approximately
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«• 21 *»
2,500,000 lbs« of finished coffee* Processing of finished coffee is split about
evenly "between three coffee processing companies. These aret
American Factors, Ltd. . ......... 3356
Captain Cook Coffee Company .....
Pacific Coffee Corporation ......
Coffee processing in Hawaii begins in August and ends in January, Much of
the coffee is still pulped and dried on the individual farms. W« were advised
that ten million pounds of finished coffee were produced in Hawaii daring the
1959-1960 year, which was considered an average year* Coffee production for 1960*
1961 was estimated at nine million pounds*
Ve departed from Zailua-Eona at 11:10 AH and arrived at Kahului Airport on
the Island of Maul at Ut'K) AM. Sam Goo, Sanatation Director for Maul, met us
at the airport and we drove promptly to the Kahului Harbor. Mr. NcMorrow re-
ported high coliform counts inside the seawall. ."Both Kahului and Wailuku are
sewered and the outfalls extend into the ocean about 1600 ft.
After lunch at the Hukllau Hotel Restaurant, we drove to the Kaanapali
Resort Area under development, which is located on the northwest edge of the
island, fhis resort area is being developed "by American Factors, Ltd. The area
had been cleared and construction of resort hotels will soon be started.
Ve Inspected the Infilco Accelo-Siox Sewage Treatment Plant that has been
constructed to serve the Kaanapali Development, fhis treatment works has been
completed anl will be placed in operation as soon as the resort area is devel-
oped. It Is designed to handle 265,000 GPD domestic sewage. There is no pro-
vision for anaerobic digestion of excess solids*
Infilco Bulletin Ho* 6520 describes the "Total Oxidation" Sewage Treatment
Works. The aim of the process is stated to be the treatment of liquid sewage
by biological oxidation, and the reduction of sewage solids by additional aerobic
digestion. Suspended solids reduction in the effluent is not as complete as In
the well balanced activated sludge plant, but the solids are said to be Inert.
Effluent from the Zaanapali Sewage Treatment Works will be mixed with Irrigation
water and should not create a nuisance.
Yellowing Inspection of this new sewage treatment works, we drove to Hapill
Bay, which is directly opposite the Island of Molokai. This is the site of a
Canadian apartment development. Hearby were two houses on an acre tract of land,
which homes recently sold for $140,000.00. Land on this point, overlooking
Molokai, is presently worth $2*50 per sq.. ft. It is understood that land front-
ing on VaikUd Beach, Oahu, Is worth $3,000,000.00 per acre, or $70.00 per sq..
ft.
Ve inspected the ocean front at Xihei, which is planned as a resort area
for the future. Ve returned to the airport by way of Puunene, which Is the home
of the Hawaiian Commercial & Sugar Company. This sugar mill at Puunene was said
to be the largest mill In the world. Ve returned to Honolulu by way of Molokai
at 5:05 PM, Tebnary 1.
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gebruary 2, 1961 (Thursday)
Robert I* Lam, Wa. B. Schreeder, and the writer left Honolulu at ?:30 AM
via Hawaiian Air Lines and arrived at Lihue, Zauai Airport at 8:10 AM. We were
met at the airport by Mr* Hoboru Takamura, District Inspector* We went directly
to the offices of the Department of Health and met Mr. T. B* Lyons, Chief In-
spector and Division Supervisor*
We first Inspected the new sewage treatment works serving Hotel Kaual Surf
at Hawiliwili. fhis treatment works was designed by H. A* R. Austin and Asso-
ciates, Ltd., Consulting Engineers, Honolulu. It was placed in operation July
5, I960.
The Kauai Surf Resort Hotel has 103 rooms. Eventually, there will be five
identical units. Present sewage flow was reported to average 80,000 SPD. The
sewage treatment works is designed for 100,000 (JED domestic sewage from each
hotel unit, or a total flow of 0.5 MOD. This resort development is being fi-
nanced by American Factors, Ltd.
This Is an Infilco Accelo-Biox Sewage Treatment Works* However, it differs
some from the Xaanapali Development on the Island of Maul. Comminuted raw sewage
is fed along with return sludge to two rectangular aeration tanks operating in
parallel. It was reported that 2k hours aeration was provided for the design
flow. Final clarification takes place in a separate rectangular tank. Anaerobic
digestion and a sand bed are provided for excess sludge. Clarified treated sew-
age is discharged through a chlorine contact chamber. Effluent from this sewage
treatment works passes through a stabilization pond and is then discharged to the
ocean through an open channel which cuts across the sand beach in front of the
hotel* The effluent was clear and odorless*
Consideration was given to Hawaiian corporations most active in developing
the islands industrially. Mr* Lam named the so-called "Big Five". These are:
Alexander and Baldwin
American factors, Ltd.
C. Brewer
Castle & Cook
T. H« Davies
Mr* Lam stated that pineapple and sugar cane were grown on all of the Hawaiian
islands*
Inspection was made of a Dorr Clarlf ier for waste water at McBryde Sugar
Company* This unit was not In operation. It was 100 ft* in diameter with 12 ft.
water depth at the center* This clarifier had an earthen bottom and appeared
similar in all respects to the Dorr Clarifier Inspected near Olaa, south of Hllo,
on the big island. We were advised that Oahu Sugar Company used a cyclone
clarifier*
We discussed dlffuser extraction for recovery of cane sugar* This process
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- 23 -
would be similar to that employed in the beet sugar industry. It is understood
that dlf fuser extraction was tried on pilot scale during the 1959-19&) season.
The cane is cut into short lengths for this process* It vas reported that the
Eekaha Sugar Company was presently using dif fuser extraction, "but we were not
inforaed as to the extent of its use or details*
In the afternoon, we drove to Kapaa for inspection of Hawaiian Trait Pack-
ers, Ltd* waste disposal system. We first conferred with Alfred Giles, Plant
Superintendent, and Irving A. Jenkins, Field Superintendent. In order to "better
understand the waste problem, we briefly discussed the canning of pineapple and
the operation of this specific cannery.
A cross section of the pineapple reveals, from the outside to the center,
the following components! skin, pulp, shell, fruit cylinder, and core. Pro-
ducts for canning includes fruit cylinder, pineapple chunks, pineapple Juice,
and pineapple syrup. Pulp is dried for composting.
Mr. Oiles described the Ginaca Machine. This unit was designed by Henry
ainaca for processing pineapple. It cuts skin from the pineapple lengthwise,
removes the top and bottom, and decor es. The Zapaa Plant operates seven trimming
tables and normally cans 750,000 cases, Ho.2 cans, annually.
Hawaiian Fruit Packers, Ltd. operates approximately 110 days each year.
During July and August, the plant operates two 10 hour shifts. The 24 hour day
is broken down into 20 hours operation, two 30 minute lunch periods, and a 3
hour cleanup.
The principal waste sources were reported to be:
1. External fruit wash
2. Trimmed fruit cylinders wash
3. Miscellaneous
When operating two shifts, process water consumption amounts to 300,000 GPD. In
addition, cooling water is used at a maximum rate of 150 GPM. Temperature of the
cooling water is raised to 120° P. and this clean water is discharged into a
drainage basin separate from the one receiving process wastes. It is planned to
return some cooling water to wash cold fruit.
Effluent from the cannery is screened through a rotary screen having
diameter openings* 'A composite of the screened cannery effluent was reported to
have an average 5-day BOD of 1000 ppm. These wastes drain by gravity to four
lagoons In series and located in a deep ravine. Capacities of these four lagoons
are given below!
Ho. 1 lagoon . ........... .. 1*0 million gallons
No. 2 lagoon . ............. 3*5 million gallons
Ho* 3 lagoon ........... *.. 6.0 million gallons
Ho. 4- lagoon . ............ • 1*0 million gallons
The objective is to store those cannery vastes in the four lagoons throughout
-------
the canning season* Seepage and evaporation make this possible. Several years
ago, the outlet valve on the fourth lagoon was inadvertently opened* Discharge
of the lagooned waste destroyed fish in the entire two miles of the stream lead-
ing to the ocean.
Ebullition of gas was observed in the Ho.l lagoon during our visit* Odors
emanating from these lagoons have created an alleged nuisance at tines when the
wind "blows in the direction of nearby dwellings* Sodium nitrate has been applied
to the screened cannery wastes at the rate of 1,000 11)8. per day in an effort to
alleviate the odor nuisance.
Sodium nitrate, containing 5^ oxygen, is worth $54*00 per ton at Kapaa. The
dosage of 1,000 IDS., during peak operations, represents a concentration of 400
ppm or a dosage rate of 0*4- ID* nitrate per 1 Ib. 5*"day BOD* This treatment has
helped to control, out has failed to eliminate, offensive odors*
A paper dealing with "Hitrate Treatment of Lagoons", which appeared in an
early Purdue Industrial Waste Proceedings, has been reproduced as Appendix D of
this report* It will be noted that a dosage of 150 IDS* of sodium nitrate has
been taken as an average value for each 1,000 cases of Ho.2 dans packed* This
represents 56 tons of sodium nitrate for the season for the Kapaa Cannery, which
would "be worth approximately $3,000.00. Considering the concentration of pine-
apple cannery wastes, the dosage of 150 IDS* sodium nitrate for each 1,000 cases
of No.2 cans might prove inadequate*
Inasmuch as sodium nitrate has not completely solved this cannery waste
problem, consideration might he given to the following:
1. Reduce waste concentration through improved housekeeping
methods within the cannery
2. Provide more efficient screening
3* Consider dilution with the cooling water which is presently
diverted to another drainage basin
4>* Acquire additional land and convert these lagoons to
stabilization ponds
5* Install a high-rate biological filter with feed from lagoon
5o.4 and discharge of filter effluent to Lagoon Ho.l. This
system has been proven effective on wastes from yeast
production
It would be advisable to Investigate on pilot plant scale each of the fore**
going suggestions prior to full scale adoption* Proceedings of the Symposium on
Waste Stabilization Lagoons held in Kansas City, Missouri, August 1-5, 1960 and
three pertinent reprints have been forwarded to the Hawaiian Department of Health
under separate cover*
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- 25 -
February 3t 1961 (Friday)
An accotrat of our conference with representatives of Standard Oil Company
Hawaiian Refinery the Morning of February 3 is given on pages 9-13 of this memo-
randum report* Mr. Schreeder and the writer spent Friday afternoon, February 3,
with Robert Las visiting the following institutions!
1. Hale Zinau (Hew building which will house the offices and
laboratories of the Hawaiian Department of Health)
2. Hawaiian Sugar Planters' Association, Eaqaeriment Station
3. Pineapple Research Institute of Hawaii
It was truly an. Inspiration to inspect the new Hale Xinau. It was reported
that this $1,250,000«00 structure will be ready for occupancy in March 1961, The
present building has four floors with a basement for storage of supplies. It Is
expected that the present department will completely fill this new building. It
is understood that the building has been designed to permit the addition of at
least two more floors.
Our first contact with Hawaiian Sugar Planters* Association (H.S.P.A.) was
with Mrs. C. M. Ho skins, Librarian, end Mrs. fed Dabagh, Assistant Librarian.
The Experiment Station maintains a very Impressive library. The following
excerpt Is taken from the I960 Report of the Experiment Station:
"Our library now contains 73,209 volumes of catalogued material;
these Include subjects on agriculture, sugar cane cultivation and tech-
nology, chemistry, biology, botany, pathology and engineering. Our
scientific collection has been increased by 1,1^3 new books and 13
microfilms and photo prints"
At the request of Mr* Lam, Mrs* Dabagh presented us with a number of pamphlets
and brochures describing the Hawaiian sugar industry. This material gives the
names and locations of the 27 sugar plantation companies. Pertinent Information
is given regarding growing, harvesting* and processing sugar cane. One brochure
shows sugar production in Hawaii from 1835« the beginning, to 1959- It Is inter-
esting to note that these 2? plantations produce about one million tons of raw
sugar annually, which is worth approximately $150,000,000.00. Cane sugar is
Hawaii1 s number one industry.
We were referred to Dr. John H. Payne, Principal Sugar Technologist, H.S.P.A.
Experiment Station* Dr. Payne briefed us on the work of the Experiment Station
and presented us with copies of the following reports!
1* I960 AF"«»fli Report of the President, Hawaiian Sugar Planters'
Association
2. I960 Report. Experiment Station, Hawaiian Sugar Planters'
Association
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« 26 ~
Review of these two reports gives a good picture of the work of the
H.S.P.A. Experiment Station. Highlights for the year 1960 were:
1. Diffusion Investigation conducted at Kekaha Sugar
Company on the island of Eausi
2. Development of a cane harvester which will cut,
convey, and load the cane into a transport unit
Studies have indicated that the loss of sugar "between the time the cane
is cut and goes through the cleaner may be as high as 10j( of the mount in the
standing cane* Most of the losses occur in the handling after the cane has
•been cut. These losses could he reflected in the cane wash water waste. These
sugar losses have prompted H.S.P.A. to spend recently as each as $300,000.00
annually on mechanical harvesting*
Dr. Payne commented on the problems that had been introduced by mech-
anical harvesting, which was started in 1937 at the Ewa Plantation on the
island of Oahu. Prior to this date, the trash was largely burned to clear
the ground. It was reported that Mr. William J. Hull, Castle & Cook, Hono-
lulu, prepared a report on sugar cane trash. Mr. Lam was of the opinion that
a copy of this report was in his office.
H.S.P.A. made a study in 195^ of incineration of wet trash (8$ moisture).
fhe trash was reported to have sufficient BTU1 a to support combustion at high
moisture concentrations. These studies revealed that a multiple hearth incin-
erator designed to burn 40 tons per hour of trash at 70$ moisture would cost
$200,000.00.
The H.S.P.A. Agronomy Department has made periodic studies on composting
of trash. Reports on these composting studies are available.
The Hawaiian Sugar Planters1 Association has not considered liquid wastes
produced by the Industry of sufficient Importance to warrant establishing a
research project. Proximity of the sugar cane mills to the ocean probably
explains this situation. Dr. Payne was not aware of any research being con-
ducted or planned in the Hawaiian islands on control and treatment of liquid
wastes from processing sugar cane.
The year—round operation of the sugar plantations in Hawaii has resulted
in their becoming fully mechanized. The same applies to the mills for process-
ing the cane. During the latter years of the 19th Century, heavy machinery was
brought in quantity from the United States, from England, and from Germany.
Some of this equipment is still in operation. Trends in modernization are in-
dicated by the Experiment Station sponsored cane diffusion project at Kekaha
Sugar Company mill* This project demonstrated 99$ extraction of sugar from the
cane, with lower capital cost, less power consumption, and reduced maintenance*
Labor problems Impose another important factor affecting healthy growth
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•» 27 «•
of the cane sugar industry. The extended strike in 1958 caused production to
drop from 1,08^,6*16 tons in 1957 to 76^,953 tons in 1958. The minimum wage for
labor in the Hawaiian sugar industry was reported to lie $1*60 per hour.
The Animal Report of the President, H.S.P.A., contains a 15 year history
of cane sugar production in Hawaii and profits for the corresponding years.
This chart reveals the present economic status of the industry in Hawaii. Of-
ficials of the Hawaiian sugar industry may "be expected to demand the minimum
capital commit merits and operating charges for non-revenue-rproducing facilities*
Ye talked "briefly with Mr. H. Z* Smoot, Business Manager, Pineapple Research
Institute of Hawaii. Mr. Smoot advised that studies of the Institute had "been
largely concerned with agriculture and the growing of pineapple. Canning is
considered the responsibility of the Individual companies. There are nine pine-
apple canneries in the Hawaiian Islands; Oahu, Kauai, and Kauai each have three
canneries. Pineapple Is a semi-arid plant and use of liquid wastes back on the
land Is not looked upon with favor*
Hawaii* s pineapple crop averages ever 29,000,000 cases of fruit and juices
annually, valued at $108,000,000.00. The Pineapple Research Institute stems
from cooperative research "by the industry which was started in 191^* Today the
Institute has six research departments: Agricultural Engineering, Agronomy,
Chemistry, Entomology, Plant Breeding, and Plant Pathology. Research is directed
toward growing and harvesting of the pineapple, and the development of new
products. Mr, Snoot knew of no organized program for study of liquid wastes
treatment. We were given "brochures prepared "by the Pineapple Growers Associa-
tion of Hawaii and the Pineapple Research. Institute of Hawaii.
Hayse H. Black
Industrial Wastes Consultant.
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APPENDIX A
SCHEDULE FOR MESSRS. BLACK AHD SCHRSEDER
Monday* January 23,
R, Lam meet Messrs. Black and Schreeder at Airport
FM Conf erence with Messrs* Lam and Hekomoto re: schedule for period of visit
Review of testing capabilities at Standard Oil
Review of tests to date "by Standard Oil
Tuesday* January 2k
Standard Oil Refinery with Messrs* Nekomoto and Hakahara
Wednesday* January 21
Mr.Black ~ S, 0* with Mr* Hekomoto
Mr* Schreeder - as above with Messrs. Lam and Nakahara or inspect projects,
Kaneohe, Kallua, Wahiawa, Pearl City
« January 26
Mr* McMorrow and entire party -» Standard Oil to review sampling program
and discuss permanent monitoring program
(Waianae)
Friday. January 2^
(McMorrow not available)
S* 0. Refinery? Other inspections?
M^onday. Jsmnary 30
Messrs* Black and Schreeder to Hilo
Inspect Hilo Bay* sugar mill, etc*
Spend night at Hilo
Tuesday. January 31
Messrs* Black and Schreeder to Xailua-Kona
McMorrow arrive Kailua-Sbna from Honolulu in afternoon
Study Kailua-Xona sewage disposal problem
Spend night at Xailua~Kona
« February 1
Messrs* McMorrow, Black and Schreeder, Zailua-Sona to Maul
Inspect site of possible paper mill
Maul to Honolulu that afternoon
* February 2
Messrs. Lam, Black and Schreeder to Kauai returning to Honolulu same day
Inspect pineapple cannery waste disposal problem and Lydgate Park development
gridar. gebruary 3 N
Tlnal conferences (also see Jan Hull of Castle & CookeJ
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APPENDIX B
STAHDARD OIL CCMPAHY-SAVAIIAH REFIHHHT
1.
2.
3.
fc.
5.
6.
7.
8.
9.
Sample
So lids-Sett leab le
100 suspended
Turbidity
Dissolved Q£
Color
Sulfide
Oils, Grease, Fat
Phenol
Nercaptan
Taste and Odor
CD
1:00 p.m.
21 Dec., I960
100 ppm
2.5 »
14.5
14.8 ppm
—
nil
39.6 ppm
-.
nil
none
EFFLUENT STUDY
(2)
3:00 p.m.
4 Jan., 1961
5 ppm
76 «
5.8
13.4 ppm
—
nil
17.6
—
nil
none
(3)
10:30 a. a.
11 Jan., 1961
traces
8.5
11.8
6.6
—
nil
15 ppm
—
nil
none
w
11:30 a.m.
18 Jan., 1961
traces
56
23.0
incubation
period
—
nil
13.2
—
nil
none
DO 27 Dec,
BOD 27 Deo.
23.1 »
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PAGE NOT
AVAILABLE
DIGITALLY
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APPEHDIX D
HITRATE TBEATHEHf OF LAGOOBS
H. H. Young
Chief Engineer, Stokely Foods, Inc.
Indianapolis, Indiana
The problem of waste treatment for canneries is obvious, and so far the
lagoon seems to be the best solution. Stokely Foods* Inc., has sixteen lagoons
in it a plants in Wisconsin, Illinois, Indiana, Michigan, and Ohio. Some of
these are not much more than holes in the ground, and in one or two instances
the lagoons serve as preliminary settling beds for additional treatment facili-
ties; but there are a few lagoons that the company can be quite proud of*
The first lagoon which the company used was constructed at South Beaver
Dam, Wisconsin, In about 19*10• It vas designed and built with the assistance
of the Engineering Department of the Wisconsin State Board of Health. This
lagoon is still doing a good job, although the design specifications have been
somewhat changed in recent years.
The figures given below on design are subject to the suggestions of any
of the State Board of Health engineers, but in general they conform to state
and federal specifications. The National Canners Association has been very
active In prevention of pollution by cannery wastes and has done a lot in help*
ing the industry work out waste-treatment methods.
Following Is an outline of some of the more Important points to follow in
lagoon constructions
1. Sufficient area of land 10 necessary. Area required depends on the
plant's marl ret" seasonal output. This will be explained later *
2. Lagoons should be as close as possible to the plant. If possible,
they should be on the side of town opposite the direction from which prevail-
ing winds come. They should be as close as possible to the eventual discharge
point, and they should be outside the corporation limits In a sparsely settled
area.
3. Adequate capacity is important for proper lagooning. Good results
have been obtained in designing for a three- to four-foot depth of liquid.
For a three-foot depth, approximately one acre of ground is required for the
retention of one million gallons of liquid.
Provision should be made for the retention of 25$ of the previous season*8
waste In order to have seed sludge for the next season. For example, in design-
ing a lagoon for a season's waste of 12,000,000 gallons, plus 25$ of this figure
to be retained and based on a liquid depth of three feet, approximately 19 acres
of ground will be requireo>»~*this 19 acres includes the area occupied by the
levees or embankments.
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APPEHJDIX D (Continued)
Levees should "be constructed to allow for a three- to four—foot free "board;
that Is, for a three-foot liquid depth the levees should be six to seven feet
high. Levees should have a minimum Inside slope of 2 1/2:1 and outside slope of
2:19 depending on soil characteristics, and should have a top width of eight to
ten feet, preferably ten feet* They should toe built up in six-inch layers, and
each layer should be well compacted* This will give a practically trouble-free
levee, and weeds and grass can easily be kept cut with power tools*
The bottom of the lagoon should be fairly flat and even, with no "islands"
projecting above the liquid levels to provide a haven for mosquitoes*
Stokely Foods, Inc., has experienced a little difficulty with muskrats
burrowing through the levees* Bo solution has been found for this problem other
than periodic inspection for leaks, end trapping*
Maintenance of the lagoon and treatment of the waste is, of course, of most
importance. A few general rules to follow in order to get satisfactory, or nearly
satisfactory as possible results from the lagoon are as follows:
Weeds, of course, should be kept cut at all times to reduce
mosquito nuisance. The company is experimenting this year (19*16) on
two lagoons by sowing the levees with "altafescue" grass* This is a
fast-growing grass and is widely used around airport runways and bor-
dering highways. It is hoped that weed growth can thus be kept to a
minimum, thereby reducing mosquito nuisance* The grass will also pre-
sent a more pleasing appearance* This seed costs approximately $50.00
per ton, and it requires about 15 to 25 Ibs* per acre of area*
As for treatment of the waste itself to eliminate or reduce ob-
jectionable odors, sodium nitrate is introduced into the liquid after
screening in the following quantities, based on each thousand cases of
Ho. 2 cans*
Pea wastes 200 Ibs.
Tomato wastes 200-250 Ibs.
Lima Bean wastes 60 Ibs*
Corn wastes 200-250 Ibs.
Pumpkin wastes 150-200 Ibs.
Other wastes 150 Ibs*
Tfor Ho. 2 1/2 cans, **& more nitrate is required per 1,000 cases.
Por Ho. 10 cans, 33# more nitrate is required per 1,000 cases.
?or Ho. 1 cans, 6# more nitrate is required per 1,000 cases. This
sodium nitrate costs about $62.50 per ton at present; 100,000 eases
of peas would require 10 tons of nitrate costing about $600.00.
During the rainy season when the streams are flowing at high
level (this is normally in the spring \fcen wastes have gone through
the winter and have become stabilized) the impounded liquid is let
out. Care should be taken, however, not to overload the streaa into
which the lagoon is emptying.
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APEBHDIX D (Continued) — 3
Periodic spraying of the lagoon with proper insecticides is
necessary to eliminate fly and mosquito nuisances. A solution of 2556
DDT is used about once a month, at which tine the inside of the tanks
and the water surface to about six feet away froa the levee are sprayed.
The company Is also trying to Introduce DDT into the waste as it gees
Into the lagoon*
It is not felt that the lagoon is the entire answer to disposal of cannery
waste* However, it is the best known means at the present time, as previously
stated; end with proper attention the lagoon will do a Jot. The company recently
installed a lagoon at one of its plants, and from the standpoint of odor control
there has been reasonable success, although this is the first year's operation.
However, in spite of all precautions at this particular lagoon* it was found after
the plant had been running a couple of weeks that someone had not plumed a drain
tile when the lagoon was built* The drain tile met have been partly stopped and
must then have broken loose because the lagoon began to drain after it had been
in use a short tlae. There was no way in the world without the use of power
equipment that this leak could be stopped. It became necessary to get a power
shovel back on the job and dig down in the water untilv the tile was found and
sandbagged until the flow stopped* She drain was finally filled with concrete*
From Proceedings of the Fourth Industrial Waste Conference, Purdue University,
September 21-22* 19%, pages 208-210.
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