£ _ -
UNITED STATES ENVIRONMENTAL PROTECTION Pt£eGWE D
REGION iv F I- A REGION !X
345 COURTLAND STREET . . -.,.,,_
ATLANTA, GEORGIA 3030B ' .'.V -VJ I ^5 I H I U
May 19, 1978
TO ALL INTERESTED GOVERNMENTAL AGENCIES, PUBLIC GROUPS
AND CONCERNED INDIVIDUALS
The Draft Environmental Impact Statement (DEIS) for Ideal
Basic Industries Cement Plant and Limestone Quarry is enclosed
for your review and comments. This document has been prepared
pursuant to Section 102(2)(c) of the National Environmental
Policy Act (NEPA) (Public Law 91-190). Four additional volumes
consisting of the baseline document and a technical appendix
are also available. These documents comprise EPA's detailed
evaluation of the proposed action and contain the supporting
data related to the DEIS. Because of the amount of information
in the baseline document and technical appendix and recent
Council on Environmental Quality directives to reduce paperwork
and to make EIS's more readable, the printing and distribution
of this material has been limited. These materials may be
reviewed at the EPA Region IV Office and at the following
libraries:
Main Library, 701 Government St., Mobile, AL
Cottage Hill Branch (Mobile, AL)
Monte L. Moorer Branch (Mobile, AL)
Parkway Branch (Mobile, AL)
Saraland Branch (Mobile, AL)
Toulminville Branch (Mobile, AL)
Government Information Division (Mobile, AL)
Fairhope Public Library (Baldwin County)
University of South Alabama Library
(Mobile, AL)
Monroeville Public Library (Monroeville, AL)
Patrick Henry State Junior College Library
(Monroeville, AL)
Monroe County High School Library (Monroe County)
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EPA has asked the Alabama Air Pollution Control Commission,
the Alabama Water Improvement Commission and the Mobile
District of the U.S. Army Corps of Engineers for input into
the development of this document. It is intended that this
document satisfy the NEPA responsibility of all other Federal
agencies and conform with the permit requirements of these
agencies and the State of Alabama.
A public hearing will be held to discuss this project on June
26, 1978 at 7:00 p.m. in the Municipal Auditorium at Mobile,
Alabama. Persons wishing to make comments should attend and
speak at this hearing. A verbatum transcript will be made.
For the accuracy of the record, lengthy or technically complex
statements should be submitted in writing to:
John E. Hagan III, Chief EIS Branch
Environmental Protection Agency
Region IV
345 Courtland Street, N.E.
Atlanta, GA 30308
The hearing record will remain open and additional written
comments may be submitted until July 11, 1978. Such additional
comments will be considered as if they had been presented
at the public hearing.
Recipients of this document should be aware that EPA will
not reprint material contained in the DEIS for the final EIS.
The final EIS will consist of the agency's statement of
findings, the decision on the new source HPDES permit, any
pertinent additional information or evaluations developed
since publication of the draft, comments on the project and
the agency responses, and the transcript of the public hearing.
You should keep this copy of the draft EIS for reference.
Please notify any persons known to you who may be interested
in attending the public hearing.
John C. White
Regional Administrator
Enclosures
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JOINT PUBLIC NOTICE
U. S. ENVIRONMENTAL PROTECTION AGENCY
REGION IV, WATER ENFORCEMENT BRANCH
345 Courtland Street
Atlanta, Georgia 30308
404/881-2328
in conjunction with
ALABAMA WATER IMPROVEMENT COMMISSION
Perry Hill Office Park, 3815 Interstate Court
Montgomery, Alabama 36109
205/277-3630
Public Notice No. PH78AL0018 Date: May 26, 1978
NOTICE OF PUBLIC INFORMATION HEARING ON DRAFT ENVIRONMENTAL IMPACT
STATEMENT, NOTICE OF PROPOSED ISSUANCE OF NATIONAL POLLUTANT DIS-
CHARGE ELIMINATION SYSTEM PERMIT, AND NOTICE OF CONSIDERATION FOR
STATE CERTIFICATION
The U. S. Environmental Protection Agency proposes to issue National
Pollutant Discharge Elimination System (NPDES) Permits to Ideal Basic
Industries, Cement Division, Ideal Plaza, 950 17th Street, P. 0.
Box 8789, Denver, Colorado 80201 for the following facilities:
Theodore Cement Plant, Theodore Industrial Park, Mobile,
Alabama, NPDES No. AL0028801. This proposed facility
will produce hydraulic cement (SIC Code 3241). The
facility will have two (2) proposed discharges. Dis-
charge 001 will consist of material stockpile run-off
(SIC Code 3241), cooling tower blowdown (SIC Code 4930),
vehicle and floor wash wastewaters (SIC Code 3241) and
fuel storage area dike drainage discharging to the
Theodore Ship Channel which is classified for fish and
wildlife propagation. Discharge 002 will consist of
uncontaminated stormwater run-off entering the North
Fork of the Deer River which is classified for fish
and wildlife propagation.
Gaillard Quarry, near Monroeville, Monroe County,
Alabama, NPDES No. AL0028819. This facility will mine
limestone (SIC Code 1422) and will have proposed point
source discharges associated with active mine dewatering
(SIC Code 1422) entering the Alabama River which is classi-
fied for fish and wildlife propagation at the points of
discharge.
The proposed NPDES permits contain limitations on the amounts of
pollutants allowed to be discharged and were drafted in accordance
with the provisions of the Federal Water Pollution Control Act,
as amended (PL 92-500), and other lawful standards and regulations.
The pollutant limitations and other permit conditions are tentative
and open to comment from the public.
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Fact sheets which outlines the applicant's proposed discharges and
EPA's proposed pollutant limitations and conditions are available
by writing the EPA (address above). Copies of the draft permits
are appended to the draft EIS summary document and are also available
from the EPA Region IV office. The permit applications, supporting
data, draft environmental impact statement, comments received and
other information are available for review and copying at 345 Court-
land Street, N. E., Atlanta, Georgia 30308, between the hours of
8:15 a.m. and 4:30 p.m., Monday through Friday. A copying machine
is available for public use at a charge of 20 cents per page.
The Environmental Protection Agency (EPA) has prepared a draft
environmental impact statement on the above referenced facilities.
The draft environmental impact statement will be made available to
the EPA Office of Federal Activities and to the public on May 19,
1978, by EPA, Region IV. The Regional Administrator of EPA has
determined that a public hearing will be held to foster further
public participation on the proposed issuance of necessary permits
and approvals for the proposed project. The public hearing is
scheduled for June 26, 1978, and will begin at 7:00 p.m. in the
Mobile City Auditorium, 401 Auditorium Drive, Mobile, Alabama.
Both oral and written comments will be accepted and a transcript of
the hearing proceeding will be made. For the accuracy of the record,
written comments are encouraged. The Hearing Officer reserves the
right to fix reasonable limits on the time allowed for oral state-
ments.
Another purpose of the hearing is to allow the public to comment
on EPA approval of air quality prevention of significant deteriora-
tion (PSD) aspects of the proposed construction of the cement plant
by Ideal Basic Industries. Such approval has already been granted
and no public hearing was required. However, the EPA regulations
under which such approval was granted are now being challenged in
the United States Court of Appeals for the District of Columbia
Circuit. If the plaintiffs prevail in this litigation, it is
possible that PSD approval could be withdrawn and a public hearing
required before reissuance of PSD approval. The public hearing on
June 26, 1978, is intended to satisfy any possible future require-
ment, with the recognition that such a public hearing is not
presently required.
Persons wishing to comment upon or object to the project, the NPDES
permit issuance, air quality prevention of significant deteriora-
tion (PSD) approval which has already been granted, the proposed
permit limitations and conditions, and/or the draft EIS are invited
to respond in writing by July 11, 1978, to Enforcement Division,
U. S. Environmental Protection Agency, 345 Courtland Street, N. E.,
Atlanta, Georgia 30308, Attn: Ms. Mona Ellison. The NPDES numbers
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(AL0028801 and AL0028819) should be included in the first page
of comments. All comments received by July 11, 1978, will be
considered in the formulation of final determinations regarding
the final EIS and the NPDES permit conditions.
Information submitted by Ideal Basic Industries in connection
with its PSD application and a copy of the PSD approval, as well
as other pertinent information, may be inspected at the Mobile
County Health Department, Room 217, 248 Cox Street, Mobile,
Alabama, Monday through Friday during regular working hours.
Further information may be obtained from Mr. Eliot Cooper of the
Air Programs Branch, EPA, Region IV, 345 Courtland Street, N. E.,
Atlanta, Georgia 30308, Telephone: (404) 881-3286, or from Mr.
Danny Herrin at the Mobile County Health Department, Telephone:
(205) 690-8112.
After consideration of all written comments and of the requirements
and policies in the Act and appropriate regulations, the EPA Regional
Administrator will make determinations regarding permit issuance.
If the determinations are substantially unchanged from those an-
nounced by this notice, the EPA Regional Administrator will so
notify all persons submitting written comments. If the determina-
tions are substantially changed, the EPA Regional Administrator will
issue a public notice indicating the revised determinations. Requests
for adjudicatory hearings may be filed after the Regional Administrator
makes the above described determinations. Additional information
regarding adjudicatory hearing is available in 40 CFR 125.36, or by
contacting the Legal Branch at the address above or at 404/881-3506.
The Alabama Water Improvement Commission has been requested to
certify the discharges in accordance with the provisions of Section
401 of the Federal Water Pollution Control Act, as amended (PL 92-500).
Persons wishing to comment on the State certification of these dis-
charges are invited to submit same in writing to the State agency
address above within 30 days of the date of this notice. Since a
public hearing will be held, the State agency will hear and receive
comments relative to State certification.
Copies of the draft EIS which includes the draft NPDES permits and
the Supporting Documents are also available for review at the
following Libraries.
Main Library, 701 Government St., Mobile, Alabama
Cottage Hill Branch (Mobile, Alabama)
Monte L. Moorer Branch (Mobile, Alabama)
Parkway Branch (Mobile, Alabama)
Saraland Branch (Mobile, Alabama)
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Toulminville Branch (Mobile, Alabama)
Government Information Division (Mobile, Alabama)
Fairhope Public Library (Baldwin County)
University of South Alabama Library (Mobile, Alabama)
Monroeville Public Library (Monroeville, Alabama)
Patrick Henry State Junior College Library (Monroeville, Alabama)
Monroe County High School Library (Monroe County)
Please bring the foregoing to the attention of persons who you know will
be interested.
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005
EPA 904/9-78-005
NPDES Application Numbers:
AL0028801, Cement Plant
AL0028819, Limestone Quarry
DRAFT
ENVIRONMENTAL IMPACT STATEMENT
6
for
Proposed Issuance of a New Source National
Pollutant Discharge Elimination System Permit
to
Ideal Basic Industries, Inc.
Cement Plant, Theodore Industrial Park, Alabama
atnd Limestone Quarry, Monroe County, Alabama
EJBD
ARCHIVE
EPA
78~
prepared by
U.S. Environmental Protection Agency
Region IV
Atlanta, Georgia 30308
BSgional
Administrator
Headquarter? and Chemical Libraries
E'PA Wesl awfl Room 334°
Maifcocte 3404T
1301 Constitution Ave NW
Washington DC 20004
202-566-0556
Environmer-
Protect/on A
Re-'- q
ai
Mav 19. 1978
Date
Repository Material
/ tr
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TABLE OF CONTENTS
SUMMARY DOCUMENT
SUMMARY SHEET FOR ENVIRONMENTAL IMPACT STATEMENT
TYPE OF ACTION 1
DESCRIPTION OF ACTION 1
MAJOR ENVIRONMENTAL IMPACTS 2
ALTERNATIVES TO THE PROPOSED ACTION 4
FEDERAL. STATE AND LOCAL AGENCIES AND INTERESTED
GROUPS REQUESTED TO COMMENT6
INTRODUCTION
PROJECT BACKGROUND 9
SUMMARY OF THE ENVIRONMENTAL ASSESSMENT 13
PROJECT HISTORY 19
SITE SELECTION 20
PLANT SITE
LOCATION 25
PROJECT DESCRIPTION 28
PLANT LAYOUT 28
PLANT CONSTRUCTION 31
CEMENT MANUFACTURING PROCESS 32
RESOURCE UTILIZATION 35
TRANSPORTATION 36
LAND USE SETTING
PRESENT LAND USE 38
FUTURE LAND USE 40
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AIR QUALITY
BASELINE CONDITIONS 44
RELEVANT PROJECT CHARACTERISTICS 45
IMPACTS 52
MITIGATING MEASURES 60
ALTERNATIVES 62
NOISE
BASELINE 65
INTRODUCTION 65
PRESENT CONDITIONS 66
RELEVANT PROJECT CHARACTERISTICS 66
IMPACTS 67
MITIGATING MEASURES 71
ALTERNATIVES 72
SOLID WASTE
BASELINE CONDITIONS 74
RELEVANT PROJECT CHARACTERISTICS 75
IMPACTS 77
MITIGATING MEASURES 78
ALTERNATIVES 78
WATER RESOURCES AND GEOTECHNICAL ASPECTS
BASELINE ENVIRONMENT 80
RELEVANT PROJECT CHARACTERISTICS 81
IMPACTS 86
MITIGATING MEASURES 88
ALTERNATIVES 89
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ARCHAEOLOGY
BASELINE CONDITIONS 91
ECOLOGY
BASELINE CONDITIONS 92
STRUCTURE OF TERRESTRIAL ECOSYSTEMS 92
SIGNIFICANT TERRESTRIAL SPECIES 95
AQUATIC ECOLOGY 97
RELEVANT PROJECT CHARACTERISTICS 98
IMPACTS 99
MITIGATING MEASURES 101
ALTERNATIVES 101
SOCIOECONOMICS
BASELINE CONDITIONS 104
PRESENT CONDITIONS 104
FUTURE CONDITIONS 107
RELEVANT PROJECT CHARACTERISTICS 108
IMPACTS 109
MITIGATING MEASURES 114
ALTERNATIVES 115
QUARRY SITE
LOCATION 117
PROJECT DESCRIPTION 121
CONSTRUCTION 121
QUARRYING PROCESS 122
RECLAMATION 124
m
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RESOURCE UTILIZATION 127
TRANSPORTATION 128
LAND USE SETTING 129
PRESENT LAND USE 129
FUTURE LAND USE 129
AIR QUALITY
BASELINE CONDITIONS 130
RELEVANT PROJECT CHARACTERISTICS 130
IMPACTS 132
MITIGATING MEASURES 132
ALTERNATIVES 133
NOISE
BASELINE CONDITIONS 135
RELEVANT PROJECT CHARACTERISTICS 135
IMPACTS 138
MITIGATING MEASURES 138
ALTERNATIVES 138
SOLID WASTE
BASELINE CONDITIONS 139
RELEVANT PROJECT CHARACTERISTICS 139
IMPACTS 140
MITIGATING MEASURES 141
ALTERNATIVES 141
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WATER RESOURCES AND GEOTECHNICAL ASPECTS
BASELINE CONDITIONS 142
GEOTECHNICAL CHARACTERISTICS 146
RELEVANT PROJECT CHARACTERISTICS 147
IMPACTS 150
MITIGATING MEASURES 152
ALTERNATIVES 152
ARCHAEOLOGY
BASELINE CONDITIONS 154
ECOLOGY
BASELINE CONDITIONS 156
TERRESTRIAL ECOLOGY 156
AQUATIC ECOLOGY 163
Introduction 163
Aquatic Fauna 167
Fishes 167
Rare and Endangered Fishes 168
Benthic Macroinvertebrates 169
RELEVANT PROJECT CHARACTERISTICS 170
IMPACTS 171
MITIGATING MEASURES 174
ALTERNATIVES 175
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SOCIOECONOMICS
BASELINE 177
PRESENT CONDITIONS 177
FUTURE CONDITIONS 179
RELEVANT PROJECT CHARACTERISTICS 181
IMPACTS 181
MITIGATING MEASURES 183
ALTERNATIVES 183
PERMIT AND APPROVAL SECTION
DRAFT NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM
(NPDES) PERMIT (PLANT SITE)P-l
DRA.FI_^TI9NAL POLLUTANT DISCHARGE ELIMINATION SYSTEM
(NPDES) PERMIT (QUARRY SITEjP-13
JOINT PUBLIC NOTICE—U.S. ARMY CORPS OF ENGINEERS AND
ALABAMA WATER IMPROVEMENT COMMISSION (PLANT SITE) P-23
JOINT PUBLIC NOTICE—U.S. ARMY CORPS OF ENGINEERS AND
ALABAMA WATER IMPROVEMENT COMMISSION [QUARRY SITE) P-33
EPA!§.. AUTHORITY I9_P.9!JSircucT (EPA REGULATIONS FOR THE
PREVENTION UF SIGNIFICANT DETERIORATION OF AIR QUALITY
40 CFR 52.21) CEMENT PLANTP-45
ALABAMA HISTORICAL COMMISSION (PLANT SITE) P-51
ALABAMA HISTORICAL COMMISSION (QUARRY SITE) P-53
ALABAMA STATE DOCKS DEPARTMENT APPROVALS (PLANT SITE) P-55
ALABAMA STATE DOCKS DEPARTMENT APPROVALS (QUARRY SITE) P-57
BIBLIOGRAPHY B-l
VI
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LIST OF TABLES
PLANT SITE
PROJECT DESCRIPTION
Table 1. Summary of Significant Adverse Environmental
Impacts, Proposed Mitigating Measures, and
Practical Alternatives
AIR QUALITY
Table 2. Summary of Existing Ambient Total Suspended
Particulate Matter Levels (ug/m3) in the
Vicinity of the Proposed Ideal Basic Industries
Plant Site, 1976 and 1977
Table 3. Maximum Allowable Atmospheric Emissions from the
Proposed Cement Manufacturing Plant for Particulate
Matter and Sulfur Dioxide and Estimated Quantities
of Other Pollutants: Nitrogen Oxides, Hydro-
carbons, and Carbon Monoxide
Table 4. Summary of PSD Evaluation Results for the Proposed
Ideal Basic Industries Cement Manufacturing Plant
SOCIOECONOMICS
Table 5. Population of the Mobile Metropolitan Area and
Component Areas, Past and Projected
Table 6. Gross and Net Employment Attributable to
Ideal Basic Industries Under Worst-Case
Conditions; Mobile SMSA
QUARRY
SOCIOECONOMICS
Table 7. Forecasts of Nonagricultural Wage and Salary
Employment in Monroe County
Table 8. Comparison of Population Forecast for
Monroe County with OBERS Series E Projections
14
47
50
58
105
112
180
180
vii
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LIST OF FIGURES
PROJECT BACKGROUND
Figure 1. Proposed Cement Plant and Quarry Sites 11
PLANT SITE
Figure 2. The Proposed Plant Site Relative to Mobile, 26
Alabama
Figure 3. The Theodore Industrial Park Site 27
Figure 4. Proposed Plant Plot Plan 29
Figure 5. Flow Diagram of Proposed Plant Process 33
LAND USE SETTING
Figure 6. Present Land Use in the Vicinity of the Proposed 39
Ideal Basic Industries Plant Site
Figure 7. Projected Land Use in the Vicinity of the Proposed 41
Ideal Basic Industries Plant Site, 1992
Figure 8. Plan View of Proposed Corps Project—Entire Harbor 43
AIR QUALITY
Figure 9. Locations of Ambient Monitoring Stations in the 46
Vicinity of the Proposed Cement Plant, Theodore,
Alabama
Figure 10. Ambient Total Suspended Particulate Matter 48
Concentrations at Stations Near the Proposed
Ideal Cement Plant, Mobile County, 1975-1977
Figure 11. Isopleths of the Incremental Contributions to 54
Predicted Annual Average Ground-Level Sulfur
Dioxide Concentrations (ug/m3), Proposed
Cement Plant Only, Theodore, Alabama, 1980
Figure 12. Isopleths of the Incremental Contributions to 55
Predicted Annual Average Ground-Level Suspended
Particulate Matter Concentrations (ug/m3),
Proposed Cement Plant, Theodore, Alabama, 1980
vm
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PLANT SITE (Continued)
NOISE
Figure 13. Equal Sound Level (Ldn) Contours Due to Worst-Case
Construction Activities from the Proposed
Plant Only
Figure 14. Equal Sound Level (Ldn) Contours Due to Plant
Operations Only
WATER RESOURCES AND GEOTECHNICAL ASPECTS
Figure 15. Surface Water Bodies
Figure 16. Photos of the Theodore Plant Site Along the
North Fork Deer River from the Bridge on Dauphin
Island Parkway
ECOLOGY
Figure 17. Vegetation Map for the Proposed Plant Site
68
70
82
83
93
QUARRY SITE
PROJECT DESCRIPTION
Figure 18. Present Land Use in the Vicinity of the Proposed
Ideal Basic Industries Quarry Site
Figure 19. Quarry Site Vicinity
Figure 20. Steps of Proposed Quarry Process
Figure 21. Mining Areas
Figure 22. Schematic Layout of Waterfront Development
AIR QUALITY
Figure 23. Trends in Ambient Total Suspended Parti cul ate
Matter Concentrations, Rural Alabama in the
Region of the Proposed Ideal Quarry Site,
1972-1977
Figure 24. Equal Sound Level (L^p) Contours Surrounding the
Quarry Site During Construction Activities
Figure 25. Estimated Boundary of Sound Level, L
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QUARRY SITE (Continued)
WATER RESOURCES AND GEOTECHNICAL ASPECTS
Figure 26. Watershed Map: MeGirts Creek, Thompson Mill 143
Creek, Hoi linger Creek, Randons Creek, Alabama
Tributaries 1, 2, 3, and 4
Figure 27. Cross Sections of a Typical Quarrying Area 148
ECOLOGY
Figure 28. Vegetation Map of the Proposed Quarry Site 157
Figure 29. Ecological Relationship of the Ecosystems 160
of the Proposed Quarry Site
Figure 30. Photographs of Thompson Mill Creek 164
Figure 31. Photographs of Hoi linger Creek 165
Figure 32. Photographs of Randons Creek 166
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NOTE ON THE USE OF THE METRIC SYSTEM:
The numbers contained In this volume and In all of the following
appendices are expressed In metric units, with the English units In
parentheses.
XI
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SUMMARY SHEET
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SUMMARY SHEET FOR ENVIRONMENTAL IMPACT STATEMENT
CEMENT PLANT AND LIMESTONE QUARRY
IDEAL BASIC INDUSTRIES, INC.
THEODORE INDUSTRIAL PARK AND MONROE COUNTY, ALABAMA
(X) Draft
( ) Final
1. TYPE OF ACTION: Administrative (X) Legislative ( ).
2. DESCRIPTION OF ACTION:
The Environmental Impact Statement (EIS) was prepared by the Region IV
office of the Environmental Protection Agency (EPA). EPA has prepared
this document to fulfill the requirements of the National Environmental
Policy Act of 1969 (NEPA) and the EPA January 11, 1977 regulations:
Preparation of Environmental Impact Statements for New Source NPDES
Permits (42 CFR 6.900). NEPA requires all Federal agencies to assess
the impacts which would occur following a major Federal action which
will result in a significant impact on the human environment.
Ideal Cement Company, a division of Ideal Basic Industries, Inc. (the
applicant), has proposed to construct and operate a new 1.4 million
metric ton (1.5 million ton) per year portland cement plant and supple-
mental limestone quarry. The cement plant will be located in the
Theodore Industrial Park along the federally-authorized Theodore Ship
Channel. The limestone quarry site will be located near Monroeville in
Monroe County, Alabama, bordering the Alabama River.
The proposed plant site will involve the clearing of approximately
20 hectares (50 acres) of the 71-hectare (175-acre) tract owned by the
applicant. When completed, the plant site will consist of a docking
facility with loading and unloading equipment, grinding mills, kilns,
storage and mixing silos, an aboveground fuel oil storage tank, under-
ground diesel and gasoline tanks, and raw material storage piles.
The quarry site consists of 1,633 hectares (4,035 acres) of modified
timberland which is currently being converted to pastureland. Approxi-
mately 40 hectares (100 acres) will be cleared and graded for the access
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SUMMARY SHEET (PLANT AND QUARRY SITE)
road, main building, and stockpile area. An estimated 14 hectares
(35 acres) of the quarry property will be impacted during each year of
operation. As the quarrying progresses, the overburden removed will be
used for reclamation of the quarried areas no longer in production.
Over the projected 50-year life of the quarry, approximately 80 percent
of the area will be impacted by quarrying. Facilities to be constructed
at the quarry site will be the barge docking and loading facility, clar-
ification basins, limestone storage piles, an office and maintenance
shop, a well and pump house for potable water, a septic tank and drain-
field, and underground diesel fuel and gasoline tanks.
No construction has commenced, pending issuance of the EPA's NPDES
Permit, EPA's Authority to Construct (EPA Regulations for the Prevention
of Significant Deterioration of Air Quality, 40 CFR 52.21), the Corps of
Engineers' Section 10 and Section 404 Construction Permit, and the nec-
essary state approval certificates and permits.
3. MAJOR ENVIRONMENTAL IMPACTS
(A) CONSTRUCTION
Plant
The plant site is undeveloped land within the Theodore Industrial Park.
Site construction will employ an average of 360 workers, with a peak of
700 workers. A short-term increase in air pollution, especially fugi-
tive dust, is expected on and near the plant site. Pollutants in the
form of suspended solids from site preparation runoff and construction
of the access road and railroad corridor on the property will drain to
the barge canal and the North Fork Deer River. Some regrowth vegetation
following recent timber harvest will be removed, which will alter
existing wildlife habitat. Increased noise in the vicinity of the pro-
posed plant site will result from site construction and increased
vehicular use of roadways.
Quarry
Construction of the quarry site will commit an estimated 80 percent of
the 1,633 hectares (4,035 acres) of company-owned and leased property to
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SUMMARY SHEET (PLANT AND QUARRY SITE)
limestone production. Construction will employ an average of
133 workers for 18 months, with a peak labor force of 250 workers.
Fugitive dust is expected on and near the quarry site during construc-
tion. Noise generated by earthmoving equipment and construction of the
docking facility will have minimal impacts. Impacts from removal of
vegetation and alteration of wildlife habitat will be of low magnitude
since much of the timber has been harvested for conversion of the area
to pastureland. Stormwater runoff may increase suspended solids levels
in some on-site creeks and the Alabama River.
Construction of the cement plant and limestone quarry will have positive
impacts on the economy in the Mobile area and in Monroe County. These
impacts will be of moderate significance. All adverse impacts resulting
from construction of the cement plant and quarry will be of moderate to
low magnitude and significance.
(B) OPERATION
Plant
Operation impacts will be long-term, i.e., occurring throughout the life
of the proposed cement plant (about 50 years). Impacts to air quality
will be increased levels of sulfur dioxide, nitrogen oxides, and partic-
ulate matter. EPA has determined that the operation of the cement plant
will not cause a violation of the applicable air quality standards.
However, the available deterioration increments will be reduced for
other new source industries which will build in certain limited areas of
Theodore Industrial Park. Wastewater discharges to the Theodore Ship
Channel will be limited to overflow from a settling basin collecting
limestone and clay storage pile runoff, cooling tower blowdown, truck
and process area wash water, and oil tank stormwater runoff. Rainfall
runoff from the remainder of the plant site will be directed to a
catchment area which will discharge into the freshwater wetlands north
of the plant site. These discharges are considered of low magnitude and
significance. EPA's preliminary determination is that the discharges
will comply with applicable water quality standards. Solid wastes will
be disposed in state-permitted sanitary landfills. Noise impacts from
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SUMMARY SHEET (PLANT AND QUARRY SITE)
plant operation will be of moderate magnitude and low significance to
the surrounding area.
Quarry
The major impact from operation of the limestone quarry will be the
constant change in topographic features over the projected 50-year life
of the quarry. Approximately 14 hectares (35 acres) will be quarried
and a comparable area reclaimed each year. Reclamation of the limestone
quarry will replace the overburden in a manner which will provide for
drainage and permit reseeding to grass and return to pasture!and. Clar-
ification basins designed to collect runoff from the quarry operation
will discharge water to the Alabama River and the creeks on the quarry
property. EPA's preliminary determination is that these discharges will
comply with applicable water quality standards and will be of low sig-
nificance. Fugitive dust will be generated from quarry operations but
will be controlled by watering and will normally be confined within the
limits of the active quarry area. Noise from the quarry operation will
not adversely impact residences. Transport of the limestone will
increase barge traffic on the Alabama River.
Adverse impacts from operation of the cement plant and limestone quarry
will be of low to moderate magnitude with low significance. Beneficial
impacts to the economy in the Mobile area and in Monroe County,
including supporting services, will result from operation of the cement
plant and limestone quarry. These impacts will be of moderate to high
magnitude and of moderate significance.
4. ALTERNATIVES TO THE PROPOSED ACTION
(A) PLANT
Twenty-seven alternative plant sites were considered for locating the
cement plant. The selected site is in an industrial park designated by
the State of Alabama and Mobile County to be used for industrial
development.
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SUMMARY SHEET (PLANT AND QUARRY SITE)
The alternatives for the manufacture of cement are the wet process and
the dry process. The dry process was selected mainly due to lower
energy requirements and possibly lower maintenance costs. Alternative
raw materials considered for the calcium supply were dolomite from the
proposed Gaillard quarry site and several other sources, aragonite from
the Bahamas, and oyster shells from the Gulf Coast area. Oil and
natural gas were considered as alternative fuels to operate the plant.
Alternatives considered for solid waste disposal were use of county-
maintained sanitary landfills and on-site burial.
Alternative air pollution abatement devices considered for control of
particulate emissions were baghouses, electrostatic precipitators,
scrubbers, and multicyclones. Water sprays and enclosing/venting to a
baghouse were the alternatives considered for fugitive dust control.
Alternative treatment and discharge of process-related wastewaters and
stormwater runoff from the plant were considered. The alternatives
were to direct wastewater discharges to the wetlands north of the plant,
to direct these discharges to the proposed ship channel, or to use the
proposed wastewater pipeline to Mobile Bay. Alternatives considered for
the general stormwater runoff were to discharge to the wetlands, to the
proposed ship channel, or partially to both the wetlands and the ship
channel. Alternative access corridors considered were from the north
across the North Fork Deer River through the wetlands, and bridging the
entire wetland area, and from Dauphin Island Parkway on the east.
(B) QUARRY
Alternative air pollution abatement devices considered for control of
particulate emissions were water sprays and enclosures with baghouses.
Solid waste alternatives considered were burning, chipping, on-site
landfill ing, and use of Monroe County Landfill.
-------
SUMMARY SHEET (PLANT AND QUARRY SITE)
Alternatives for controlling wastewater discharges considered were
clarification basins, vegetative buffers, and quarry pit storage. Alter-
natives for reclamation of quarry lands were pastureland, timberland,
and industrial development.
5. FEDERAL. STATE AND LOCAL AGENCIES AND INTERESTED GROUPS REQUESTED TO
COMMENT
FEDERAL AGENCIES
Bureau of Outdoor Recreation
U.S. Coast Guard
Corps of Engineers
Department of Commerce
Department of Energy
Department of Health, Education and Welfare
Department of Interior
Department of Transportation
Department of Housing and Urban Development
Economic Development Administration
Federal Highway Administration
Fish and Wildlife Service
Food and Drug Administration
Forest Service
Geological Survey
National Park Service
Office of Federal Activities
Soil Conservation Service
MEMBERS OF CONGRESS
Honorable John J. Sparkman, United States Senate
Honorable James B. Allen, United States Senate
Honorable Jack Edwards, United States House of Representatives
-------
SUMMARY SHEET (PLANT AND QUARRY SITE)
STATE AGENCIES
Alabama Air Pollution Control Commission
Alabama Department of Conservation and Natural Resources
Alabama Forestry Commission
Alabama Water Improvement Commission
Alabama State Docks Department
Alabama State Highway Department
Bureau of Environmental Health
STATE OFFICIALS
Honorable George Wallace, Governor of Alabama
L.D. Owens, Alabama State Senator
Mike Perl off, Alabama State Senator
L.W. Noonan, Alabama State Senator
Bill Roberts, Alabama State Senator
John McMillan, Alabama State Representative
J. Henry McCulley, Alabama State Representative
Dal C. Younce, Alabama State Representative
Cain J. Kennedy, Alabama State Representative
James E. Buskey, Alabama State Representative
J. Tommy Sandusky, Alabama State Representative
H.L. Callahan, Alabama State Representative
Nat Sonnier, Alabama State Representative
Gary Cooper, Alabama State Representative
Doug Johnstone, Alabama State Representative
Bob Glass, Alabama State Representative
LOCAL AGENCIES
Mobile City Commission
Mobile County Commission
Board of Water and Sewer Commissioners of the City of Mobile
Mobile County Board of Health
South Alabama Regional Planning Commission
-------
SUMMARY SHEET (PLANT AND QUARRY SITE)
INTERESTED GROUPS AND INDIVIDUALS
Alabama Bass Chapter Federation
Alabama Conservancy, South Alabama Representative
Alabama Environmental Council
Alabama Federation of Women's Clubs
Alabama Ornithological Society
Alabama Wildlife Federation
Baldwin County Wildlife and Conservation Association
Bon Secour Fisheries, Inc.
Coastal Area Board
Ducks Unlimited
League of Women Voters, Baldwin Chapter
League of Women Voters, Mobile Chapter
Marine Environmental Science Consortium
Mobile Area Chamber of Commerce
Mobile Bass Masters Club
Mobile Bay Audubon Society
Mobile County Wildlife and Conservation Association
Mobile United
Save Our Bay Club
Sierra Club
South Alabama Seafood Processors
Wildlife Management Institute
6. This draft EIS was made available to the Office of Federal
Activities (OFA) and the public on May 19, 1978.
8
-------
INTRODUCTION
-------
PROJECT BACKGROUND (PLANT AND QUARRY)
INTRODUCTION
PROJECT BACKGROUND
Ideal Basic Cement Division of Ideal Basic Industries, Incorporated, of
Denver, Colorado, plans to construct and operate a cement manufacturing
facility near Mobile, Alabama, and a limestone quarry near Monroeville,
Alabama (see Figure 1). The cement plant will use limestone from the
quarry as its principal raw material. The plant and quarry water
discharges, which are described in the Water Resources/Geotechnical
sections of this document, will be subject to the National Pollutant
Discharge Elimination System (NPDES) new source effluent limitations and
permit requirements. As a prerequisite to granting the required new
source NPDES permits, the U.S. Environmental Protection Agency (EPA) is
required by the National Environmental Policy Act of 1969 (NEPA) to
evaluate all potential environmental impacts of the proposed project.
In order to fulfill NEPA requirements, this Draft Environmental Impact
Statement (DEIS) has been prepared and will be reviewed by other local,
state, and .federal agencies, and by concerned individuals and public
interest groups. During the public comment period and at the public
hearing, comments on the environmental effects of these two facilities
and on EPA's action of issuing the NPDES permits will be received. A
Final Environmental Impact Statement (FEIS) will respond to these
comments and present EPA's decision on the issuance of the permits for
the proposed project.
This Draft Environmental Impact Statement deals with expected signi-
ficant effects of the construction and operation of the proposed
facilities on the natural and social environment. The EIS also
considers:
1. Practical alternatives to the proposed projects;
2. Adverse environmental impacts of the proposed projects; and
3. Possible mitigating actions that could be taken to lessen these
adverse impacts.
-------
MONTGOMERY
QUARRY SITE
QUARRY SITE
CLAY AND SAND QUARRY
CLAY AND
MOBILE
BAY I
PLANT SITE
Figure 1
PROPOSED CEMENT PLANT AND QUARRY SITES
(EXISTING CLAY AND SAND QUARRY ALSO SHOWN)
0 40 M
SCALE IN KILOMETERS
SOURCE: Environmental Science and Engineering, Inc., 1977.
REGION IV
U.S. ENVIRONMENTAL PROTECTION
AGENCY ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
PROPOSED CEMENT MANUFACTURING
PLANT THEODORE INDUSTRIAL PARK
AND PROPOSED GAILLARD QUARRY
10
-------
PROJECT BACKGROUND (PLANT AND QUARRY)
In order to expedite the preparation of the Environmental Impact State-
ment, Ideal Basic Industries has chosen the option of entering into a
third-party arrangement with an independent consultant to prepare the
DEIS under EPA supervision. EPA approved the consultant selected and
has retained sole responsibility for the technical content and
environmental assessments contained in the document. Environmental
Science and Engineering, Inc., of Gainesville, Florida has served as the
third party consultant.
The DEIS has been prepared before detailed plans for the proposed Ideal
Basic Industries project have been finalized in order to be responsive
to the comparative evaluation of possible alternatives and mitigating
measures. The description of the proposed project incorporates the
information available at the present time, and the assessment deals with
the worst-case condition in terms of environmental impact. No future
alterations will be incorporated in the project unless they involve
either improvement or no significant change in environmental quality.
This summary document presents in abbreviated form sufficient informa-
tion for understanding all significant project impacts. Most of the
discussion is organized according to environmental disciplines (e.g.,
air, water resources, ecology) in order to permit a cohesive treatment
of each area of impacts. For every discipline there is discussion of
baseline environmental conditions; relevant project actions, including
environmental safeguards to be taken by Ideal Basic Industries;
environmental impacts (positive and negative); possible mitigative
measures for some negative impacts; and practical project alternatives.
More detailed information is provided in the technical support documents
which contain the following information:
Appendix A (Volume I). Project Description—A description of the
proposed project with detailed information on air, noise, solid
wastes, water usage, wastewater discharges, and socioeconomic
factors.
Appendix B (Volumes II and III). Baseline—A report of the findings
of an intensive data survey of the existing (1977) environmental
11
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PROJECT BACKGROUND (PLANT AND QUARRY)
and socioeconomic conditions at both sites. In addition, future
conditions (1992) without the proposed project are projected. This
appendix covers the following discipline areas: Climatology and
Meteorology, Air Quality, Noise, Solid Waste, Geotechnical, Water
Resources, Archaeology, Ecology, and Socioeconomics.
Appendix C (Volume IV), Impacts—An assessment of the expected
positive and negative impacts of the proposed projects relative to
the baseline conditions. Each impact is rated according to
magnitude, significance, duration (long- or short-term), reversi-
bility, and avoidability.
Appendix D (Volume IV). Mitigating Measures—An analysis of the
possible actions that could be taken by Ideal Basic Industries to
lessen the effects of the adverse impacts.
Appendix E (Volume IV), Alternatives—An environmental assessment
of the practical alternative actions which could be taken in place
of the proposed actions. The proposed project is reviewed
according to the no-action alternative (project not allowed), as
well as the site location, process and resource, and pollution
abatement alternatives. The rationale for selection of the
specific project action over the possible alternatives is given.
The figures used in all documents (summary and technical support) are
given in both metric and English units for easier review. The English
units are given in parentheses.
The impacts, mitigating measures, and alternatives are summarized in the
next section to give the reader a quick overview of the project. The
draft NPDES permits and other federal and state agency approvals and
notices currently available are presented in the Permit and Approval
section of this document.
The bibliography for the Summary Document and all the appendices is
presented at the end of this document.
12
-------
ENVIRONMENTAL ASSESSMENT (PLANT AND QUARRY)
SUMMARY OF THE ENVIRONMENTAL ASSESSMENT
The proposed project of constructing and operating a cement plant and
limestone quarry has been investigated in relation to adverse impacts,
possible mitigating actions, and practical alternatives. The signifi-
cant aspects of these three factors are summarized in Table 1. In
order to better understand the assessment methodology, a brief review
is presented in the following paragraphs.
Impacts, which are classified as either primary (direct) effects of the
proposed action or secondary (indirect) effects, are rated according
to:
1. Magnitude—a quantification based on some measurable physical
property, assessed in degrees of low, moderate, or high.
2. Significance—a consideration of the importance of the mag-
nitude, duration, and reversibility of the impact relative to
expected area conditions. Significance is assessed in terms
of low, moderate, or high.
3. Duration—persistency of the impact, assessed as long-term
(greater than several years) or short-term (less than several
years).
4. Reversibility—rates the ability of the environment to nat-
urally return to existing conditions without a major direct
action of man. Impacts are rated as either reversible or
irreversible.
5. Avoidability—assesses the possibility of an adverse impact
being completely eliminated by some alternative action. The
effects are rated as avoidable and unavoidable.
Mitigating actions are possible measures that could be taken by the
applicant to reduce adverse impacts. These measures could be performed
in addition to the proposed action and environmental safeguards.
(Environmental safeguards are those actions taken by the applicant
specifically to lessen potential effects of their project and are con-
sidered in assessing the expected adverse impacts.)
13
-------
PLANT SITE
Table 1. Summary of Significant Adverse Environmental Impacts, Proposed Mitigating Measures, and Practical Alternatives
Action
PLANT SITE
Air Quality
1. Controlled Burning of
Land-Clearing Wastes
2. Fugitive Dust
3. Particulate Emissions
4. Sulfur Dioxide Emissions
5. Nitrogen Oxide Emissions
6. Use of PSD Increment
Noise
1. Construction Activities
2. Plant Operations
Solid Wastes
1. Landfill ing
2. Disposal of Dredged
Material
3. Landfill ing
Socioeconomlcs
1. Traffic
2. Land Value
3. Truck Traffic
Phase*
C
C
0
0
0
0
C
0
C
C
0
C
C
0
Magni-
tude
Low
Mod
Low
Low
Low
Mod
Mod
Mod
Low
Mod
Low
Mod
Mod
Mod
Signi-
ficance
Low
Low
Low
Low
Low
Low
Low
Low
Low
Low
Low
Low
Low
Low
Revers-
ible
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
Yes
Yes
Yes
Yes
Dura-
tion
(Term)
Short
Short
Long
Long
Long
Long
Short
Long
Long
Long
Long
Short
Short
Long
Avoid-
able
Yes
No
No
No
No
No
No
No
No
No
No
No
No
No
Mitigating Measures
None
Chemical
stabilizers; wind
breaks; paving roads
Higher stack heights
Lower sulfur fuel
None
None
None
Noise suppression on
baghouse fans;
enclose facilities
None
None
None
Reschedule work
shifts
None
Reschedule truck
Alternatives
On- site burial ; fire-
wood; use In pulp mills
and waste wood boilers
None
Scrubbers; cyclones;
electrostatic precipl-
tators; enclosing fugi-
tive dust sources and
venting to baghouses
None
None
None
None
Change facility layout
to minimize noise
Impact
On-slte burial
None
On-slte burial;
use as fill
None
None
None
4. Land Value
Mod
Low
Yes
Long
No
shipments
None
None
-------
PLANT SITE
Table 1. Summary of Significant Adverse Environmental Impacts, Proposed Mitigating Measures, and Practical Alternatives
(Continued, page 2 of 3)
Action
Dura-
Magni- Signi- Revers- tion Avoid-
Phase* tude ficance ible (Term) able
Mitigating Measures Alternatives
in
PLANT SITE, cont.
Water Resources and Geotechnical
1. Erosion/Sedimentation
from Land Clearing,
Grading, and Access
Roadway
2. Dredging
3. Oil Spills
4. Oil Spills
5. Wastewater Discharge
to Ship Channel
6. Stormwater Discharge
to Freshwater Marsh
Ecology
1. Loss of Pine Forest
and Wildlife Habitat
2. Loss of Wetlands for
Access Corridor
3. Loss of Habitat for
Special Species
4. Dredging
5. Noise Effects
6. Erosion/Sedimentation
7. Oil Spills
8. Noise Effects
9. Oil Spills
10. Stormwater Discharge
to Freshwater Marsh
11. Wdstewater Discharge
to Ship Channel
Mod Low Yes Short No Minimize slopes;
soil stabilizers;
buffers; artificial
structures
None
None
None
Chemical treatment
Low Low Yes Long Yes Chemical treatment
c
c
0
0
Mod
Low
Low
Low
Low
Low
Low
Low
Yes
Yes
Yes
Yes
Short
Short
Short
Long
No
No
No
No
C
C
C
C
C
C
C
0
0
0
Low
Low
Low
Low
Low
Low
Low
Low
Low
Low
Low
Low
Low
Low
Low
Low
Low
Low
Low
Low
No
No
No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Long
Long
Long
Short
Short
Short
Short
Long
Short
Long
No
No
No
No
No
No
No
No
No
Yes
None
None
None
None
None
None
None
No
None
None
Low
Low
Yes
Long
No
No
None
None
None
None
Discharge to marsh or
use outfall in Bay
Discharge to ship chan-
nel or to marsh and ship
channel
None
Access from Dauphin
Island Parkway; bridg-
ing the marsh
None
None
None
None
None
None
None
See Water Resources/
Geotechnical
See Water Resources/
Geotechnical
-------
QUARRY SITE
Table 1. Summary of Significant Adverse Environmental Impacts, Proposed Mitigating Measures, and Practical Alternatives
(Continued, page 3 of 3)
Action
QUARRY SITE
Air Quality
1. Fugitive Dust
2. Controlled Burning of
Vegetative Wastes
3. Fugitive Dust--Quarry
Area
4. Fugitive Dust—Other
Areas
Noise
1. Construction Activities
2. Plant Operation
Solid Waste
1. Landfill ing
2. Landfilling
Phase*
C
C
0
0
C
0
C
0
Magni-
tude
Low
Low
Mod
Low
Low
Low
Low
Low
Signi-
ficance
Low
Low
Low
Low
Low
Low
Low
Low
Revers-
ible
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Dura-
tion
(Term)
Short
Short
Long
Long
Short
Long
Long
Long
Avoid-
able
No
Yes
No
No
No
No
No
No
Mitigating Measures
Chemical stabili-
zers; wind breaks
None
Chemical stabi-
lizers
None
None
None
None
None
Alternatives
None
Landfilling; on-slte
burial
None
Enclosing and venting
to control devices
None
None
On-slte burial
On-site burial
Mater Resources and Geotechnical
1. Erosion and
Sedimentation
2. Discharge of Runoff
3. Drainage
4. Groundwater
Ecology
1. Loss of Existing
Vegetation
2. Loss of Habitat
for Existing Species
3. Loss of Habitat for
Special Species
4. Erosion and Sedimentation
5. Dust and Noise Effects
6. Topography and Drainage
7. Waterway Traffic
C
0
0
0
CSO
C«0
CSO
CSO
CSO
0
0
Low
Low
Low
Low
Low
Low
Low
Low
Low
Low
Low
Low
Low
Low
Low
Low
Low
Low
Low
Low
Low
Low
Yes
Yes
No
No
Yes
Yes
Yes
Yes
Yes
No
Yes
Short
Long
Long
Long
Long
Long
Long
Long
Long
Long
Long
No
No
No
No
No
No
No
No
No
No
No
Greater use of
erosion controls
None
None
None
None
Create ecological
blend areas
None
None
None
None
None
None
Vegetative buffers;
quarry pit storage
None
None
None
None
None
None
None
None
None
•Phases: C = construction
0 = operation
jurce: Environmental Science and Engineering, Inc., 1978.
-------
ENVIRONMENTAL ASSESSMENT (PLANT AND QUARRY)
Alternatives are practical actions that could be taken In place of the
proposed action. The alternatives are rated according to their spe-
cific environmental impacts and economic feasibility.
As indicated in Table 1, the adverse impacts of the project are typi-
cally considered to be of low to moderate magnitude and low signifi-
cance; reversible, and unavoidable. The construction impacts will
usually be short-term, whereas the operational impacts will persist
throughout the project life of 50 years (long-term). The irreversible
impacts relate to permanent effects on land, such as dredging, land
clearing, and drainage patterns. The avoidable impacts have viable
alternative actions that do not affect the same environmental parame-
ters. The only avoidable impacts are considered to be the burning of
vegetative wastes and the discharging of general stormwater runoff to
the freshwater marsh. Burning could be completely replaced by chipping
or landfill ing methods, and stormwater runoff could be discharged to
the ship channel. In both these cases, the impact on air quality and
wetland vegetation would be eliminated by these replacement actions.
Ideal Basic Industries has proposed numerous environmental safeguards
that should effectively reduce the potential impacts to the low level
of impact shown in the table. Possible mitigating measures are limited
because of these planned safeguards. Measures that could be taken to
further reduce the adverse impacts are listed in the mitigating mea-
sures column of Table 1.
In addition to the adverse impacts associated with the project, there
will be several important positive impacts. The economic stimulus of
the construction and operation of the cement plant will be of a high
magnitude and moderate significance in the Mobile area. Similar eco-
nomic effects of moderate magnitude and significance will occur in the
Monroe County area because of the limestone quarry. These effects are
discussed in the socioeconomic sections.
17
-------
ENVIRONMENTAL ASSESSMENT (PLANT AND QUARRY)
Practical alternative actions that would modify the adverse impacts are
presented in the last column of Table 1. Other alternatives not shown
but assessed in the document are:
1. Environmental characteristics of air quality, noise levels,
water quality, aquatic and terrestrial communities, and land
uses 15 years in the future (1992) without the proposed
project being constructed and operated;
2. Twenty-seven possible plant locations;
3. Possible quarry sites;
4. Three types of the main raw material—limestone, oyster
shells, and aragonite;
5. Two types of cement manufacturing processes (wet and dry);
6. Fuels and resources that could be utilized;
7. Possible arrangements of facility layout; and
8. Reclamation of quarried areas to pastureland, timberland, or
industrial use.
The information in this section gives a brief overview of the proposed
project's effects on the environment. Detailed analyses are presented
in the following sections of this summary document and the various
appendices.
18
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PROJECT HISTORY (PLANT AND QUARRY)
PROJECT HISTORY
Ideal Basic Industries, Inc. was founded by Charles Boettcher, a Denver
entrepreneur who acquired controlling interest in a small cement plant
near Portland, Colorado, in the late 1890's. The cement company formed
by Mr. Boettcher expanded into the southcentral and plains states, and
after World War II established facilities in the southeastern states and
the far west. The present Ideal plant at Mobile, purchased in 1946, was
an operation designed during the war to process low-grade aluminum ore.
Potash Company of America was merged with Ideal Cement Company in 1967,
and the corporate name became Ideal Basic Industries. The company has
also acquired a short-line railroad, two natural gas pipeline companies,
a marine cement transport operation, a sand and gravel company, a lime-
stone producing operation, and a coal production company. Through
subsidiaries, the company engages in real estate development at several
locations. The Potash Division is the largest producer of potash in the
United States and the second largest in North America. The Cement
Division is the largest manufacturer of cement in the country, with an
annual productive capacity of 5.9 million metric tons (6.5 million
tons).
The proposed Ideal Basic Industries manufacturing plant in Theodore
would be the largest facility of its kind ever constructed in a single
stage in the United States. The plant, which would utilize a dry-
process suspension preheater system designed for maximum thermal
efficiency, would involve the expenditure of more than $20 million for
air and water pollution abatement. The two projects will cost over
$200 million (in 1977 dollars) and will provide over $7.9 million (in
1977 dollars) annually in direct and indirect salaries.
19
-------
SITE SELECTION (PLANT AND QUARRY)
SITE SELECTION
This section describes the plant site selection and limestone supply
studies performed by Ideal Basic Industries. Although these studies
were not conducted as part of the EIS, they demonstrate that the final
site selections for the plant and quarry are environmentally sound.
The proposed Theodore project is the outcome of a 5-year planning
process. Market studies conducted in 1972 identified a strong demand
for cement manufacturing capacity to serve the Gulf Coast market. This
market was defined to include the coastal areas of Louisiana, Alabama,
Mississippi, and Florida that were also served by Ideal's plant and
terminal facilities at New Orleans, Baton Rouge, Lake Charles, Mobile,
and Tampa. The magnitude of demand was placed at 1.4 million metric tons
(1.5 million tons) of cement per year. The options available for
meeting this demand were:
1. Modernization and expansion of existing plants,
2. Multiple new plant locations, and
3. Consolidated capacity at a single new location.
Upgrading of existing facilities was evaluated for the Ideal Basic
Industries plants at Ada (Oklahoma), Okay (Arkansas), Baton Rouge, and
Mobile. Investigations conducted in 1972 and 1973 concluded that the
Ada and Okay plant sites could accommodate additional production, but
that the advantages of these sites would be negated by problems arising
from their locations geographically removed from the Gulf Coast market.
Neither the Mobile nor Baton Rouge operations could be upgraded without
demolishing the present facilities; this step would be highly
undesirable in view of demolition costs, the loss of revenues during
construction, and the potential loss of market position.
The second option considered would have involved two new 700,000 metric
ton (750,000-ton) per year plants rather than a single plant. This
possibility was ruled out by differentials in capital and operating
costs. Even allowing for the transportation cost savings with two
20
-------
SITE SELECTION (PLANT AND QUARRY)
plants, the single-plant option would be roughly 25 percent lower than
the multiple-plant option in terms of the total cost of sales.
The evaluation of potential sites for a single new cement plant was a
lengthy process involving three levels of screening. The major site
selection criteria were the following:
1. Site availability;
2. Physical suitability and engineering feasibility;
3. Access to deep water transportation;
4. Location with respect to expected markets;
5. Location with respect to raw material supply sources;
6. Capital and operating costs;
7. Highway, rail, and other supporting facilities;
8. Environmental compatibility;
9. Community resources;
10. Land use compatibility; and
11. Natural hazards.
The criteria involving transportation (Items 3 through 5 above) were
attributed great importance. Cement and its component materials are
high in weight relative to value, so that moderate differentials in the
distances or unit costs of transport can be critical to the overall
profitability of a cement manufacturing operation. Water transportation
is generally cheaper than other available modes and is more flexible
than rail in terms of scheduling and ownership of equipment. Therefore,
access to water transportation was considered a limiting prerequisite
for any potential site. Because of the cost advantages of deep-draft
vessels relative to shallow-draft barges, a high premium was placed on
sites with access to deep water [10-meter (30-foot) depth or more].
Twenty-seven potential plant sites were identified in 1973 and 1974 with
the assistance of state and local development agencies, port authori-
ties, chambers of commerce, and utility companies. These included 12
sites in Alabama, 5 in Mississippi, 6 in Louisiana, 3 in Florida, and
1 in Georgia. A first-level screening based on the above criteria
21
-------
SITE SELECTION (PLANT AND QUARRY)
resulted in the elimination of 19 sites from further consideration. Six
of the eight remaining candidate sites were located in Alabama.
One of the Alabama sites surviving the first cut was the Monroe County
Gail lard tract which was already partially owned by Ideal Basic
Industries. The Gaillard tract was under consideration as a source of
limestone, whether or not it was also selected as the plant location.
The remaining Alabama sites included: a property in Jacintoport; the
old shipyard site in Chickasaw; Blakely Island in Mobile; a bayfront
property adjacent to the route of the Theodore Ship Channel; and the
Barrett property, located inland on the ship channel. The second-level
screening eliminated the two sites outside Alabama (at Pascagoula and
Lake Charles) and all of the Alabama sites except the Gaillard tract and
the Barrett property. Physical constraints upon site development were
important in several cases.
Further analysis of the Gaillard tract and the Barrett property as
potential plant sites revealed many points of difference. However,
there was no'decisive advantage for either site in terms of cost-
effectiveness, since the lower capital and operating costs of production
at Gaillard would be offset by the need to build and operate a
distribution terminal in Mobile. The critical factors leading to
rejection of the Gaillard tract were potential problems involving
equipment delivery, labor force availability, construction of
transportation facilities, navigability of the Alabama River during
extreme conditions, availability of specialized industrial services, and
flexibility in securing raw materials and marketing plant outputs. A
preliminary analysis of environmental impacts suggested that some
detrimental effects would occur at either location and that the impacts
of the plant would be somewhat less severe on the whole at the Theodore
site. Therefore, the Barrett property was acquired by Ideal Basic
Industries and designated as the preferred location of the new
manufacturing facility.
22
-------
SITE SELECTION (PLANT AND QUARRY)
In addition to the plant site selection process, various alternatives to
the use of limestone from the Gail lard tract have been considered.
At least two other calcium carbonate (calcareous) materials, oyster
shells or aragonite, could serve as the principal ingredient of cement.
The existing Ideal Basic Industries plant in Mobile utilizes oyster
shells dredged from Mobile Bay. Oyster shells, however, would not be a
feasible source of calcium carbonate for the Theodore facility, since
the existing supply is limited and would not be available for the entire
50-year estimated life of the cement plant.
Aragonite is a high purity calcareous sand that is precipitated from sea
water. The only economically recoverable deposits known to exist are
found in the Bahamas, roughly 1,300 kilometers (800 miles) from Mobile.
The chemical properties of aragonite are highly favorable for cement
manufacturing, but the use of this material would involve several
disadvantages. There would be risks of price fluctuation, disruption of
supply, and increase in ocean freight rates. The most significant
disadvantage is that aragonite materials contain chlorides which would
have to be removed by a washing operation involving 2 to 13 million
liters (0.5 to 3.5 million gallons) of water per day. Such an operation
could overtax the capacity of water supply facilities at the Theodore
Industrial Park and could create a wastewater disposal problem. There-
fore, because of environmental and economic considerations, aragonite
has been rejected in favor of limestone as the calcium carbonate
source.
Ideal Basic Industries searched the Gulf Coast area for sources other
than the Gaillard tract which could supply a suitable amount of lime-
stone per year. Most potential sites were rejected because of limestone
characteristics, difficulties in quarrying, site acquisition problems,
or excessive transportation costs. The best location other than the
Gaillard tract was a site near Crystal River, Florida. The ultimate
selection of Gaillard was primarily an economic decision based on the
accessibility of the site by barge and its relative proximity to
Theodore.
23
-------
PLANT SITE
-------
LOCATION (PLANT SITE)
PLANT SITE
LOCATION
The proposed cement plant site Is located In south Mobile County just
beyond the southern edge of the city limits of Mobile, Alabama (see
Figure 2). The 70.8-hectare (175-acre) site is within the Theodore
Industrial Park, a 1,800-hectare (4,400-acre) area. Completion of the
federally-authorized Theodore Ship Channel will provide deep water
access for industries within the park.
Development of the Theodore Industrial Park began in the 1960's with a
purchase by the Alabama State Docks Department of federal lands which
formerly had contained an ammunition depot. Roadways and utilities were
extended into the area, and water access was provided by construction of
a 3.7-meter (12-foot) deep barge canal along the approximate alignment
of the Middle Fork Deer River. The barge canal is soon to be replaced
by the Theodore Ship Channel, a waterway of 12-meter (40-foot) depth
which will extend from the Mobile Bay Channel to Rangeline Road. Over
one-half billion dollars already has been invested by manufacturing
firms in Theodore Industrial Park, and a high rate of development is
projected for the future.
The Ideal Basic Industries plant site, which is part of the Theodore
Industrial Park, is bounded on the south by the barge canal; on the west
by the Airco plant site; on the east by the Dauphin Island Parkway; and
on the north by a narrow strip of land bordering the State Docks
Terminal Railway (see Figure 3). The property is uninhabited and is
covered primarily by remnant pine and scrub vegetation that has been
affected by previous (1974) lumbering activity. The North Fork Deer
River, bordered by freshwater and saltwater marsh systems, crosses the
central portion of the property. The proposed cement manufacturing
facility would occupy only the area located south of this river.
25
-------
Figure 2
THE PROPOSED PLANT SITE RELATIVE TO
MOBILE, ALABAMA
PROPOSED CEMENT MANUFACTURING
PLANT THEODORE INDUSTRIAL PARK
MOBILE, ALABAMA
SOURCE. USGS, 1974.
26
-------
Figure 3
THE THEODORE INDUSTRIAL PARK SITE
(Adapted from Mobile Area Chamber of Commerce, 1976)
0 1000
SCALE IN METERS
SOURCE: Environmental Science and Engineering, Inc., 1978.
REGION IV
U.S. ENVIRONMENTAL PROTECTION
AGENCY ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
PROPOSED CEMENT MANUFACTURING
PLANT THEODORE INDUSTRIAL PARK
MOBILE, ALABAMA
27
-------
PROJECT DESCRIPTION (PLANT SITE)
PROJECT DESCRIPTION
PLANT LAYOUT
The layout of the proposed cement manufacturing facility at Theodore is
depicted in Figure 4. Only the southern portion of the Ideal Basic
Industries property and an access corridor extending along the western
edge of the property will be developed. The wetland areas bordering the
North Fork Deer River will be undisturbed except for the access corridor
crossing in the freshwater portion of the wetlands. There will be no
encroachment into the brackish portion of the wetlands. Along the
eastern property line bordering the Dauphin Island Parkway, a strip of
wooded land about 90 meters (300 feet) in width will be left undevel-
oped. This vegetated strip, plus the wooded northern portion of the
Ideal property and the ship channel to the south, will all serve as
natural buffers between the cement plant and the developed areas along
these boundaries. A 20-meter (65-foot) high dead-storage pile of
limestone will be formed along the eastern side of the facility.
Besides providing the plant approximately a 60-day supply of reserve
limestone, the dead-storage pile will reduce noise effects east of the
plant site.
The entire waterfront at the plant site [about 716 meters (2,350 feet)]
will be developed as a dock area for loading, unloading, and holding of
marine equipment. The docking facility for unloading raw material will
accommodate barges berthed two abreast. The facility's depth of water
will vary depending upon draft requirements; however, a conservative
depth of 12 meters (40 feet) below mean sea level (msl) has been
projected to coincide with the depth of the future ship channel. The
marine terminal will have a concrete wharf elevated to the level of the
plant site, approximately 4.6 meters (15 feet) above msl.
The process areas will be clustered in the central portion of the plant
site. The tallest structures will be two 90-meter (300-foot) high
stacks and two 76-meter (250-foot) high suspension preheaters. A rail-
car unloading and staging area will be located in the northern portion
28
-------
I T*
FUTURE | '
BUHNER I'BURNER
BUILDING! teuiLDiwc
I/T\
a,
FUTURE V >\ %*.„'; -
m(CAt.CIN[B^J--,r--ltO
BUILDING *•• FAh
H E;=iTlSiJ'''i ««» i—
;:wdL3«J Ls^Ta
! ii k
! !! IFUTU.E
1 II IBAGHOUSES
w
ELECTRICAL
BUILDING
iNER BUILDING
ooooooo
GYPSUM
COAL
CLAV
SILICA
IRON
ORE
HIT " ^
Of EN
LIMESTONE
STORAGE
Of EN \'
LIMESTONE
STORAGE A
^R ,''
1
1
RESERVE
LIMESTONE
STORAGE
J>
Figure 4
PROPOSED PLANT PLOT PLAN
0 100
SCALE IN METERS
SOURCE: Ideal Basic Industries, 1977.
REGION IV
U.S. ENVIRONMENTAL PROTECTION
AGENCY ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
PROPOSED CEMENT MANUFACTURING
PLANT THEODORE INDUSTRIAL PARK
MOBILE, ALABAMA
29
-------
PROJECT DESCRIPTION (PLANT SITE)
of the site, with rail access provided by a track extending north along
the western property boundary to the State Docks Terminal Railway.
Non-process areas of the plant site will be landscaped wherever
practical. The proposed layout has been designed to accommodate future
expansion of the plant's production capacity, as shown in Figure 4.
The project plan includes a 150-car employee parking lot and a 7.3-meter
(24-foot) wide access road, both of which will be paved with concrete.
The access road and railroad spur line will form a corridor about
47.2 meters (155 feet) from the western boundary line and will extend
north to the connection with the State Docks Railroad. The access road
will continue north and intersect Island Road (Hamilton Boulevard).
A 380,000-liter (100,000-gallon) aboveground fuel oil tank will be
on-site. Although coal is the principal fuel to be used in the process,
oil will be used to preheat the kiln and to produce a pilot flame for
the coal burners.
A portion of the plant site will be utilized for storage of raw
materials. Approximately 604,000 metric tons (665,000 tons) of lime-
stone will be stored on-site, of which all but 110,000 metric tons
(120,000 tons) will be in dead storage. About 4,200 metric tons
(4,600 tons) of wet clay will be stored near the docking facility. A
covered storage area will be provided for approximately 3,300 metric
tons (3,600 tons) of dried clay; 4,200 metric tons (4,600 tons) of wet
sand; 4,200 metric tons (4,600 tons) of iron ore (wet basis);
27,000 metric tons (30,000 tons) of gypsum (wet basis); and
45,000 metric tons (50,000 tons) of coal (wet basis).
The stormwater runoff from the uncovered storage areas will be drained
to a settling basin and mixed with the stormwater runoff from the con-
tainment area around the oil storage tank and with wastewater from
cooling tower blowdown and various process wash areas. The wastewater
will be treated for reduction of suspended solids before being dis-
charged to the ship channel. The approximate capacity of the basin will
30
-------
PROJECT DESCRIPTION (PLANT SITE)
be 16 million liters (4.2 million gallons). The average daily flow from
the basin is expected to be 341,000 liters (90,100 gallons).
Another physical feature of the plant design is that the site will be
graded so that storm water will drain to the north into an approximately
2-hectare (5-acre) catchment area. This area, which will be formed
during construction by grading and berming the low side of the area,
will contain the first flush from a rainstorm and will reduce the
suspended particulate loading of the runoff prior to discharging it into
the freshwater marsh.
PLANT CONSTRUCTION
Construction of the cement manufacturing plant is scheduled to start
in the third quarter of 1978 and will last approximately 30 months. The
facility will have an effective operating life of about 50 years and
will be constructed at a cost of over $165 million (in 1977 dollars).
The construction labor force will average 360 workers during the
construction period, with a peak of 700 workers. The total construction
payroll will be approximately $15,000,000 in 1977 dollars, and another
$10,000,000 will be spent for local purchases of construction materials.
Approximately 80 to 85 percent of construction workers involved in the
project at Theodore will be local hires, i.e., workers already living in
south Alabama who will commute to the site on a daily basis.
The first stage of construction will involve clearing and grading of the
access corridor and a site area of about 20 hectares (50 acres). Land-
clearing debris (wood and brush) will be disposed of by three methods:
burning in an air-blower type pit burner; chipping for use on-site as
mulch; and hauling to the Irvington Landfill. Since the area was logged
in 1974, there will be a minimum of large trees to be cleared. About
130,000 cubic meters (170,000 cubic yards) of soil will be moved during
the grading period, with cut and fill activities balanced so that there
is no excess excavation material.
31
-------
PROJECT DESCRIPTION (PLANT SITE)
Later construction activities will include erection of structures and
equipment, installation of utility connections, final grading, and
revegetation. Approximately 14,000 to 16,000 piles will be driven to
provide adequate foundations for structures. Construction of the dock-
ing facility will require dredging approximately 500,000 cubic meters
(650,000 cubic yards) of material. It is anticipated that this material
will be disposed in one of the approved spoil disposal areas to be used
for the ship channel project.
CEMENT MANUFACTURING PROCESS
The dry process manufacturing plant proposed by Ideal Basic Industries
requires limestone, sand, clay, and iron ore to be ground and mixed in
specific proportions. The mixture is fed into a rotating furnace, or
kiln, where high temperatures fuse the materials into marble-sized
granules called clinker. The clinker is then mixed with gypsum and
ground again to form cement. The end product is a fine powder which is
shipped primarily in bulk. A flow diagram of the cement manufacturing
process is presented in Figure 5.
Three general characteristics of the proposed dry cement manufacturing
process are the efficient use of waste heat, a high degree of material
recycling, and the use of air pollution control equipment in the
material-handling and recycling functions of the plant. Because the
manufacturing process involves handling of dry, finely-ground materials,
a potential environmental problem is the emission of particulate matter
to the atmosphere. These emissions are controlled by venting dust-laden
gas streams through fabric filter collectors known as baghouses, which
have collection efficiencies of over 99 percent and have been approved
by EPA as the best available control technology (see Air Quality
section). All materials collected by these devices are recycled into
the cement manufacturing operation, thus conserving resources and
preventing accumulation of solid wastes.
-------
RAW MATE RIAL
UNLOADING
AND STORAGE
7
CLAY
DRYER
RAW MATERIAL
FEED
CLAY
SILICA
IRON ORE
LIMESTONE
COAL
GYPSUM
RAW MILLS
REGRIND
1
DRY
LIMESTONE
1
LIMESTONE
STORAGE
SILOS
KILNS/CLINKER
COOLERS
FINISH MILLS
COAL GRINDING
AND DRYING
COAL DISTRIBUTION
SYSTEM
GYPSUM
STORAGE
SILOS
I
\
HOUSE >
__/
^
r
RAIL AND
TRUCK
SHIPPING
]
MAR
SHIP!
Figure 5
FLOW DIAGRAM OF PROPOSED PLANT PROCESS
REGION IV
U.S. ENVIRONMENTAL PROTECTION
AGENCY ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
PROPOSED CEMENT MANUFACTURING
PLANT THEODORE INDUSTRIAL PARK
SOURCE: Environmental Science and Engineering, Inc.. 1977.
, ALABAMA
33
-------
PROJECT DESCRIPTION (PLANT SITE)
The raw materials, which will be received at the plant by rail or water
transportation, will be unloaded and stored In specific areas. The
coal, gypsum, iron ore, sand, and clay (after it is dried) will be
stored in the covered stockpile area. The wet limestone and clay will
be placed in uncovered storage piles. The raw materials have a high
natural moisture content (roughly 21 percent) which should reduce the
dust generation potential. However, a water spray dust suppression
system is planned for use on conveyor transfer points and storage piles.
The major components of the proposed dry cement manufacturing process
are the following:
I. Raw mills,
2. Regrind mill and kiln feed system,
3. Kiln suspension preheaters,
4. Kilns and precalciners,
5. Clinker coolers, and
6. Finish mills.
Starting in the raw mill circuit, most elements of the production pro-
cess are divided into two parallel systems, each designed to handle half
the plant's process weight (i.e., there are two raw mills, two kilns,
two clinker coolers, etc.). Another design option is the substitution
of a single-kiln system as shown in Figure 4. The process parameters of
a single kiln system, such as the process rate, fuel burning rates,
exhaust volumes and emissions, should be approximately the same as the
total from the two-kiln system.
The purpose of the raw mill is to dry the raw materials, grind them to a
fine consistency, and store them in silos for use in the next area. The
drying and grinding is accomplished in airswept mills that utilize the
hot exhaust gases from the kiln and clinker cooler circuits, with
additional heat provided by separate coal furnaces.
Next, the raw mix is fed into a regrind circuit for fineness control.
An air separator allows fines to pass through the circuit while over-
sized material is returned for regrinding. The raw mix is blended for
34
-------
PROJECT DESCRIPTION (PLANT SITE)
proper consistency and is transported into kiln suspension preheaters
which utilize the kiln exhaust gases to heat the material. Just prior
to entering the kiln, the raw mix is heated to about 840°C (1550°F) in a
coal-fired precalciner. This additional heating reduces the size
requirements for the kiln. Inside the kiln, the raw mix is thermally
transformed into clinker at about 1480°C (2,700°F). The clinker is
dropped from the kiln onto an enclosed grate and cooled with ambient
air in the clinker cooler.
In the finish mills, the clinker is ground and mixed with gypsum to form
Portland cement. If dry limestone is also mixed with the clinker and
gypsum, a masonry cement is produced. Six grades of cement are planned
to be produced: five portland cements and one masonry cement.
The finished product is conveyed to two storage areas—marine silos for
bulk cement shipments by water and land silos for all other shipments.
The land silos serve the bulk rail car and truck loading facilities and
also supply a packhouse that will bag approximately 5 percent of the
total cement output.
RESOURCE UTILIZATION
Each day's operation of the Ideal Basic Industries cement plant will
require about 9,900 metric tons (10,900 tons) of wet raw materials and
coal to produce 4,600 metric tons (5,100 tons) of dry cement. Limestone
will be obtained from Ideal's Gaillard quarry at an average rate of
7,788 metric tons (8,585 tons) per day on a wet basis. An existing clay
quarry operated by Ideal Basic Industries at 24-Mile Bend on the Alabama
River, roughly 60 kilometers (40 river miles) from the plant site, will
supply 645 metric tons (711 tons) of clay and 325 metric tons (358 tons)
of sand per day. The clay reserves at the quarry amount to only a
5-year supply, so that another source of material must eventually be
found.
35
-------
PROJECT DESCRIPTION (PLANT SITE)
Iron ore and gypsum, consumed at rates of 68 metric tons (75 tons) and
212 metric tons (234 tons) per day, respectively, will be obtained by
Ideal Basic Industries from commercial suppliers. About 841 metric tons
(927 tons) per day of coal will be required, depending upon heat
content. The coal will have a maximum sulfur content, by weight, of
1.5 percent. The sulfur limitation is required for proper operation of
the kiln suspension preheaters. Coal will be obtained on a contract
basis from a supplier.
Electric service to the plant will be provided at 13.8 kilovolts by
Alabama Power Company. Approximately 30 megawatts will be required for
normal plant operations. Present plans for the transmission system
indicate that aboveground power lines will be located within the plant's
access corridor.
The daily requirements for potable and process cooling make-up water
will be 1,080 cubic meters (285,000 gallons), which will be supplied by
the Board of Water and Sewer Commissioners of the City of Mobile.
The plant will follow a 24-hour-per-day schedule for manufacturing oper-
ations. However, because of maintenance requirements and other factors,
only an 85 percent operating rate for the pyroprocesses (kiln and raw
mill) is projected. A total of 135 workers, including 26 supervisory
personnel, will be employed at the plant. Most of the plant workers
will be transferred from the existing Ideal Basic Industries facility in
Mobile. The clay and sand quarry in north Mobile County will employ 10
additional workers, and the marine operations needed to support the
Theodore plant will create approximately 50 jobs.
TRANSPORTATION
Marine transportation will be utilized for an estimated 57.5 percent of
all outbound shipments, by weight. Tentatively, all marine shipments
will be destined for Ideal's terminal facilities in Louisiana and
Florida. It is presently undecided whether Ideal Basic Industries will
36
-------
PROJECT DESCRIPTION (PLANT SITE)
own and operate its own marine equipment, or whether independent
contractors will be utilized. Truck transportation will account for
31.9 percent of outbound cement shipments, and rail transportation for
10.6 percent. Outside contractors will be used in both cases. The
specifications of the land fleet vehicles and the number of workers
involved in land transportation are indefinite at present.
37
-------
LAND USE (PLANT SITE)
LAND USE SETTING
PRESENT LAND USE
A map of the present land use in the vicinity of the Ideal Basic Indus-
tries plant site is presented in Figure 6. This area includes Theodore
Industrial Park, the Hollingers Island community, and the Dauphin Island
Parkway corridor from Deer River to Laurendine Road. A large proportion
of the area consists of land that is currently vacant, i.e., not used
for any purpose other than possibly hunting and harvesting of forest
products. The other major land use categories represented are industry,
residence, and transportation.
Most of the land west and southwest of the plant site either is held by
manufacturing firms or is being marketed actively for industrial use.
Less than half of this land is occupied by industrial establishments at
the present time.
Residential land is predominant to the north, east, and south of the
proposed plant site, but the overall density of settlement is low. A
field count of dwelling units in 1977 revealed that the area within
4.8 kilometers (3 miles) of the plant site contained 974 dwelling units,
with an average density of one dwelling unit for every 8 hectares
(19 acres). Residential development is concentrated in waterfront areas
(Alligator Bayou, Dog River, Mobile Bay) and in the Hollingers Island
community east of the Dauphin Island Parkway. The residential
properties closest to the proposed Ideal Basic Industries plant site are
located on the southern portion of San Marino Drive, on the Dauphin
Island Parkway directly across from the site, on Deer River Road, and in
the area south of the barge canal but north of Baker Sorrel 1 Road and
Claudia Lane.
The land used for transportation includes street and highway rights-of-
way, the State Docks Terminal Railway, and the barge canal. The major
highways in the area are Rangeline Road, Island Road (also known as
Hamilton Blvd.), and Dauphin Island Parkway. The use of these three
38
-------
ISLAND ROAD
I I I I I
NOT TO BE
»NOEVELOPEDj
BrtOrtCCn^J
PROPOSED^
PLANT SITE j
ROW
CLAUDIA LANE v
BQ
| RESIDENTIAL
COMMERCIAL
MOBILE BAY
INSTITUTIONAL
l AGRICULTURAL
NURSERY
| INDUSTRIAL
Figure 6
PRESENT LAND USE IN THE VICINITY OF THE
PROPOSED IDEAL BASIC INDUSTRIES PLANT SITE
REGION IV
U.S. ENVIRONMENTAL PROTECTION
AGENCY ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
o o.s i
SCALE IN KILOMETERS
SOURCE. Environmental Science and Engineering, Inc., 1977.
PROPOSED CEMENT MANUFACTURING
PLANT THEODORE INDUSTRIAL PARK
MOBILE, ALABAMA
39
-------
LAND USE (PLANT SITE)
highways provides the main north-south route through the Theodore
Industrial Park. The State Docks Railway, which will provide rail
access to the proposed cement plant, extends from the State Docks
Terminal facility on Mobile Bay to the Louisville and Nashville line
near Theodore.
The area contains a number of plant nurseries, the largest being an
establishment at Island Road and Dauphin Island Parkway. Institutional
land uses are limited to five small churches at various locations on the
Parkway and the Hoilingers Island Elementary School on Hammock Road.
There are fewer than ten commercial establishments in the area, plus
several small marinas and boatyards. The only recreational land within
4.8 kilometers (3 miles) of the plant site is a Bay Road park area which
belongs to the Hoilingers Island Community Association.
FUTURE LAND USE
Land use changes will occur near the plant site as a result of the
Theodore Ship Channel project and general pressures for industrial and
residential development. A forecast of land use in the year 1992 is
presented in Figure 7.
Land takings for the ship channel will result in the elimination of two
boatyards and a number of dwellings located near the present barge
canal. It is expected that some additional residential properties will
be converted to industrial use. Figure 7 incorporates the assumption
that by 1992 less than five dwelling units will remain between the ship
channel and Baker Sorrel1 Road or Claudia Lane, with the exception of
units fronting on Claudia Lane.
A large proportion of land within 4.8 kilometers (3 miles) of the Ideal
Basic Industries plant site is expected to convert to industrial use,
with possibly some commercial development along Island Road and Dauphin
Island Parkway. The anticipated land use conversions are not dependent
upon the presence of the cement plant. Without the proposed project,
40
-------
ISLAND ROAD I
I I I I I
NOT TO BE
.DEVELOPED^
; PROPOSED BARCe'
Hiilp PROPOSED^
PLANT SITEj
ROAD
11.-.;! RESIDENTIAL
Kf<\3 COMMERCIAL
lilllii
ill! i
!iij!iiil!lllijj!illli:ll|
111!
HEODORE SHIP CHANNEL
RIGHT-OF-WAY
MOBI
Ut-y::! INSTITUTIONAL
|^"^.| AGRICULTURAL
fgJ3 NURSERY
roa INDUSTRIAL
Figure 7
PROJECTED LAND USE IN THE VICINITY OF THE
PROPOSED IDEAL BASIC INDUSTRIES PLANT SITE.
1992
0 0.5 1
SCALE IN KILOMETERS
SOURCE. Environmental Science and Engineering, Inc., 1977.
REGION IV
U.S. ENVIRONMENTAL PROTECTION
AGENCY ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
PROPOSED CEMENT MANUFACTURING
PLANT THEODORE INDUSTRIAL PARK
MOBILE, ALABAMA
41
-------
LAND USE (PLANT SITE)
It Is probable that the property, because of Its value as waterfront
land, would be developed by some other Industrial firm.
Four important highway improvements in the Theodore Industrial Park area
will be completed by 1985. These are: (1) the widening of Island Road
(Hamilton Blvd.) to three lanes (by 1980); (2) the construction of
Range!ine Expressway (by 1982); (3) the improvement of the Rangeline
Road-Island Road intersection and conversion of Rangeline Road to four
lanes between this intersection and Deer River; and (4) conversion of
the Dauphin Island Parkway to four lanes from Perch Creek to Island
Road.
Land use changes will occur near the plant site as a result of the
Theodore Ship Channel project. The ship channel project (see Figure 8)
will involve:
1. A channel of 12-meter (40-foot) depth and 90-meter (300-foot)
bottom width, occupying a right-of-way up to 300 meters
(1,000 feet) wide;
2. A bay cut of 122-meter (400-foot) bottom width providing deep-
water access to the Mobile Bay channel;
3. A 17-hectare (42-acre) turning basin at the end of the ship
channel near Rangeline Road;
4. An extension of the existing canal with 4-meter (12-foot) depth
west of Rangeline Road.
A second turning basin at the mouth of the land cut has been authorized
but will not be included in the initial construction program. Construc-
tion will take place during approximately the same time period as the
proposed cement plant construction project.
42
-------
"S>^
MOBILE CO.
MOBILE
BALDWIN CO.
ROBERTSDALE
PROPOSED
IDEAL BASIC CEMENTS
PLANT SITE
r
tlSLAND i
APPROACH CHANNEL
BARGE CANAL
Si:** DISPOSAL
*!: ISLAND
PROPOSED^
THEODORE
SHIP CHANNEL
IP CHANNE
ROJECT AR
SCALE IN KILOMETERS
Figure 8
PLAN VIEW OF PROPOSED CORPS PROJECT-
ENTIRE HARBOR
SOURCE: U.S. Army Engineer District, Mobile Corps of
Engineers, 1975.
REGION IV
U.S. ENVIRONMENTAL PROTECTION
AGENCY ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
PROPOSED CEMENT MANUFACTURING
PLANT THEODORE INDUSTRIAL PARK
MOBILE, ALABAMA
43
-------
AIR QUALITY (PLANT SITE)
AIR QUALITY
BASELINE CONDITIONS
Mobile County is an industrialized urban area with over 180 permitted
point sources of air pollutants. These sources include paper mills,
chemical manufacturers, the power industry, and various other industries
located primarily in waterfront areas near the Mobile River and Mobile
Bay. Permitted sources were responsible for the emission of 6,800
metric tons (7,500 tons) of particulate matter and 79,800 metric tons
(88,000 tons) of sulfur dioxide during 1976. In addition, 4,500 metric
tons (5,000 tons) of particulate matter emissions were attributable to
population-related activities (e.g., automobiles, home heaters,
fireplaces, open burning).
Ambient air quality in Mobile County has improved since 1972, due
largely to the development and implementation of an Air Quality
Maintenance Plan for the county. The Division of Air Pollution Control
of the Mobile County Board of Health has monitored particulate matter
levels at stations in the county since 1972. Since that time, the
average of the annual geometric mean suspended particulate matter
concentrations recorded at these stations declined by 33 percent.
Ambient sulfur dioxide concentrations have been monitored less
intensively; data are available only from a downtown Mobile station and
from the Big Sniffer station in the Theodore Industrial Park. This
information indicates that sulfur dioxide levels do not exceed standards
in Mobile County and that conditions are substantially better in the
Theodore Industrial Park area than in downtown Mobile.
The State of Alabama has reviewed Mobile County for attainment status
with the National Ambient Air Quality Standards. Two areas, downtown
Mobile and north of Mobile, have been determined the only areas of the
county in non-attainment for particulate matter. The entire county has
44
-------
AIR QUALITY (PLANT SITE)
been determined to be in attainment for all the other standards except
oxidants. The high oxidant levels measured in the county are believed
to be primarily caused by automobile emissions and natural conditions,
not industrial sources.
Air quality in the Theodore Industrial Park area currently is affected
by emissions from two chemical plants, a metallurgical processing plant,
a small refinery, and vehicular traffic. One Mobile County monitoring
station for particulate matter is the Big Sniffer station on Rangeline
Road near Deer River.
In addition, a three-station ambient monitoring network is currently in
operation by Ideal Basic Industries to collect samples of suspended
particulate matter. As shown in Figure 9, Station 1 is located north of
the proposed plant site near Island Road, Station 2 is near Baker
Sorrel 1 Road south of the plant site, and Station 3 is on the eastern
boundary of the Ideal Basic Industries property.
The sampling results from all four stations are presented in Table 2 and
are displayed in Figure 10. The lower portion of the table shows the
primary and secondary Ambient Air Quality Standards (AAQS). The
secondary standards, which are more stringent, apply to all of Mobile
County.
The data show that the air quality in the park area has been within the
standards for particulate matter since the monitoring was initiated.
RELEVANT PROJECT CHARACTERISTICS
During construction activities, fugitive dust emissions will be reduced
by the use of water sprays on roads and other areas where heavy
equipment is used. In addition, the main access road will be surfaced
as soon as possible to reduce the dust potential.
45
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IDEAL SITES
MOBILE COUNTY SITE
Figure 9
LOCATIONS OF AMBIENT MONITORING STATIONS IN
THE VICINITY OF THE PROPOSED CEMENT PLANT,
THEODORE, ALABAMA
SOURCE: Environmental Science and Engineering, Inc., 1977.
PROPOSED CEMENT MANUFACTURING
PLANT THEODORE INDUSTRIAL PARK
MOBILE, ALABAMA
46
-------
Table 2. Summary of Existing Ambient Total Suspended Particulate Matter Levels (ug/m3) in the
Vicinity of the Proposed Ideal Basic Industries Plant Site, 1976 and 1977
Station Description
Mobile Big Sniffer
County #11
Ideal #1 Nursery
Ideal #2 Weaver's
Residence
Ideal #3 Lift Station
Number
of
Time Period Observations
1976 56
1977 50
5/28/77 to 12/31/77 47*
5/28/77 to 12/31/77 47*
5/28/77 to 12/31/77 47*
Primary Standard
Secondary Standard
Geometri
Mean
48
43
42
35
31
75
60
24-Hour
c Second
Max Highest
156 148
161 90
179 134
93 89
94 90
260
150
Standard
Geometric
Deviation
N/A
1.63
1.62
1.55
1.62
NA = Not Available.
*Sampling and analysis by Federal Reference Method (Code of Federal Regulations, Part 50,
Appendix B). Continuous 24-hour sampling was conducted every third day from May 28 to August 31,
and every sixth day thereafter.
Sources: Mobile County Board of Health, Division of Air Pollution Control, 1977.
Environmental Science and Engineering, Inc., 1977.
-------
JT* 120-
E
5
O 100-
JE 90-
111
0 80-
Z
0 70-
z
••• CH—
•5 OU~
0
OC 50-
LU
o 40"
UJ
O
Uj 30-
0
OC 20-
Ul
< 10-
^
0_
PRIMARY STANDARD
SECONDARY STANDARD
^^^•^^
^**l*^*>*11^ ^**^«**»^^
BIG SNIFFER ^
o
o
O IDEAL STATION 1
O IDEAL STATION 2
O 'DEAL STATION 3
l 1 1 l 1 l
1972 1973 1974 1975 1976 1977
YEAR
-
-
_
_
-
-
-
-
•
Figure 10
AMBIENT TOTAL SUSPENDED PARTICULATE MATTER
CONCENTRATIONS AT STATIONS NEAR THE
PROPOSED IDEAL CEMENT PLANT, MOBILE COUNTY.
1975-1977
SOURCE: Mobile County Board of Health, 1978.
Environmental Science and Engineering, Inc., 1978.
REGION IV
U.S. ENVIRONMENTAL PROTECTION
AGENCY ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
PROPOSED CEMENT MANUFACTURING
PLANT THEODORE INDUSTRIAL PARK
MOBILE, ALABAMA
48
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AIR QUALITY (PLANT SITE)
The burning of land-clearing wastes will be performed with an air-blower
type pit burner to reduce potential smoke emissions. Burning will be
conducted under the conditions of the permit from the Mobile County
Board of Health, and only during favorable dispersion conditions.
Burning will be supervised at all times.
The design of the cement plant has inherent features which will reduce
the potential for air pollution emissions. A suspension preheater
requires use of a coal with no more than 1.5 percent sulfur content due
to potential sulfate deposits forming and blocking flow of material and
kiln exhaust gases. The use of the kiln/raw mill system and combined
baghouse control provides less fuel usage and allows intimate contact of
the sulfur dioxide in the exhaust with the alkaline raw materials. This
contact could reduce the amount of sulfur dioxide emissions by an
estimated 75 percent (U.S. EPA, Office of Air Quality Planning and
Standards, 1975).
In addition, about 60 percent of the coal usually burned in the kiln
will be fired in the precalciner. This system reduces the amount of air
passing through the hot zone of the kiln and could act to reduce
formation of nitrogen dioxide (Bauer, 1977).
The operation of the cement plant has the potential for emissions of
particulate matter, sulfur dioxide, nitrogen oxides, hydrocarbons, and
carbon monoxide, as shown in Table 3. The allowable quantities of
particulate matter and sulfur dioxide shown are based upon EPA deter-
mination of use of the Best Available Control Technology (BACT) and
compliance with the Prevention of Significant Deterioration (PSD)
requirements.
The use of baghouses (fabric filter dust collectors) on all process
exhausts and the use of 1.5 percent sulfur coal (by weight) have been
determined to be BACT for this proposed project (see Permit and Approval
section). Typically, a baghouse reduces the amount of particulate
matter emitted by greater than 99 percent. The collected dust is
49
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AIR QUALITY (PLANT SITE)
Table 3. Maximum Allowable Atmospheric Emissions from the Proposed
Cement Manufacturing Plant for Particulate Matter and
Sulfur Dioxide and Estimated Quantities of Other Pollutants:
Nitrogen Oxides, Hydrocarbons, and Carbon Monoxide
Allowable
Grams/ (Ibs/
Pollutant/Source Sec hour)
Particulate Matter
Raw Mills/Kilns/Coolers* and
Clay Dryer 12.4 98
Regrind Mill 0.6 4
Kiln/Cooler System** 0.8 6
Gypsum Storage and Unloading 0.2 2
Finish Mills 2.6 21
Clay Handling System 0.2 2
Coal Drying System 2.9 23
Shipping
Marine 0.6 5
Land 0.3 2
Packhouse 0.3 3
TOTAL 20.9 166
Sulfur Dioxidet
Raw Mi 11/Kiln/Clay Dryer 249.4 1,980
Coal Dryer 22.7 180
TOTAL 272.1 2,160
50
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AIR QUALITY (PLANT SITE)
Table 3. Maximum Allowable Atmospheric Emissions from the Proposed
Cement Manufacturing Plant for Particulate Matter and
Sulfur Dioxide and Estimated Quantities of Other Pollutants:
Nitrogen Oxides, Hydrocarbons, and Carbon Monoxide
(Continued, page 2 of 2)
Estimated
Grams/ (Ibs/
Pollutant/Source Sec hour)
Nitrogen Oxides
Raw Mi 11/Kiln/Clay Dryer 131.5
Coal Dryer 20.8
TOTAL 152.3 1,209
Hydrocarbons
Raw Mi 11/Kiln/Clay Dryer 0.3 3
Coal Dryer 0.1 _!_
TOTAL 0.4 4
Carbon Monoxide
Raw Mi 11/Kiln/Clay Dryer 1.1 9
Coal Dryer 0.4 _3
TOTAL 1.5 12
*KiIns/coolers exhaust through raw mill.
•(•Calculated based upon 1.5 percent sulfur coal, 100 percent conversion
of S to S02.
**Excluding kiln/cooler emissions (included in raw mill estimates) for
raw mix and clinker exhausts.
Sources: H.K. Ferguson Associates, 1975.
Ideal Basic Industries, 1977.
Prevention of Significant Deterioration Application, Volumes I
and II, 1977.
51
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AIR QUALITY (PLANT SITE)
returned to the process and thereby a potential solid waste problem Is
eliminated.
The other criteria pollutants from the plant are not subject to the BACT
and PSD requirements and are listed as estimated, not allowable. The
hydrocarbons and carbon monoxide emissions are of small quantities,
while the nitrogen oxide emissions are somewhat higher. The nitrogen
oxides are a direct function of the amount of air used in combustion of
the coal and the high temperatures involved. The nitrogen in the air
(about 78 percent) is oxidized at high temperatures to form various
types of nitrogen oxides. While direct control is not practical nor
available, the process parameters of excess air and kiln temperature are
to be maintained within the operational constraints required for the
cement manufacturing process to act as a limiting factor to the forma-
tion of nitrogen oxides.
Another potential air emission is fugitive dust from the handling and
storage of the raw materials. However, in order to reduce this emission
potential, the barge unloading, conveyor transfer points, and storage
piles will utilize water spray dust suppression systems on various
sources of dust; some transfer points will be enclosed and vented
through baghouses; and the coal, dried clay, iron ore, sand, and gypsum
storage area will be covered. About 85 percent of the raw materials
(the limestone and clay) have moisture contents of roughly 22 percent,
which helps to suppress dust emissions from their handling and storage.
IMPACTS
The majority of the fugitive dust generated during the construction
phase of the proposed project should settle out close to the source
(Kosky and Wanielista, 1975). The remaining dust could cause short-term
but reversible impacts of a moderate magnitude, but the impact is
expected to be of a low significance in the area. The emission of smoke
due to burning of land-clearing debris will also contribute to air
quality impacts. However, assuming the worst case of burning all the
52
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AIR QUALITY (PLANT SITE)
wastes rather than chipping or landfill ing, the impact is expected to be
of a low magnitude due to the use of the air-blower type pit burner and
burning only during favorable dispersion conditions. Therefore, the
significance is considered low, the duration very short, and the effect
reversible. The adverse impact of burning is avoidable by using the
other proposed methods of disposal: chipping and landfilling.
The impacts of permanent operations at the Ideal Basic Industries plant
upon sulfur dioxide and suspended particulate matter concentrations have
been analyzed through mathematical modeling of atmospheric dispersion
processes. The projected changes in average annual concentrations of
these pollutants due to the proposed plant are plotted in Figures 11 and
12.
The importance of air quality impacts resulting from the proposed facil-
ity can best be evaluated in terms of the Prevention of Significant
Deterioration (PSD) review process. It involves demonstrating that the
following two conditions will be met:
1. Ambient Air Quality Standards (AAQS) must not be exceeded at
any location as a result of the proposed new source. These
standards pertain to the following air quality measures:
Sulfur dioxide
(a) annual arithmetic mean concentration;
(b) second highest 24-hour concentration in an annual
period;
(c) second highest 3-hour concentration in an annual period;
Suspended particulate matter
(a) annual geometric mean concentration;
(b) second highest 24-hour concentration in an annual
period.
2. Allowable federal increments in air pollutant concentrations
must not be exceeded. These increments represent fixed limits
upon the amounts by which the air quality measures listed above
can change relative to 1974, the baseline year. All sources of
air quality degradation are included, not just the proposed new
53
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PROPOSED CEMENT MANUFACTURING
PLANT THEODORE INDUSTRIAL PARK
MOBILE. ALABAMA
POINT OF PREDICTED MAXIMUM INCREMENTAL
CONTRIBUTION (1.2ug/m') / /
Figure 11
ISOPLETHS OF THE INCREMENTAL CONTRIBUTIONS
TO PREDICTED ANNUAL AVERAGE GROUND-LEVEL
SULFUR DIOXIDE CONCENTRATIONS (ug/m3),
PROPOSED CEMENT PLANT ONLY, THEODORE,
ALABAMA, 1980
SOURCE: Environmental Science and Engineering, Inc., 1977.
54
-------
0.4
0.6
ISLAN
ROAD
FININI
0.8
KERF
'on/.
DEGl
1.0
r«/vj
^1.5
0.6
'0fpLAN^
;ITE
0.8
0.4
LAURENDINE
0 0.5 1
SCALE IN KILOMETERS
ROAD
POINT OF PREDICTED MAXIMUM INCREMENTAL
CONTRIBUTION (2.3 ug/m')
O&LZ BAY
LJ
Figure 12
ISOPLETHS OF THE INCREMENTAL CONTRIBUTIONS
TO PREDICTED ANNUAL AVERAGE GROUND-LEVEL
SUSPENDED PARTICULATE MATTER CONCENTRATIONS
(ug/m3), PROPOSED CEMENT PLANT, THEODORE,
ALABAMA, 1980
SOURCE: Environmental Science and Engineering, Inc., 1977.
REGION IV
U.S. ENVIRONMENTAL PROTECTION
AGENCY ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
PROPOSED CEMENT MANUFACTURING
PLANT THEODORE INDUSTRIAL PARK
MOBILE, ALABAMA
55
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AIR QUALITY (PLANT SITE)
source. As In the case of AAQS, the new source must be shown
not to violate the allowable increment at any location, under
expected worst-case meteorological conditions. The purpose of
the increments is to prevent significant air quality
deterioration in areas where the 1974 ambient concentrations
were substantially below the applicable standards.
The forecast year used in the present case is 1980, which represents the
start-up of the cement plant. The estimated baseline conditions reflect
the actual air pollutant emissions that occurred in 1974, whereas the
forecasts for 1980 pertain to a hypothetical situation in which all
sources are emitting at the maximum allowable or permitted rates (except
for a few cases in which this would not be theoretically possible). The
cement plant emissions used in the modeling were based on an alternative
process design no longer viable and were roughly 10 percent greater than
the totals shown in Table 3. In addition, the sulfur dioxide emissions
do not reflect any reduction because of contact with the alkaline dust.
These factors mean that the results of the modeling overestimate the
plant's contribution to ambient levels.
In order to determine whether the PSD requirements will be met and to
show the maximum impact of the cement plant, it is necessary to consider
ambient air quality for three types of receptor concentrations for each
standard:
1. Maximum pollutant concentration from all sources in 1980;
2. Maximum degradation in air pollutant concentrations between
1974 and 1980 due to all sources;
3. The maximum contributions of the cement plant to pollutant
concentrations in 1980.
For each air quality measure, the maximum concentration represents the
worst case in terms of compliance with Ambient Air Quality standards,
the maximum degradation is used for determining compliance with allow-
able federal PSD increments, and the maximum contribution of the cement
plant relates to its worst-case impact.
56
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AIR QUALITY (PLANT SITE)
A summary of the PSD evaluation results for the proposed Ideal Basic
Industries project is presented in Table 4. The air quality concentra-
tions shown have been estimated by mathematical modeling based on
meteorological conditions known to have occurred. In comparing these
numbers, it should be remembered that the maximum values for the air
quality parameters generally occur at different locations, depending on
specific meteorological conditions relative to the desired standard.
The 24-hour and 3-hour concentrations are actually the highest (maximum)
of all the second highest concentrations predicted for the five years of
meteorological conditions used. This highest, second highest concept is
needed in order to assess compliance with the ambient air quality
standards that cannot be exceeded more than once per year.
Each of the maximum values projected to occur in 1980 with the proposed
project in operation (first row) is less than the respective air quality
standard, shown at the bottom of the table. This indicates that the
standards will not be exceeded at any location affected by the proposed
plant. As shown in the last column, the 24-hour suspended particulate
standard will nearly be exceeded. However, this condition exists only
in a very localized area near a present emission source (unrelated to
the Ideal project) and will not be affected by the emissions from the
cement plant under the meteorological conditions represented.
The central portion of Table 4 deals with the locations of maximum air
quality degradation, or the change between 1974 and 1980. The largest
degradation should occur with the sulfur dioxide highest, second highest
24-hour standard (second column) since only 12 percent of the PSD
increment should remain. The cement plant will use 31 percent of the
increment, the other portion will be consumed by other sources in the
area.
The maximum usage of a PSD increment by the cement plant should occur
with respect to the highest, second highest 24-hour suspended particu-
late standard (last column). About 62 percent of the PSD increment will
be used by the plant. In all cases shown in Table 4, maximum
57
-------
Table 4. Summary of PSD Evaluation Results for the Proposed Ideal Basic Industries Cement Manufacturing
Plant
Ambient Ground-Level Concentration (ug/m^)
Emission Situation
Annual
Arithmetic
Mean
Sulfur Dioxide
Second
Highest
24-Hour
Period
Suspended Particulates
Second
Highest
3-Hour
Period
Annual
Geometric
Mean
Second
Highest
24-Hour
Period
POINTS OF MAXIMUM CONCENTRATION
1980 With Ideal * 20
Percent of Standard 25%
Ideal Impact(Contribution) <1
POINTS OF MAXIMUM DEGRADATION
1974 Baseline 8
1980 With Ideal t 20
Degradation 12
Increment Remaining 8
Percent of Increment Remaining 40%
Ideal Impact(Contribution)
Percent of Increment
<1
90
25%
28
10
90
80
11
12%
28
31%
315
24%
146
32
315
283
229
45%
146
28%
46
77%
44
44
0
19
100%
<1
149
99%
45
68
23
14
21
38%
57%
MAXIMUM IMPACT OF IDEAL **
Ideal Impact
Percent of Increment
Increment Remaining
Allowable Federal Increment
Federal Primary Standard
Federal Secondary Standard
1.2
6%
15
20
80
NA
38
42%
53
91
365
NA
199
39%
<313
512
NA
1300
2
12%
21
19
75
60
23
62%
26
37
260
150
* Concentrations from all sources at points of maximum impact from all sources combined.
t Concentrations from all sources at points of maximum degradation since 1974.
** Concentrations from Ideal at points of maximum Ideal effect.
73
JO
•o
Source: Environmental Science and Engineering, Inc., 1977.
-------
AIR QUALITY (PLANT SITE)
degradation since 1974 will not occur at the same locations as the
maximum Impact of the cement plant.
The emissions from the sources modeled may be somewhat conservative
because of the use of permitted emission rates that are typically higher
than actual rates, and the cement plant's sulfur dioxide emissions
should be substantially lower than the values used. In addition, for
each meteorological condition, the concentrations everywhere else will
be lower than the values at the points described in Table 4.
The extent to which the proposed cement plant might limit allowable
emissions by other new sources (also subject to PSD review) and thereby
might influence future industrial growth could be a serious community
impact, since much of the land near the Ideal Basic Industries plant
site is intended for industrial development. The detailed air quality
forecasts indicate that the proposed project will not place significant
limitations upon future growth.
The growth limitation issue relates primarily to short-term air quality
increments, since the proposed project does not place significant stress
upon annual increments or annual ambient air quality standards. An
important characteristic of short-term air quality measures is that the
maximum values tend to involve highly specific combinations of emission
sources, geographic areas, and meteorological conditions. As an
example, the point of maximum consumption of the 24-hour sulfur dioxide
increment (88 percent total consumption, 31 percent due to Ideal) is a
location northwest of the proposed plant site near Island Road. A high
consumption of the 24-hour suspended particulate matter increment
(54 percent total consumption, 22 percent due to Ideal) also occurs near
this point. The reason is that this location is aligned with two
existing emission sources as well as Ideal, so that winds from the
southeast can cause the location to be impacted by all three sources.
However, there are few sites where an industry could locate an
additional emission source that would contribute to this impact. The
critical areas for the 24-hour particulate increment (where total
59
-------
AIR QUALITY (PLANT SITE)
utilization by all sources In 1980 will exceed 50 percent) are situated
close to the plant site, except for the location discussed In the
previous paragraph. The suspended particulate matter increment probably
will not be subject to additional stress in these areas. In the case of
the 24-hour sulfur dioxide increment, all of the high-utilization areas
other than the above-mentioned location will be affected only slightly
by the proposed cement plant.
Therefore, the utilization of the PSD increments by the proposed plant
is considered to be of a moderate magnitude, but of low overall signi-
ficance to the future growth of the industrial park. The impact is
long-term and reversible. The PSD review has been completed and the
"Authority to Construct" has been issued for the cement plant (see the
Permit and Approval section of this document).
The impact of the particulate matter and sulfur dioxide on the ambient
air quality levels emissions will be of a low magnitude based on the
modeling analysis performed. The significance is also rated low because
of the small area affected; impacts will be long-term, but reversible.
Since the estimated quantities of hydrocarbons, carbon monoxide, and
fugitive dust are very low, impacts should be negligible. Modeling of
the nitrogen oxide emissions determined that the levels will be well
below the National Ambient Air Quality Standards. Therefore, the
magnitude of the nitrogen oxide concentrations is considered low and the
overall significance in the area is also considered low. The related
impact is long-term and reversible.
MITIGATING MEASURES
Watering of exposed areas will be employed as an environmental safeguard
to lessen fugitive dust impacts during the construction phase. Some
possible mitigating measures would be:
1. Use of chemical soil stabilizers;
2. Adoption of techniques to reduce wind speeds across exposed
surfaces; and
3. Paving of construction roads.
60
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AIR QUALITY (PLANT SITE)
Over 100 chemical products can be used as soil stabilizers, some of
which are applied to the land surface and some of which are incorporated
into the soil. The major disadvantages of chemical stabilizers are the
expense involved and the fact that traffic and other activities can
break down the stabilizing layer. This control tends to be effective
only for inactive areas, which typically have small emission rates
relative to active areas.
Reductions in wind speed across exposed surfaces, as a means of mini-
mizing wind-entrained dust, can be achieved by enclosures, coverings, or
placement of tall vegetation. Such control measures ordinarily are not
feasible for construction projects of short duration, however. The
option of paving all construction roads, rather than just the principal
access road, could reduce fugitive dust emissions significantly. This
approach is considered impractical because movements of heavy machinery
and equipment would break up the road surfaces and thus necessitate
frequent repaying.
With reference to burning the portion of land-clearing wastes not
chipped or taken to a landfill, there are no mitigating actions that
could be performed to lessen the projected impacts.
The environmental safeguards that will be employed to control emissions
of particulate matter from permanent operations at the Ideal Basic
Industries plant will account for approximately $20 million of the
overall project cost. The use of baghouse dust collectors to control
stack emissions, which is considered BACT, will reduce emission rates to
below the allowable rates. It is not economically feasible, nor tech-
nically practical, to control stack emissions of particulate matter to a
greater degree.
Impacts involving sulfur dioxide could be mitigated by the use of lower
sulfur coal; however, the resulting decrease would be slight given the
inherent reduction by contact with the alkaline raw materials in the
proposed process.
61
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AIR QUALITY (PLANT SITE)
Impacts associated with pollutant emissions from the kiln/cooler/raw
mill system will be mitigated by the use of stacks [90 meters (300 feet)
high] for release of the exhaust gases. These high stacks will
facilitate dispersion and dilution of emissions before the effluent
plume reaches ground level and also minimize the possibility of plume
downwash. As a mitlgatlve measure, higher stacks could be utilized for
other sources (along with the continued use of baghouse control). This
approach has not been considered practical for all sources because the
emission rates of most sources are too small to justify the use of
higher stacks.
ALTERNATIVES
The major project alternatives affecting air quality are:
1. The no-action alternative, under which the proposed project
would not be built;
2. The use of a wet rather than a dry cement manufacturing
process; and
3. The use of air emission controls other than baghouses.
Future air quality in the absence of the proposed Ideal Basic Industries
project would be dependent upon general industrial development and the
alternative use of the Ideal property. The air quality modeling study
suggests that ambient air concentrations will tend to increase in the
Theodore Industrial Park area over the next 15 years, but that air
quality standards and allowable increments will not become seriously
limiting on future growth. The factors responsible are the high levels
of emission control required for new sources and the relatively low
spatial density of industrial development in the industrial park area.
An alternative which would affect the operating characteristics of the
proposed cement plant would be the substitution of a conventional wet
process for the proposed dry process plant. In a wet process plant, the
raw materials are mixed with water before grinding to form a slurry,
62
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AIR QUALITY (PLANT SITE)
which Is then fed to the kiln. Wet and dry process plants cost about
the same to build and have similar emissions of particulate matter
(U.S. EPA, Office of Air Quality Planning and Standards, 1975).
However, overall fuel usage per ton of clinker produced is approximately
twice as great for a wet plant as for a dry plant.
Higher fuel usage with the wet plant would tend to result in greater
emissions of sulfur dioxide. The higher exhaust gas volumes with the
wet plant would also contribute to higher air pollution control costs.
A wet plant would have the potential for greater wastewater discharges
and more maintenance problems due to its use of the slurry kiln feed.
Therefore, a wet process plant, although a practical alternative to the
dry process, would be less desirable because of energy, environmental,
and maintenance factors.
Several alternatives to baghouse technology for control of pollutant
emissions from cement manufacturing include cyclones, wet scrubbers, and
electrostatic precipitators. Multicyclones are effective in removing
the larger particles contained in gas streams, but do not capture the
finer dusts. Therefore, cyclones are usually limited to the role of
pretreatment devices. Wet scrubbing devices can achieve a high degree
of particulate control, but involve wastewater problems, high energy
requirements, high operating costs, and waste products that are
difficult to recycle.
Electrostatic precipitators would be economically feasible only for the
large volume exhaust gas streams of the kiln/cooler/raw mill system.
Their potential shortcomings relative to baghouses include:
1. Explosion potential because of combustible gases and coal dust
in the gas stream; and
2. The need for conditioning of gases prior to entry into the
precipitator.
63
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AIR QUALITY (PLANT SITE)
Therefore, baghouses were chosen over the other devices because of
their higher collection efficiencies and lack of comparable operating
problems.
An alternative to the use of water sprays on sources of fugitive dust,
such as conveyor drop and transfer points, would be enclosing the
location and venting displaced air to a baghouse. The difference in the
levels of emissions does not warrant the use of this alternative action.
64
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NOISE (PLANT SITE)
NOISE
BASELINE
INTRODUCTION
Environmental noise commonly is measured in decibels (dBA) on a scale
that matches the receptive characteristics of the human ear (the
A-scale). Since sound levels tend to vary from moment to moment,
various statistical measures are needed to characterize overall noise
conditions.
The Leq(24) represents the equivalent sound level equal in cumulative
energy to all time-varying noise produced during a 24-hour period. The
L((jn) is the equivalent sound level for day and night based'upon the
Len(24)» but is biased high to account for greater potential noise
sensitivity during the night.
The U.S. EPA has suggested noise levels requisite to protect the public
against hearing loss or activity interference (EPA, 1974). These values
are for long-term exposures and consider the cumulative effects of
noise, but are not intended to be used as standards nor discrete
numbers. The outdoor annual energy equivalent sound levels are as
follows:
1. 55 dBA (L(jn)—could interfere with normal outdoor activi-
ties, such as speech communication at about 3 meters
(10 feet). The level is suggested for residential areas, but
is typically exceeded in metropolitan areas of the U.S.
2. 70 dBA (Leq24)--could cause a hearing loss in 96 percent
of the population by 40 years of continual exposure.
65
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NOISE (PLANT SITE)
PRESENT CONDITIONS
Baseline noise monitoring was conducted at 12 stations near the proposed
Ideal Basic Industries plant site. Three stations were located on the
Ideal property; the other nine stations were located at noise-sensitive
sites such as schools and residences, and at strategic points near noise
sources. Traffic was the dominant noise source in the area. Other
sources that were important at some stations included two manufacturing
plants and a drydock area on the barge canal. The highest noise levels
were measured at two stations on Island Road, one station on Range!ine
Road, and one station on the south bank of the barge canal. These
stations had Leq(24) values between 59 dBA and 66 dBA, and Ldn values
ranging from 65 dBA to 72 dBA. The lowest equivalent sound levels were
at the Dauphin Island Parkway crossing of North Fork Deer River. These
levels were 48 dBA (Ldn) and 45 dBA [Leq(24)].
RELEVANT PROJECT CHARACTERISTICS
During construction of the proposed Ideal Basic Industries manufacturing
plant, noise will be generated by the heavy equipment used for earth-
moving, lifting, welding, paving, pile driving, and transportation. At
the time of peak construction activity, there will be a variety of heavy
equipment on-site.
Based on estimates of the number of pieces of construction equipment to
be used at anytime, a worst-case situation was modeled for the area.
Figure 13 shows the expected equivalent sound level contours [L/dn)]
during the most active three-month period of construction. These levels
are from only the plant activities and do not include background levels.
[It is important to remember that sound levels are not directly cumula-
tive. Adding 55 dBA to a background of 55 dBA (doubling the sound
energy) will produce a level of 58 dBA. In addition, adding 75 dBA to a
background of 55 dBA will produce a level of approximately 75 dBA].
Therefore, a background level should not substantially increase noise
levels from those shown in Figure 13 unless the background level is
greater than the level shown for the cement plant.
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NOISE (PLANT SITE)
During permanent operations of the cement plant, noise will be generated
by process equipment, raw material handling, finished product handling,
and vehicular traffic. Noise from process equipment will be generated
continuously during operating hours, whereas noise from employee traf-
fic, waterway traffic, haul trucks, and rail operations will be produced
on an intermittent basis.
In order to obtain a proper understanding of the sound levels that could
be generated at the proposed plant, a noise survey has been performed at
an existing cement plant. This facility utilizes a dry process similar
to the Ideal Basic Industries plant, but has only one-third the
production capacity. Noise levels were recorded at 20 locations around
the plant in order to gain information on the noise effects typically
associated with dry process cement manufacturing.
The noise information for the other dry process plant was used to
forecast the effects of the Ideal Basic Industries operation by assuming
that the sound power levels from the Ideal facility would be roughly
three times as great. A number of adjustments were made for factors
such as topography and vegetation. The results are depicted in
Figure 14, which shows the sound level contours (L^) resulting from
just the operation of the proposed cement plant. The sphere of influ-
ence is slightly smaller than that associated with the construction of
the cement plant.
IMPACTS
In relation to the EPA suggested equivalent sound levels during
construction, there should be about 75 existing residences inside the
55 dBA contour shown in Figure 13. By 1980, the number of residences
affected should be about 60 due to property takings for the ship channel
project. Within this zone of influence, the construction activities
will increase sound levels to equal to, or greater than, the 55 dBA
C-(dn)) suggested for interference with outdoor speech communication
67
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Figure 13
EQUAL SOUND LEVEL (Ldn) CONTOURS DUE TO
WORST CASE CONSTRUCTION ACTIVITIES FROM
THE PROPOSED PLANT ONLY
PROPOSED CEMENT MANUFACTURING
PLANT THEODORE INDUSTRIAL PARK
MOBILE, ALABAMA
Environmental Science and Engineering, Inc., 1977.
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NOISE (PLANT SITE)
at about 3 meters (10 feet). As mentioned previously, these levels are
similar to levels in typical metropolitan residential areas in the
United States.
Due to the expected levels, the noise impact from plant construction is
considered of moderate magnitude, short-term, and reversible. The sig-
nificance in the area is rated low because:
1. Most construction activities will occur only during daylight
hours, which should approximately coincide with normal working
and school hours.
2. The projections are for the worst 3-month period out of the
30-month construction schedule. At all other times the equi-
valent sound levels will be lower.
3. The noise levels from plant construction outside of this zone
of influence (55 dBA), although probably perceptible, should
not disturb outdoor communication or activities.
4. The levels suggested by EPA are for outdoor activities; the
projected levels will be significantly attenuated (lower)
inside residences.
During the initial plant operations (1981), there should be about
20 residences within the 55 dBA zone of influence shown in Figure 14.
This is a decrease of 12 residences from existing conditions and repre-
sents the effect of the property takings for the right-of-way of the
ship channel. By 1992, it is expected that another 14 residences will be
sold for industrial or commercial land use (see Land Use section).
The noise impact from operating the cement plant is considered of moder-
ate magnitude, long-term, and reversible. The significance is rated low
because of the small number of residences to be affected as compared to
the total number of residences in the area.
The noise impact should be less than that shown on the eastern side of
the plant because after the modeling was performed, the 20-meter
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•AKEH SORRELLROAO
LAURENDINE ROAD
Figure 14
EQUAL SOUND LEVEL (Ldn) CONTOURS DUE TO PLANT
OPERATIONS ONLY
PROPOSED CEMENT MANUFACTURING
PLANT THEODORE INDUSTRIAL PARK
MOBILE, ALABAMA
SOURCE: Environmental Science and Engineering, Inc., 1977
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NOISE (PLANT SITE)
(65-foot) high dead storage pile of limestone was added to the plant
layout. This pile will attenuate the noise generated from most of the
ground-level facilities.
MITIGATING MEASURES
In order to minimize noise impacts during construction, equipment with
effective noise suppression devices complying with the Walsh-Healy
Act and Occupational Safety and Health Administration (OSHA) regulations
will be used. Construction activity will be limited to daylight hours
as much as possible. During permanent operations at the plant, the
following environmental safeguards will apply:
1. Most of the process equipment (with the exception of portions
of the kilns as required for heat dissipation) will be
enclosed within buildings.
2. Noise impacts will be lessened by the presence of vegetation,
particularly the vegetated buffer strip along the eastern
property boundary.
3. The access road will be located away from residential areas.
4. The 20-meter (65-foot) high dead storage pile of limestone
will be located along the eastern edge of the facility.
A noise study will be performed by Ideal Basic Industries in order to
determine appropriate measures and requirements regarding enclosures,
barriers, and machinery arrangement.
Additional actions could be taken to help mitigate the noise impacts.
First, noise suppression equipment could be installed on the various
fans used with the baghouses for controlling air emissions. Second, all
process components and/or the entire facility could be completely
enclosed.
The aspects of noise suppression for fans could be investigated during
the proposed noise study. However, completely enclosing the facility
would be impractical for a plant of this size.
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NOISE (PLANT SITE)
ALTERNATIVES
The no-action alternative indicates that noise levels in the Theodore
Industrial Park area will increase in the future whether or not the
proposed cement plant is constructed. The major factors responsible for
long-term changes in noise levels will be: (1) increased highway
traffic; (2) larger volumes of waterway traffic; and (3) new industrial
development. An additional factor that will be very important in the
short-term is the construction of the Theodore Ship Channel, which will
be accomplished by deep dredging along the route of the present barge
canal.
Future noise levels without the Ideal Basic Industries project have been
modeled mathematically for the year 1992. It was not possible to take
into account other new industrial development.
As would be expected with increased road and channel traffic, the
equivalent noise levels should increase along Rangeline Road [L(,jn) of
81 dBA and Leq(24) of 75 dBA], Island Road [L^n) of 71 dBA and Leq(24)
of 68 dBA], and the ship channel [L(dn) ofr 64 dBA and Leq(24) °f 57 dBA].
No change from 1977 levels is projected for the location of the crossing
of the Dauphin Island Parkway and North Fork Deer River.
The 1992 baseline noise projections have included estimates of highway
traffic impact based upon a mathematical model developed by the Highway
Research Board (Gordon, jt eil_., 1971). Noise effects due to waterway
traffic on the ship channel have been estimated using information
contained in the environmental impact assessment of the ship channel
project (USC, Incorporated/Consulting Engineers, 1974). The modeling
has assumed that waterway traffic will amount to ten round trips of tug
and tow per day. In summary, the projected 1992 noise levels without
the cement plant are higher than present levels in all areas near the
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NOISE (PLANT SITE)
ship channel and In areas adjacent to Rangeline Road and Island Road.
Little change is expected elsewhere.
The plant layout has been modified for various process and environmental
reasons. The present facility plan utilizes a physical barrier (dead
storage pile of limestone) and natural buffers (greenbelt to the east,
natural vegetation to the north) to reduce noise impacts on the
surrounding area.
An alternative to this action would be to relocate the main facilities
as far west as possible and to place noise barriers to the north, south,
and east. This arrangement would move the noise sources farther away
from the residential areas and possibly attenuate the noise more
effectively.
The proposed plant layout with its natural buffers does not differ
greatly from this alternative, but is more desirable as a practical
balance of process requirements and ecological effects. However, the
design consultants are continuing their study to determine noise
reduction effects of layout and equipment changes. If specific types of
equipment are determined to generate lower noise levels, have practical
operating requirements, and are cost-effective, they will be used.
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SOLID WASTE (PLANT SITE)
SOLID WASTE
BASELINE CONDITIONS
Most solid waste generated at the Ideal Basic Industries plant site will
be disposed in an approved off-site landfill. Therefore, a field inves-
tigation of landfills in Mobile County has been conducted to survey
present conditions and establish the availability of landfill capacity
in 1980. The three principal landfills in Mobile County which operate
under the supervision of state and local agencies are the Irvington,
Kushla, and Mobile sites.
The closest landfill to Theodore Industrial Park is the Irvington site
which is owned by Mobile County and operated under contract to Mobile
Waste Company. A trench method of disposal is utilized, in which a
dragline digs a trench in the clay soil and the wastes are deposited on
a 3 to 1 slope. Each trench is about 15 meters (50 feet) wide and
23 meters (75 feet) long. The wastes are compacted and covered each day
with a layer of clay.
The wastes accepted at the Irvington Landfill are restricted to garbage,
non-bulk refuse, industrial containers, etc. Bulky items are not
acceptable unless they are cut to a size that allows for easy compaction
by a dozer. The remaining life of the landfill is estimated as greater
than 15 years.
The Kushla Landfill is also owned by Mobile County and operated by
Mobile Waste Company. This site is approximately one-third the size of
the Irvington Landfill and has a relatively short remaining life.
At the City of Mobile Landfill, located at the end of Hickory Street, a
lift method of waste disposal is used. This landfill handles only non-
putrescible wastes (i.e., wastes not containing decomposable organics).
The life of the Mobile landfill is presently estimated to be 5 years,
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SOLID WASTE (PLANT SITE)
based on the assumption that only several more lifts are practical for
the site.
An additional site which could be utilized is an old clay quarry owned
by Ideal and located about 32 kilometers (20 miles) north of Mobile. A
pit is currently being filled with waste from Ideal's existing wet
process cement plant in Mobile. The pit is imbedded in impermeable
clays and there is sufficient land to continue such operations for at
least 15 years.
Mobile County does not have a municipal incinerator or resource recovery
facility, and such facilities do not appear likely in the near future.
However, recent state and federal legislation dealing with the disposal
of hazardous and toxic substances may lead to the development of special
regional facilities (e.g., sealed or leachate-treated landfills, or high
temperature incinerators) in Mobile County or elsewhere. The Mobile
County Board of Health issues permits for burning of wastes from land
clearing, with provisions governing air pollution emissions.
RELEVANT PROJECT CHARACTERISTICS
The construction phase of the proposed Ideal Basic Industries project
will generate three major types of solid waste: debris from land
clearing, dredged soil materials, and general construction wastes.
Approximately 20 hectares (50 acres) of modified longleaf pine forest
will be cleared during the first three months of construction. Three
types of disposal methods are under consideration for partial or
exclusive use: chipping for mulch, controlled burning, and landfill ing.
The small-sized wastes could be chipped and used for mulch and erosion
control. The larger wastes could be burned in an air-blower type pit
burner (see Air Quality section). All of the land-clearing wastes could
be taken to the Irvington Landfill for burial. The actual use of any
one or all of these methods would be based on the practical application
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SOLID WASTE (PLANT SITE)
of each method within the time constraints of the construction
schedule.
Grading of the plant site and construction of stormwater clarification
basins will not yield excess soil materials, because of a balancing of
cut and fill activities. However, about 500,000 cubic meters (650,000
cubic yards) of material will be removed from the site during dredging
of the waterfront area. It is anticipated that this material will be
taken to the approved disposal sites used by the Corps of Engineers for
dredged material from the ship channel project.
Construction wastes resulting from the erection of structures and site
cleanup will include lumber, concrete, brick, cardboard, and metal
scraps. This material will be conveyed to the Irvington Landfill for
disposal by a private contractor.
Permanent operations at the Ideal Basic Industries cement plant will
yield approximately 1,043 metric tons (1,150 tons) of solid waste per
year. The largest sources of solid waste will be the refractory linings
of kilns and suspension preheaters. During the course of normal opera-
tions, portions of the refractory brick lining deteriorate and must be
replaced. The debris removed in this process will amount to 667 metric
tons (736 tons) per year.
The raw materials and coal received by the plant may contain pieces of
rock, wood, or metal, which must be removed. These will contribute
approximately 248 metric tons (274 tons) per year of waste material.
Bag breakage in the packhouse will account for 14 metric tons (16 tons)
of paper waste per year, and scraps and oily maintenance waste from the
shop area will amount to 34 metric tons (37 tons) per year. Approxi-
mately 11 metric tons (12 tons) of paper waste will be produced every
year by the company lunchroom and office area.
Sediment will accumulate in the stormwater catchment area and the
wastewater settling basin. This material must be removed to avoid loss
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SOLID WASTE (PLANT SITE)
of storage capacity, yielding about 68 metric tons (75 tons) of sediment
(dry basis) per year. The sediment will be re-introduced, if possible,
to the raw material piles, but otherwise must be removed by the disposal
contractor.
All of the materials listed, with the exception of recyclable metal
scraps, waste oil, and paper, will be hauled to the Irvington Landfill.
Special regulations under the recently-enacted Resource Conservation and
Recovery Act (RCRA) classify hazardous or toxic wastes. Although
hazardous and toxic materials under RCRA have not yet been defined
precisely, the cement plant wastes will probably not be included.
IMPACTS
Disposal of general construction debris at the Irvington Landfill will
not involve any special problems other than utilization of available
landfill capacity. Burning of vegetative wastes could have some
intermittent effects on air quality, as discussed in the Air Quality
section. These disposal activities are assigned low magnitude and
significance as environmental impacts. Disposal of dredged materials
from the waterfront area is an impact of moderate magnitude due to the
quantities involved, but low significance since an approved site will be
utilized. The impact is long-term and irreversible.
The solid waste load from the Ideal Basic Industries plant will shorten
slightly the active life of the landfill. The magnitude and signifi-
cance of these solid waste disposal activities, as environmental
impacts, are considered low. Centralized land disposal of solid waste
is a long-term, but reversible action because of the many possibilities
for re-use of landfill sites.
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SOLID WASTE (PLANT SITE)
MITIGATING MEASURES
A general class of actions which will minimize resource utilization and
potential problems associated with solid waste disposal will be the
practice of recycling all possible materials (e.g.* spillage, oily
wastes, scraps) either Internally or through sales to dealers. Environ-
mental safeguards with regard to controlled burning have already been
discussed. There are no mitigating measures for the disposal of solid
wastes.
ALTERNATIVES
The no-action alternative would involve marginal, short-term air quality
benefits due to the absence of burning of vegetative waste at the con-
struction sites and in the long run would decrease slightly the utiliza-
tion of public landfill capacity.
The land-clearing wastes are to be burned, chipped for mulch, or taken
to the Irvington Landfill for disposal. Alternative actions Include
public use as firewood; use in local pulp mills or waste wood boilers;
and on-site burial.
The use of the wastes for firewood, paper pulp, or fuel are sound
environmental alternatives. Their major disadvantage, which is shared
somewhat with the proposed action of chipping and landfill ing, is the
extra commitment of time and money during the beginning of the
construction schedule. All other construction-related activities would
be delayed if the clearing operation was extended beyond its projected
three-month period. While these are not environmental criteria, they
are important factors since controlled burning is only slightly less
desirable on an environmental basis. The on-site burial alternative
might cause a soil stability problem when the wood decays and would
require clearing of additional land to serve as a disposal site.
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SOLID WASTE (PLANT SITE)
The proposed disposal actions for construction wastes are environment-
ally acceptable and the most practical for the construction contractor
to Implement.
During plant operatons, the solid wastes not being recycled will be
taken to the Irvington Landfill. Alternatives to this action are burial
on-site and partial use as fill off-site. The majority of the waste,
such as bricks, scraps, and sediment, could be used as fill material
without presenting an environmental problem. The putrescible and
maintenance wastes would require proper burial techniques as practiced
at a sanitary landfill.
The three proposed waste disposal techniques, if properly performed,
would be environmentally sound actions. The two alternatives would
eliminate or reduce the use of available land at the Irvington Landfill.
However, the on-site landfill alternative would require development of
an additional portion of the plant property that would be sufficiently
above the groundwater table and out of the wetlands. Also, the practi-
cal necessities of daily cover material, equipment, and personnel would
have to be provided. From an environmental viewpoint, proper disposal
could be better achieved on a regular basis by trained operators at a
public landfill.
The off-site use of some of the wastes as fill material 1s a viable
action that could be used if an acceptable area could be found.
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WATER RESOURCES/GEOTECHNICAL (PLANT SITE)
WATER RESOURCES AND GEOTECHNICAL ASPECTS
BASELINE ENVIRONMENT
The proposed plant site is situated in the Southern Pine Hills sub-
province of the East Gulf Coastal Plain. The area is characterized by
low, smooth hills developed on floodplain, terrace, and beach deposits.
The plant site is on Quaternary alluvium (silt and sand deposits). Test
holes at the site reveal at least 41 meters (135 feet) of unconsolidated
sands, silts, and clays. Nearby wells indicate that at least 200 meters
(656 feet) of unconsolidated sediments lie below the area. Because of
the thick section of clayey material, some settling of the land surface
can be expected to result from compaction under heavy loads. The area
is not technically active (earthquakes or ground tremors) and is
classed in the lowest seismic risk category.
Groundwater supplies are available in Mobile County from permeable sand
layers. Twelve wells within an 8-kilometer (5-mile) radius of the
proposed plant site range in depth from 15 to 150 meters (50 to 500 feet
and tap either alluvial or Miocene-Pliocene aquifer beds. The latter
units generally yield good quality soft water, but local groundwater
quality problems are known to occur. There is some evidence of salt-
water intrusion near Mobile.
Elevations on the site range from 6 meters (20 feet) above mean sea
level near the barge canal to sea level along the canal waterfront and
marsh areas. Most of the plant site (the portion of the property
proposed for development) drains north to the marsh, with the remainder
draining directly to the barge canal.
The surface water bodies of primary importance for the proposed project
are the Deer River/Barge Canal and the North Fork Deer River (see
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WATER RESOURCES/GEOTECHNICAL (PLANT SITE)
Figure 15). The barge canal was created In 1968 by dredging the Deer
River bed to a depth of 3.7 meters (12 feet) and a width of 90 meters
(300 feet). Some sections of the river that were bypassed now remain as
marshy bayous. The dead-end barge canal extends inland a distance of
3.2 kilometers (2 miles) and receives little freshwater inflow because
of its limited drainage area. As a result, there is relatively little
water circulation, which allows stagnant bottom conditions to develop,
especially during the summer months when salinities in the barge canal
and bay are high. Because the system has little assimilative capacity
for additional oxygen-demanding materials, the South Alabama Regional
Planning Council has recommended that no point discharges to the canal
be permitted unless the effluent is demonstrably better in quality than
the existing water in the canal (SARPC, 1977). This recommendation is
being implemented by EPA in the review of NPDES permit applications.
The North Fork Deer River, which bisects the Ideal Basic Industries
property, is bordered by both saltwater and freshwater marsh systems
(see Figure 16). The freshwater marsh system, which is along the
river's western reach, appears to have a substantial capacity for assim-
ilating pollutants. However, the marsh appears to have been degraded in
the past by industrial-related discharges.
Both the barge canal and the North Fork Deer River are characterized by
high summer water temperatures, low to moderate color, and low alkalin-
ity. Nutrient levels are sufficiently high to support very productive
phytoplankton populations, and concentrations of lead are periodically
high in the North Fork Deer River.
RELEVANT PROJECT CHARACTERISTICS
During construction of the plant there will be stormwater runoff and
disturbances in the existing bodies of water. The cleared areas will
have a potential for erosion which will cause sedimentation and
turbidity effects in both the North Fork Deer River and the ship
channel. Early in the construction period, a permanent stormwater
81
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Figure 15
SURFACE WATER BODIES
SCALE IN KILOMETERS
SOURCE: Environmental Science and Engineering, Inc., 1977.
PROPOSED CEMENT MANUFACTURING
PLANT THEODORE INDUSTRIAL PARK
MOBILE, ALABAMA
82
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EAST VIEW
WEST VIEW
Figure 16
PHOTOS OF THE THEODORE PLANT SITE ALONG THE
NORTH FORK DEER RIVER FROM THE BRIDGE ON
DAUPHIN ISLAND PARKWAY
SOURCE: Environmental Science and Engineering, Inc., 1977.
REGION IV
U.S. ENVIRONMENTAL PROTECTION
AGENCV ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
PROPOSED CEMENT MANUFACTURING
PLANT THEODORE INDUSTRIAL PARK
MOBILE, ALABAMA
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WATER RESOURCES/GEOTECHNICAL (PLANT SITE)
catchment area will be built to reduce the solids content of the water
prior to discharge into the wetlands. The site grading will maintain a
northernly drainage to reduce runoff directly into the ship channel.
The access roadway will cross the North Fork Deer River with a 15-meter
(50-foot) long bridge and the railroad will trestle across both the
river and wetlands. The construction of these structures will include
the use of temporary berms and barriers to reduce the effect on the
water quality in the river.
The docking facilities will require about 500,000 cubic meters (650,000
cubic yards) of material to be dredged. It is anticipated that this
activity will occur during dredging of the ship channel and that spoil
from constructing the dock will be taken to the approved disposal areas
used by the U.S. Army Corps of Engineers.
During operations the cement plant will use about 1,080,000 liters
(285,000 gallons) per day of potable water supplied by the Board of
Water and Sewer Commissioners of the City of Mobile. The water will be
used for cooling tower make-up, sanitary requirements for 135 employees,
truck and floor wash areas, and process cooling systems.
The sanitary wasteloads of 20,000 liters (5,000 gallons) per day will be
pumped to the new McDuffie Island treatment plant (during plant con-
struction portable toilets will be provided and serviced by a local
contractor).
There are four sources of industrial wastewater projected for the plant:
1. The runoff from the uncovered raw material piles,
2. Truck and car wash and floor washes,
3. Process cooling tower blowdown, and
4. The runoff from the aboveground fuel oil tank's containment
berm.
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WATER RESOURCES/GEOTECHNICAL (PLANT SITE)
The daily average flow expected from the two uncovered stockpiles of
limestone and clay will be 166,000 liters (43,800 gallons) per day.
Simulated leachates were collected from samples of all the raw materials
(limestone, clay, gypsum, sand, iron ore, and coal) and subjected to
chemical analysis and fish bioassays. The results showed that the
materials are nontoxic and their leachates, when diluted with the other
wastewaters, should be of acceptable water quality meeting Fish and
Wildlife Standards.
Approximately 6,600 liters (1,750 gallons) per day of wastewater is
expected from the truck and car wash, and another 17,700 liters (4,680
gallons) per day is anticipated from the various floor wash areas. This
wastewater, like the stockpile leachates, will be nontoxic since it will
contain the same materials.
The cooling system is to be a noncontact type in which the cooling tower
will vent or blow down some of its water in order to maintain desired
suspended solids content. The vented water is to be replaced by potable
"make-up" water. The blowdown will contain suspended solids and an
algicide that is not yet specified, but must be approved by EPA prior to
use. The blowdown will partially evaporate and will leave about
140,000 liters (36,000 gallons) per day that will enter the settling
basin.
The aboveground fuel oil tank and its containment berm will have an
average daily flow of 700 liters (190 gallons) from runoff and direct
rainfall. This stormwater will be drained to the settling basin to pro-
vide full capacity of the containment berm in case of a tank failure.
The settling basins will be designed to meet the effluent requirements
of 50 mg/1 of total suspended solids, and a pH within the range of
6.0 to 9.0 (the draft NPDES permit presented in the Permit and Approval
section of this document contains more detailed effluent requirements).
The settling basin will have a storage capacity of 16 million liters
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WATER RESOURCES/6EOTECHNICAL (PLANT SITE)
(4.2 million gallons) which is double the runoff expected from a
10-year, 24-hour storm event.
The stormwater catchment area will collect and retain the initial flush
of most storms. The 2-hectare (5-acre) area will consist of two bermed
basins in series. The berm height will be 0.9 to 1.5 meters (3 to
5 feet) and will have a storage capacity of 12 million liters
(3.3 million gallons). This storage capacity is roughly equivalent to
the runoff from the plant site area during the first 50 minutes of a
10-year, 1-hour storm event. The catchment area will discharge the
runoff into the freshwater marsh. The average daily flow from the
catchment area is expected to be 910,000 liters (240,300 gallons). The
area, which will provide reduction of the suspended solids level in the
runoff, is considered by EPA as a best management practice (see Permit
and Approval section). In addition, the discharged water will undergo
natural treatment in the wetlands prior to entering the ship channel via
North Fork Deer River.
IMPACTS
Land clearing and grading activities on about 20 hectares (50 acres) of
the Ideal Basic Industries property will result in land erosion and
sediment transport during storm events. However, except for a short
period prior to construction of the stormwater catchment area, the
sediment loads to the North Fork Deer River should be small because of
the reduction of solids provided and the additional filtering action of
the marsh vegetation. Sediment transport to the ship channel should be
minimal because only a small portion of the plant site drains to the
south. Construction of the rail trestle and access roadway over the
North Fork Deer River will cause localized sediment and turbidity
effects of moderate magnitude. However, all of these erosion-related
effects are attributed low significance as water resource impacts
because of their short duration and reversible nature.
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WATER RESOURCES/6EOTECHNICAL (PLANT SITE)
Construction of docking facilities on the ship channel waterfront will
affect turbidity and suspended solids concentrations in the immediate
vicinity of the Ideal Basic Industries property. Although this effect
will be moderate in magnitude, its significance is considered low
because of the small portion of the channel affected and because the
action is short-term and reversible.
Diesel fuel oil used to power heavy equipment could conceivably be
spilled during construction. However, a berm will surround the fueling
area and most spills could be easily contained. The magnitude of pos-
sible contamination of surface waters is thus considered very low. The
significance is considered low since the amount of water affected would
be small. The impact would be short-term and reversible.
Permanent operations at the plant site can affect surface water
resources through general stormwater discharges, industrial wastewater
discharges, and oil spills. As described earlier, the discharge of
process wastewaters from the settling basin will meet all applicable
water quality standards. The magnitude and significance of the effluent
as a water resource impact are thus considered low, long-term and
reversible.
The stormwater runoff from the plant site into the freshwater marsh will
approximately double the existing runoff for the same size storm. The
catchment area and wetland filtration will reduce the suspended soils
levels so that the effect on the water quality of the North Fork Deer
River should be of low magnitude and significance. The impact is con-
sidered long-term but reversible. The impact is avoidable by
discharging the stormwater runoff directly into the ship channel.
The present design of the plant shows a 380,000-liter (100,000-gallon)
aboveground fuel oil storage tank with a containment berm. The berm is
sized to hold all of the oil in case of a spill or tank failure. The
probability of any oil reaching the North Fork Deer River is slight due
to the northward grading into the stormwater catchment area. If a spill
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WATER RESOURCES/GEOTECHNICAL (PLANT SITE)
did reach the ship channel, it would not quickly disperse because of the
poor flushing action of the channel and should be easily contained and
removed. Therefore, the water quality impact from a potential oil spill
is considered low in magnitude as well as significance; short-term and
reversible.
MITIGATING MEASURES
The environmental safeguards to be employed during construction will
include the stormwater detention basin, the placement of berms and
barriers at the bridge/trestle construction site, and the temporary
surfacing of access roadways and the use of chipped wood wastes for
mulch to reduce erosion.
Mitigating measures which could reduce erosion/sedimentation effects
are: (1) grading of the site to minimize slope lengths; (2) temporary
soil stabilization measures such as netting and chemical binders;
(3) natural or installed buffers, such as vegetated strips; and
(4) artificial structures including inlet filters, sediment traps,
dikes, and ditches. Most of these measures would be feasible during at
least some stages of the project, but are not considered necessary in
addition to the proposed safeguards to achieve adequate environmental
protection.
Water resource impacts during permanent operations will be lessened by
four major environmental safeguards—the industrial wastewater settling
basinr the stormwater detention area, the coverage of raw material
stockpiles, and the berm around the fueling area.
The mitigating measure which could be employed in addition to these
safeguards would be to provide chemical treatment of industrial
wastewater and/or stormwater as part of the clarification process (e.g.,
through the use of flocculants, coagulants, etc.). This step is
feasible, but at the present time it is not considered necessary to
preserve environmental quality and to meet all water quality standards.
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WATER RESOURCES/GEOTECHNICAL (PLANT SITE)
ALTERNATIVES
The no-action alternative relates to the expected conditions of the ship
channel and North Fork Deer River. The most important determinant of
water resource characteristics in 1992 will be the Theodore Ship Channel
project. The water quality problems now observed in the barge canal may
also characterize the proposed ship channel. Modeling studies have con-
cluded that the rate of flushing will be too slow to remove waste from
the channel effectively, so that water quality could degrade from
existing levels. A possible solution is to have industrial wastewater
dischargers use the proposed common outfall into Mobile Bay and thereby
eliminate direct discharge into the ship channel. An Environmental
Impact Statement is being prepared for the Corps action of reviewing the
construction applications for the outfall line.
The water quality of North Fork Deer River could degrade in the future
because of existing and additional industrial discharges. It is most
likely that in 1992 the river will experience moderate water quality
degradation.
The alternatives to discharging the industrial wastewater to the ship
channel would include: (1) discharge of the settling basin effluent
into the freshwater marsh; and (2) utilization of the proposed common
wastewater outfall in Mobile Bay. The major advantage of discharging
the industrial wastewater effluent into the marsh system is that the
effluent would receive additional treatment and purification by natural
processes prior to reaching open water. The possible disadvantage is
that the assimilative capacity of the marsh might become overloaded,
resulting in long-term damage.
The common wastewater outfall project, which has been proposed by the
Board of Water and Sewer Commissioners of the City of Mobile, would
involve an outfall extending approximately 5.6 kilometers (3.5 miles)
into Mobile Bay. Utilization of this facility by Ideal Basic Industries
would be environmentally acceptable; however, this step does not appear
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WATER RESOURCES/6EOTECHNICAL (PLANT SITE)
necessary as a means of preventing Impacts In the ship channel by the
effluent from the cement plant.
Alternatives to discharging the general stormwater runoff into the
freshwater marsh during the construction and operation phases are
diverting all or part of the general runoff from the site to the ship
channel. A benefit of discharging treated stormwater to the ship
channel rather than to the North Fork Deer River would be to increase
the flushing of the channel by providing additional flow.
From an environmental viewpoint, as long as the runoff characteristics
to the wetlands are not reduced from existing conditions, the alterna-
tive actions would be feasible and essentially equivalent to the pro-
posed action. However, discharging all or part of the runoff to the
ship channel would require a catchment basin close to the waterfront
area. Under present facility layout and grading plans, these
alternatives would not be very practical due to space limitations.
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ARCHAEOLOGY (PLANT SITE)
ARCHAEOLOGY
BASELINE CONDITIONS
The archaeological-historical inventory of the Ideal Basic Industries
plant site has included a review of historic literature, topographic
maps, aerial photographs, and previous site surveys. A review of the
National Register of Historic Places has indicated that there are no
certified historic sites within the vicinity of the Ideal property.
An on-site "walk-over" archaeological-historical survey was conducted
under the supervision of the University of South Alabama. All roads,
ditches, creek banks, and cleared or eroded areas were investigated for
possible features and artifacts. Vegetation was examined, since cal-
ciphile vegetation in an otherwise acid soil is often an indicator of
buried sites. No archaeological or historical sites were recorded dur-
ing the survey. Artifacts present on the site represent debris that has
been deposited there within the last ten years.
Research and on-site investigation indicate that no sites of archaeo-
logical-historical interest will be impacted by either construction or
operation of the proposed cement plant. The Alabama Historical
Commission, state historic preservation office, has concluded that the
development will have no adverse effect on any cultural resources
included in, or eligible for, the National Register of Historic Places.
However, in the event that a site of potential interest is uncovered
during construction, the Commission will be notified to appraise the
discovery.
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ECOLOGY (PLANT SITE)
ECOLOGY
BASELINE CONDITIONS
STRUCTURE OF TERRESTRIAL ECOSYSTEMS
The two major vegetative communities found at the proposed plant site
are a modified longleaf pine forest and a marshland which has gum and
titi swamps at its perimeter. A map of these communities is presented
in Figure 17. The upland pine forest areas have an overstory of long-
leaf pine with a well-developed understory of hardwoods. The mature
pines were last harvested in 1974, and the use of controlled burning for
forest management has been discontinued. As a result, hardwoods have
developed rapidly and there is a greatly increased abundance of weedy
and/or disturbed area species (e.g., broomstraw, muhly, meadowbeauty,
throughwort).
The marsh areas at the proposed plant site include a tidally-influenced
brackish marsh, a freshwater marsh, and an intermediate forested area of
somewhat higher land. The brackish marsh is composed primarily of
sawgrass. The intermediate marsh is characterized by the presence of
overstory species (titi, black willow, red maple) which are small in
stature but clearly define the upper limit of saline influence.
Upstream from the intermediate zone, overstory species become sparse and
are replaced by grasses and other low-lying vegetation (goldenrod, dog
fennel, pickerel weed, arrowhead). Higher in the freshwater marsh, near
the property boundary, the vegetation is almost entirely cattail and
reeds.
The animal community in the longleaf pine upland area is characterized
by a number of exclusives (species occurring in a single habitat), which
include nuthatches, warblers, squirrels, flatwoods salamanders, and
black pine snakes. Animal species most frequently observed at the
proposed plant site are cardinals, quail, doves, red-bellied
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I MODIFIED LONGLEAF
PINE FOREST
I BRACKISH MARSH
I FRESHWATER MARSH
INTERMEDIATE MARSH
ZONE
DEVELOPED
SCALE IN METERS
WATER | ROADS
RAILROAD ~~ IDEAL BASIC INDUSTRIES
PROPERTY BOUNDARY
Figure 17
VEGETATION MAP FOR THE PROPOSED PLANT SITE
SOURCE: Environmental Science and Engineering, Inc., 1977.
REGION IV
U.S. ENVIRONMENTAL PROTECTION
AGENCY ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
PROPOSED CEMENT MANUFACTURING
PLANT THEODORE INDUSTRIAL PARK
MOBILE, ALABAMA
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ECOLOGY (PLANT SITE)
woodpeckers, raccoons, and rabbits (cottontail and swamp). The bog
areas, consisting of relatively small, moist depressions in the land
surface, are frequented by reptiles and amphibians such as the scarlet
kingsnake and flatwoods salamander.
An aquatic-associated group of birds, mammals, reptiles, and amphibians
are represented on the site because of the presence of wetland areas.
The exclusives found in the marshes include marsh wrens, rails, rice
rats, nutria, and salt marsh snakes, all of which are adapted to the
periodic inundation of marsh vegetation. Other species (e.g., barn
owls, fish crows, raccoons, and skunks) utilize the marsh as well as a
wide variety of other habitats. The most commonly observed vertebrate
animals are swallows, snipe, sharptailed sparrows, and red-wing
blackbirds. Although the fresh and brackish marshes have different
vegetation and vary in terms of salinity, the animal populations differ
more quantitatively than qualitatively. For example, there were more
red-wing blackbirds seen in the freshwater marsh than in the brackish
marsh because cattails provide more suitable nesting habitat.
Timbering has reduced most of the upland portion of the plant site to a
disciimax shrub and early forest growth state, corresponding to one of
the early serai stages of the Southern Mixed Deciduous Forest
(Quarterman and Keever, 1962). The present disturbed nature of the site
is characterized by poor nutrient conservation (erosion, leaching); poor
microclimate regulation (drying of bogs in logged and early regrowth
areas); and relatively short and unstable food webs associated with the
early successional state (Odum, 1971). The normal ecosystem functions
of the forested area, which include soil retention and formation as well
as surface water storage and recharge, are impaired by the disturbed
condition of the site. Hunting for quail, rabbit, and dove occurs on
the property, and there is some fishing for mullet and trout along the
barge canal. Prior to lumbering, significant red squirrel populations
were present (Athens, 1977). However, the site is not considered a
major hunting and fishing area.
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ECOLOGY (PLANT SITE)
Wetlands are valuable resources for water conservation, flood control,
and waste recycling (Wharton, jt ^1_., 1976). The marshes at the plant
site provide these services and in addition appear to improve the qual-
ity of water delivered from the North Fork Deer River drainage area to
Mobile Bay. The marsh areas constitute a relatively stable system,
which is characterized by high biomass productivity. Such tidal marshes
serve as important nursery grounds for seafood, and the organic material
exported from these areas to estuarine systems is very important to com-
mercial marine organisms. Peat has accumulated in the North Fork Deer
River marsh system and is augmented by silt carried from the uplands.
The effectiveness of the marsh system in trapping sediment is indicated
by the fact that the accumulation of gray silt is twice as thick in the
upper end of the freshwater marsh as in the intermediate forested area,
and decreases still further in the brackish marsh.
SIGNIFICANT TERRESTRIAL SPECIES
Two categories of plant and animal species have received special
attention in the field surveys, namely:
1. Commercially and recreationally important species, and
organisms which are critical to these species or to overall
ecological health; and
2. Rare and endangered species.
Commercially important plant species at the Theodore site are limited to
pine and oak, which have limited value because of past cutting and
because the site is too small for efficient commercial forestry. How-
ever, the marsh plants at the site are considered valuable collectively
for wildlife and fisheries production. The conditions produced by past
clearance of the upland area also appear favorable for supporting
populations of some important faunal species.
The important animals which occur, or can be expected to occur, on the
proposed plant site are either fur-bearing animals (nutria, raccoons) or
game species (swamp and cottontail rabbit, bobwhite quail, mourning
dove, various rails, common snipe, waterfowl). Suitable habitat for
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ECOLOGY (PLANT SITE)
nutria, raccoon, and opossum Is found at the plant site. Raccoons
utilize both the upland and marsh areas, and nutria have been observed
In both the freshwater and brackish marsh. Bobcats are considered
likely at the plant site on the basis of habitat characteristics. No
signs of beaver, muskrat, mink, or river otter have been observed, but
these species are reported to occur locally.
The entire upland area of the plant site provides good rabbit habitat.
The marsh areas are relatively undisturbed and provide adequate cover
for migratory and resident birds. Three species of rails have been
observed in both the fresh and brackish marshes. Habitat analysis indi-
cates the probable use of the marsh and barge canal by wintering ducks
and geese, although few waterfowl breed in Alabama. Quail, snipe, and
mourning doves are abundant.
One threatened species (the American alligator) and two species of
special concern (merlin and little blue heron) have actually been
observed, all in the marsh area. On the basis of habitat analysis,
twelve additional special-status animal species are considered likely to
occur at the site. These include two birds of special concern whose
habitat requirements are not highly restrictive, and ten animal species
that occupy marsh or swamp areas.
A similar analysis of plant species has identified four endangered
species and eleven threatened species that are known to occur in Mobile
County habitats resembling the plant site. None of these plant species
have been observed at the site, and all except one (a marsh plant) are
assigned a low probability of occurrence due to recent logging of the
upland area. Therefore, the plant site is not considered an important
part of the habitat of these species.
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ECOLOGY (PLANT SITE)
AQUATIC ECOLOGY
The aquatic habitats at the plant site are North Fork Deer River and the
barge canal. The few bogs on the site and the flora in the wide band of
marsh along the creek are described in the terrestrial section.
North Fork Deer River is a small meandering tidal creek about 6 meters
(20 feet) wide as it crosses the center of the plant site. Several
industrial wastes are discharged into its upper reaches; however, due to
a peculiar feature of the river, water in the lower reaches is of
relatively good quality. A raised area forms a small dam across the
marsh as it crosses the Ideal Basic Industries property. There is no
channel, and water seeps through this ridge which supports the low
intermediate forest described in the terrestial section. This seepage
markedly cleans the water. This ridge also marks the transition between
brackish and freshwater marsh.
The straight barge canal was dredged through the marsh of the meandering
Middle Fork Deer River, and the complete drainage of the Middle Fork
flows through the barge canal. However, the depth of the canal prevents
mixing, and oxygen levels in the deeper parts of the canal become low,
especially in summer. For at least four months of the year, only the
top 2.5 meters (8 feet) of the water column in the canal are really
useful for fish and wildlife.
The effects of this stagnation are especially clear in the distributions
of shrimp. In the spring, brown shrimp (Penaeus aztecus) occur in
Middle Deer River and also in the barge canal, although in reduced
numbers. In the summer, brown shrimp are replaced by white shrimp
(£. setiferus) in Deer River, but white shrimp never appear in the barge
canal.
Composition of trawl catches in Deer River and the barge canal is
similar to that for other parts of Mobile Bay. Anchovies (Anchoae
mitchilli), menhaden (Brevoortia patronus), spots (Leiostomus xanthurus).
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ECOLOGY (PLANT SITE)
and Atlantic croakers (Mlcropogon undulatus) are also abundant through-
out Mobile Bay (Swingle, 1971) and have high commercial importance
(Chermock, 1974). Mullet and blue crabs are other commercially impor-
tant species common at the plant site (Environmental Science and Engi-
neering, 1977), but gar and abundant killifishes were also observed.
A 5-hectare (12-acre) oyster reef exists north of the site at Hollingers
Island (May, 1971). Most of the oysters immediately south of the canal
were removed in 1967, in response to plans for expansion of the canal,
and no surveys have since been conducted. Pollution forces periodic
closure of all reefs in Alabama (May, 1972); and most of northern Mobile
Bay, including the area of Deer River, is permanently closed to shell-
fishing (U.S. Army Corps of Engineers, Mobile District, 1977).
In summary, available data suggest that the aquatic fauna of Deer River
is comparable to that of other marshy creeks bordering Mobile Bay. The
barge canal has a reduced fauna, largely because low flow rates relative
to depth and inadequate mixing result in stagnation and oxygen depletion
during the summer.
RELEVANT PROJECT CHARACTERISTICS
In the proposed plant layout, about 34.4 hectares (85 acres) of the
70.8-hectare (175-acre) property will be developed. The land north of
the North Fork Deer River, the brackish marsh, most of the freshwater
marsh, and a 90-meter (300-foot) wide greenbelt along the southeastern
boundary will not be developed. Along the entire waterfront boundary,
dredging will be performed to provide a depth of up to 12 meters
(40 feet) below msl. A plant access corridor for a 2-lane road and
railroad trestle will parallel the western property line and be about
47.2 meters (155 feet) wide. This corridor will disturb about 0.5 hec-
tares (1.2 acres) of wetlands. The roadway will cross the North Fork
Deer River with a 15-meter (50-foot) bridge and will fill in about
0.2 hectare (0.5 acre) of the 3.0-hectare (7.3-acre) freshwater marsh.
The railroad trestle will consist of twenty 9-meter (28-foot) spans and
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ECOLOGY (PLANT SITE)
will cross the river and entire wetlands. The stormwater catchment area
will be formed just outside the southern edge of the freshwater marsh
and the plant site will be graded to drain into this area. The proposed
project will increase the volume of both waterway traffic and highway
traffic in the vicinity of the plant site.
IMPACTS
The landclearing of the modified longleaf pine forest represents a loss
of about 50 percent of the trees on the property, but this action is
considered of low magnitude due to the early successional state and dis-
turbed condition of the remnant forest. This impact will be of low sig-
nificance in the area, but long-term, irreversible, and unavoidable.
In relation to wildlife, these activities will eliminate habitat and
displace animals from the developed portion of the property. Due to the
commonness of the habitat and the wildlife populations throughout the
surrounding area, the loss is considered of low magnitude and signifi-
cance, but it is a long-term, irreversible impact. Reducing the
possible habitat of the 11 animals and 14 plants of special status is
considered an impact of low magnitude since there is a low probability
of these species occurring on the site. This impact is of low signifi-
cance because of the availability of similar habitat in the area and is
long-term and irreversible.
The ecological impacts of disturbing the wetlands are the loss of pos-
sible habitat for the river frog (special concern status) and the suit-
able habitat for the nutria and other marsh-associated species. Both
impacts are of low magnitude and significance since there is a low prob-
ability of the river frog on-site and due to the small area involved.
These impacts will be long-term and irreversible.
The other construction impacts of dredging, noise, oil spills, and
stormwater discharges are also considered of low magnitude and signifi-
cance. Dredging effects will be minimal due to the small area involved
and the relationship of the area to the ship channel project. Noise
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ECOLOGY (PLANT SITE)
will affect only the undeveloped area and remaining wildlife. An oil
spill during construction is of very low probability and an oil spill
would involve only small quantities from construction equipment or a
bermed fueling area. Prior to construction of the stormwater catchment
area, runoff will be slowed by use of temporary berms or ditches and
some settling will probably occur in a small area of the marsh. All of
these impacts are considered short-term and reversible.
The discharge of storm water after collection in the catchment area will
continue during plant operations and will be a long-term and reversible
impact. Because the system will reduce the solids content of the run-
off, the impact on the marsh will be of low magnitude and significance.
This impact is avoidable by discharging the runoff to the ship channel.
The discharge of the industrial wastewater from the settling basin is
not expected to have serious ecological impacts. A basic fish bioassay
has shown the runoff from the storage piles to be non-toxic, and any
algicide to be used in the cooling tower system must be approved by EPA
prior to use. Therefore, the magnitude of the wastewater discharge to
the ship channel will be low. The significance is also low in compari-
son to the water quality of the channel. Any effects from the discharge
will be long-term and reversible.
Since there will be an aboveground fuel oil tank on the site, an oil
spill or tank rupture is possible. However, the capacity of the tank,
380,000 liters (100,000 gallons), will be fully contained in a sur-
rounding berm if a tank failure occurs. The site drainage is to the
stormwater catchment area; therefore an oil spill at the plant site
would be collected in this area and would not enter the wetland area.
The magnitude of a spill is considered low due to the safeguards to be
used. The impact of a spill should be of low significance, short-term,
and reversible.
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ECOLOGY (PLANT SITE)
MITIGATING MEASURES
The environmental safeguards affecting ecological conditions at the
plant site will include all of the measures already discussed to mini-
mize sedimentation, water pollutant emissions, air pollutant emissions,
and noise.
It is significant that only about one-half of the land area owned by
Ideal Basic Industries will be cleared and developed as part of the
project. During construction, precautions will be taken so that the
marshes and other preservation areas will not be disturbed unnecessarily
by heavy equipment operation.
The ecological impacts are typically unavoidable and do not have pos-
sible additional actions for mitigation.
ALTERNATIVES
The 1992 ecological condition of the property under the no-action alter-
native is expected to be similar to existing baseline conditions.
If the proposed cement manufacturing facility were not constructed,
there would be no immediate loss of upland vegetation or habitat for
terrestrial species. Habitat characteristics would change gradually,
however, as succession proceeds. Mature pine forests would replace the
existing scrub vegetation, and the area would ultimately develop as a
mixed deciduous woodland. The populations of many animal species would
decline moderately from present levels.
By 1992, without the proposed cement plant in operation, the cumulative
effects of the many pollutants presently released into North Fork Deer
River could lead to a deterioration of the river and marshes. However,
barring any further developments affecting the river or barge canal, it
is expected that the aquatic fauna in 1992 will be similar to existing
fauna. Alternative use of the Ideal property could involve other eco-
logical impacts.
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ECOLOGY (PLANT SITE)
Because of the secondary and unavoidable nature of the ecological
Impacts, the alternative actions deal only with specific placement of
roadways and facilities. (The stormwater discharge to the freshwater
marsh is avoidable, and relevant alternatives are discussed in the Water
Resources/Geotechnical section.)
From a practical viewpoint, the facility will be located in the optimum
portion of the property, i.e., out of the wetlands and along the ship
channel. Alternative access corridors could be from Airco's access
roadway (west), from Dauphin Island Parkway across North Fork Deer River
and the adjacent wetlands (north), or from Dauphin Island Parkway south
of the river and wetlands (east). Another alternative is the total
bridging of the wetlands by both road and railways.
Using Airco's access roadway to cross the river and wetlands would alle-
viate the portion of the disturbance of the wetlands due to the access
road and bridge (but not the railroad trestle). However, one access
road for two separate industrial facilities has some undesirable
aspects; e.g., problems of a strike at one plant closing the other
plant, liability, security requirements, ownership rights, etc. The
action is not considered a practical alternative due to the magnitude of
these problems.
The alternative access route that would cross the wetlands at another
location would not decrease the overall impact on the wetlands. Access
from the east would eliminate disturbance of the wetlands bordering the
North Fork Deer River; however, in order to use this route, the state-
owned Dauphin Island Parkway to Island Road and its bridge over the
North Fork Deer River would have to be upgraded to withstand the truck
traffic from the operation of the cement plant. In addition, the
facility layout would have to be redesigned to accommodate this new
access route.
Bridging the entire section of the wetland would reduce the potential
impacts of the use of fill. However, direct sunlight would be
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ECOLOGY (PLANT SITE)
eliminated beneath the structure and would cause some Impacts on the
wetland vegetation.
The proposed action is considered environmentally acceptable. The
alternatives of bridging the entire freshwater marsh and the eastern
entrance from the parkway are also environmentally acceptable but are
not as practical as the proposed action.
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SOCIOECONOMICS (PLANT SITE)
SOCIOECONOMICS
BASELINE CONDITIONS
PRESENT CONDITIONS
The Mobile metropolitan area, consisting of Mobile and Baldwin Counties,
Alabama, had a 1977 population of approximately 414,000 persons. The
mainstays of the area economy are the Port of Alabama and manufacturing
activities linked to the region's natural resources and transportation
facilities. A period of slow growth in the late 1960's, caused by the
phase-out of Brookley Air Force Base, has been followed by rapid
expansion in nearly all sectors of the economy, resulting in population
growth rates between 1.0 and 1.5 percent per year since 1970. With net
in-migration exceeding 1,000 persons per year, the Mobile metropolitan
area has emerged as a locus of economic opportunity for persons living
in south Alabama and neighboring states.
Socioeconomic assessment of the proposed Ideal Basic Industries project
has focused on south Mobile County (census tracts 65 through 73), which
consists roughly of all land in Mobile County located south or southwest
of the Mobile city limit. South Mobile County contains suburban
residential areas, concentrated near the Mobile city limit and along the
Interstate 10/U.S. Route 90 corridor, as well as Theodore Industrial
Park, the fishing village of Bayou La Batre, the Dauphin Island resort
community, and very large areas of agricultural and vacant land. The
population of south Mobile County has increased by more than 4 percent
per year since 1960, reaching approximately 47,400 persons in 1977 (see
Table 5). Although the establishment of Theodore Industrial Park has
had some influence upon population growth in recent years, the most
important factors have been residential amenity and land availability
rather than job opportunities in the suburban area. At present, roughly
25 percent of employed south Mobile County residents work within this
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SOCIOECONOMICS (PLANT SITE)
Table 5. Population of the Mobile Metropolitan Area and Component
Areas, Past and Projected
South Mobile County
1960
1970
1977
1985
1992
2000
Mobile
SMSA*
363,389
376,690
414,000
455,000
476,000
492,000
Mobile
County
314,301
317,308
343,000
380,000
394,000
404,000
Percent of
Number Mobile SMSA
22,846
34,924
47 ,400
57,300
65,400
70,900
6.3
9.3
11.4
12.6
13.7
14.4
* Mobile and Baldwin Counties, Alabama.
Sources: SARPC, 1977.
Environmental Science and Engineering, Inc, 1977.
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SOCIOECONOMICS (PLANT SITE)
area; 40 percent work in Mobile; 20 percent work at the Ingalls shipyard
in Pascagoula, Mississippi; and 15 percent work elsewhere.
The population of south Mobile County is predominantly middle income,
with some relatively affluent communities located near the Mobile city
limit and along the Mobile Bay waterfront. The occupational
distribution of employed persons is similar to that of the Mobile
metropolitan area as a whole, with a substantial mix of blue- collar and
white-collar occupations.
An extremely high proportion of all dwelling units (98 percent) consist
of single-family homes and mobile homes. Over 82 percent of all units
are owner-occupied. Recent residential growth has occurred primarily in
the Till mans Corner area and elsewhere along the I-10/Route 90 corri-
dor. The residential areas closest to the Ideal Basic Industries
property, namely the Hoi lingers Island community and scattered neighbor-
hoods to the south along the Dauphin Island Parkway, have gained popula-
tion at a relatively modest pace. During the 1960's, these residential
areas were heavily oriented toward Brookley Field employees, and thus
were affected very significantly by the Brookley closing.
With the exception of Theodore Industrial Park and the tourist-oriented
facilities at Dauphin Island, there is a relative lack of non-residen-
tial, developed land uses in south Mobile County. Retail trade is
limited primarily to convenience establishments and stores on Route 90
that sell high-bulk items (e.g., cars, furniture). The area's popula-
tion remains heavily dependent upon Mobile for most services. There is
no form of local public transportation outside Mobile.
Population growth in South Mobile County has resulted in greatly
increased demands for public facilities and services. A highly notice-
able effect has been the increase in highway traffic. For example,
traffic counts on U.S. Route 90 between Theodore and the Mobile city
limit rose by 60 to 80 percent between 1970 and 1976, and the comparable
increases for Interstate 10 were 70 to 85 percent. Increased school
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SOCIOECONOMICS (PLANT SITE)
enrollments have created serious problems of overcrowding in south
Mobile County schools. As of 1975, five of the eleven public schools
were operating above classroom capacity, by amounts ranging from 7 per-
cent to 61 percent (SARPC, 1976). No new school buildings have been
constructed in the area since 1975.
Approximately half of all dwelling units in south Mobile County obtain
water from public systems, but only about 10 percent have public sewage.
All public water provided to residential users in south Mobile County is
obtained from local wells. Demand is approaching the capacity of
existing wells in the area near Mobile, but the water authority
presently serving this area is to be taken over by the Board of Water
and Sewer Commissioners of the City of Mobile, which has ample water
supplies. Public sewer service is provided in the Tillmans Corner area
and Theodore Industrial Park by the Board of Water and Sewer
Commissioners of the City of Mobile, and in Bayou La Batre and Dauphin
Island by independent systems. Sewer service in the northern area
(which ties into the Halls Mill and McDuffie Island treatment plants)
and the Bayou La Batre sewer system are being progressively expanded.
The Mobile County governments, including the Boards of Education and
Health, constitute the only forms of local government in south Mobile
County, except for: (1) the City of Bayou La Batre, and (2) the police
jurisdiction of the City of Mobile, which extends 3 miles beyond the
Mobile city limit. The mechanisms of land use control in south Mobile
County are the exercise of subdivision review by the City of Mobile
within the Mobile police jurisdiction, and the building permit
requirements for flood-prone areas established under the Federal Flood
Insurance Program.
FUTURE CONDITIONS
The Mobile metropolitan area population is expected to approach a half
million persons by the year 2000 (see Table 5). A major growth factor
107
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SOCIOECONOMICS (PLANT SITE)
will be the completion of the Tennessee-Tombigbee Waterway, which will
shorten the water distances from Mobile to all points in the United
States interior above Cairo on the Mississippi River. Other factors
will be the continuing industrial investment in Theodore Industrial Park
and elsewhere, and possible large-scale developments related to petro-
leum and natural gas. Population growth in south Mobile county is pro-
jected to continue at a gradually decreasing rate, so that this area
will have roughly 65,400 inhabitants by 1992 and 70,900 residents by the
year 2000.
The most rapid residential growth in south Mobile County will probably
occur in areas south and west of Theodore and in the Hollingers Island
community. Significant development is also expected in the lower
Dauphin Island Parkway corridor (south of Baker Sorrel 1 Road). This
development, which has already begun to occur, will consist of dwellings
oriented specifically toward workers at Theodore Industrial Park.
RELEVANT PROJECT CHARACTERISTICS
Most elements of the proposed Ideal Basic Industries project that relate
to socioeconomic impact have been mentioned earlier in other contexts.
The factors affecting the local economy will include an average employ-
ment of 360 workers at the plant site during the 30-month construction
period, and a total construction payroll of approximately $15,000,000.
Permanent employment of 135 persons at the Theodore plant sites will
generate an annual payroll of approximately $3,000,000 in 1977 dollars
(including fringe benefits). There will also be 50 workers employed in
maritime operations who may or may not be Ideal Basic Industries
employees. Ideal Basic Industries will spend approximately $10,000,000
locally for materials during construction and will purchase a wide
variety of commodities from local suppliers once the plant is in
operation, including transportation, fuels, electric power, water and
sewer service, and equipment repair services.
108
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SOCIOECONOMICS (PLANT SITE)
The project will generate substantial volumes of waterway and highway
traffic. Construction activity will be responsible for approximately
900 trips per day on the average, with a peak of about 1,750 trips per
day (referring always to one-way rather than round trips). Most
vehicles departing from the plant site during construction will either
travel east on Island Road (Hamilton Blvd.) to reach Dauphin Island
Parkway or west on Island Road to reach U.S. 90 and Interstate 10. Soon
after the plant is in operation, Rangeline Expressway should be
completed and should serve as the primary access route. The highway
traffic generated after the plant is in operation will include roughly
250 auto trips per day (on a 7-day per week basis) and an average of
150 truck trips per weekday. With regard to waterborne traffic on the
ship channel and nearby waterways, the Ideal Basic Industries project
will generate 0.5 to 1.5 trips per day for cement shipment; close to 2
trips per day for delivery of limestone; and an unknown, but much
smaller, number of trips for delivery of other raw materials. Each trip
refers to the arrival or departure of a tug/barge tow or possibly some
other type of deep-draft vessel.
IMPACTS
The construction phase of the proposed Ideal Basic Industries project
will have positive economic impacts of high magnitude and moderate
significance. When indirect effects are taken into account, the overall
economic impact on the Mobile metropolitan area will amount to roughly
1,370 person-years of employment and $30 million in personal income over
the two-year construction period. Although the income benefits of the
project will be dispersed throughout the Mobile area, it is expected
that a total of at least $10 million, or $5 million per year, should
accrue to residents of south Mobile County.
The proposed construction project is not expected to have significant
effects upon the housing market, public facilities, or social conditions
as a result of labor importation. For reasons discussed earlier, the
number of workers at the project who are newcomers to Mobile County
109
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SOCIOECONOMICS (PLANT SITE)
(i.e., outsiders who take up residence for periods exceeding a week at a
time) should not exceed 150 and should average less than 60 over the
duration of the project.
The highway traffic generated by the Ideal construction project will
contribute traffic congestion in the industrial park area. Based upon
the estimates of present traffic volumes, the following increases are
expected:
8.3 percent—Island Road west to Rangeline Road,
1.2 percent—Rangeline Road south,
7.9 percent—Island Road west of Rangeline Road, and
3.6 percent—Island Road east to Dauphin Island Parkway.
The average changes for the entire construction period will be
approximately half these percentages. The magnitude of traffic impact
caused by Ideal's construction is rated moderate, but the significance
is considered low due to the expected highway improvements. This impact
is short-term and reversible.
Permanent operations at the proposed plant will also generate very
positive impacts upon the regional economy. As is typical of
highly-capitalized manufacturing operations, the indirect effects of
Ideal Basic Industries will exceed the direct impacts. A major example
of these indirect effects is that Ideal's purchases from the trucking
industry alone will support close to 75 full-time drivers, exclusive of
support and maintenance personnel. Income received by the cement plant
workers, the related maritime workers, and the employees of firms
providing services to the plant/will be spent and respent within the
local economy and thus will create additional jobs. It is estimated
that the total employment impact of the proposed facility within the
Mobile SMSA will be approximately 500 jobs. This estimate assumes an
employment multiplier of 2.7, applied to the 185 jobs directly created
in cement manufacturing and water transportation. (The economic
analysis of the Port of Mobile by Dunphy and Chiang (1974) assumed a
multiplier of 3.0 for basic employment in the State of Alabama as a
whole.)
110
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SOCIOECONOMICS (PLANT SITE)
The plans for the new facility in Theodore have not assumed necessarily
that the existing Ideal plant in Mobile will shut down. However,
computations of economic impact should consider that the new plant is
likely to accelerate the phase-out of the old plant. The new facility
will employ approximately the same number of persons as the Mobile plant
(depending upon whether or not maritime employees are included), but
will produce three times as much cement. The indirect economic effects
thus will be substantially greater. The total employment generated
directly or indirectly by the proposed Theodore plant is estimated to
exceed by more than 100 workers the corresponding employment effect of
the existing facility. Table 6 indicates the net employment benefits of
the Theodore project under the worst-case assumption that the Mobile
plant will close upon startup of the new facility in 1980, whereas
otherwise the Mobile plant would continue in operation until roughly
1985. (The assumed employment multipliers are 2.5 for the Mobile plant
and 1.9 for the construction project at Theodore.) As shown by the last
two lines of Table 6, the new cement plant will generate roughly
5,500 person-years of employment between 1978 and 1992, on a net basis
under the worst-case assumption. This amounts to an average of 393 jobs
over the 14-year period. The positive economic impacts of the proposed
project are thus considered high in magnitude and moderate in signifi-
cance in the area.
The truck traffic generated by permanent operations at the proposed
cement plant will represent an impact of moderate magnitude and low
significance. About 760 one-way truck trips during a 50-hour work week
are assumed for the operation of the proposed plant. The magnitude of
this impact should decline in 1982, when Rangeline Expressway is
completed north to Interstate 10. This impact is considered long-term
and reversible.
In the near future, traffic conditions in the Theodore Industrial Park
area will be improved by: (1) the widening of Island Road (Hamilton
Blvd.) to three lanes; (2) the completion of Rangeline Expressway;
(3) the improvement of Rangeline Road from Island Road (Hamilton Blvd.)
Ill
-------
Table 6. Gross and Net Employment Attributable to Ideal Basic Industries Under Worst-Case Conditions;
Mobile SMSA
Gross Employment Gener-
ated by Ideal Basic
Industries Operations
Direct Indirect
Net Employment Attributable to
Proposed New Manufacturing Facility
Direct Indirect Total
Comments
ro
Time Interval
1978-1980
(24 months)
1980-1985
1985-1992
510
185
185
Total Man-Years
Average Employment
for 14-Year Forecast
Period
3,240
550
315
315
4,880
360
35
185
2,190
325
90
315
3,305
685
125
500
5,495
393
Construction phase
for new facility;
existing plant in
operation.
New facility 1n
operation; old
plant shut down as
a consequence of
new facility.
Old plant would be
terminated with or
without the new
facility.
Source: Environmental Science and Engineering, Inc., 1977.
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SOCIOECONOM1CS (PLANT SITE)
to Deer River; and (4) the conversion of the Dauphin Island Parkway to
four lanes between Perch Creek and Island Road. These improvements will
minimize the impacts produced by the substantial volume of heavy truck
traffic generated by Ideal. The impact of auto traffic generated by
permanent operations at the plant will be negligible because of the
24-hour-per-day operation and because there will only be about
300 one-way trips per day.
Other transportation requirements of the proposed cement plant are not
expected to involve significant impacts. Rail transportation could be
utilized for delivering up to 270,000 metric tons (300,000 tons) of
materials per year to the Theodore site and for shipping as much as
180,000 metric tons (200,000 tons) per year of finished cement. Rail
traffic to and from the plant site must use a grade crossing of the
State Docks Terminal Railway and Rangeline Road (plus an additional
grade crossing of Island Road if the traffic is northbound). The
potential disruption of highway traffic is considered a very minor
impact, however, since the tonnage figures cited above would imply an
average of only 2 unit trains per week.
Water transportation, which will involve greater tonnages than either
highway or rail transportation, is not expected to have significant
impacts upon the waterway system. Ample dockage space will be provided
to allow efficient use of the waterfront area at the plant site. The
traffic created by the proposed cement plant should be accommodated
without disrupting the other anticipated traffic in the ship channel.
The downriver shipments of limestone, clay, sand, and iron ore will
increase by 5 to 10 percent the total tonnage passing through the Mobile
harbor area and should not create any significant congestion problems.
The construction and operation of the proposed Ideal Basic Industries
manufacturing facility could have both positive and negative effects
upon land value in nearby areas. The positive effects would relate to
employment opportunities at the plant and the general stimulus to
113
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SOCIOECONOMICS (PLANT SITE)
economic growth In the Industrial park area. The negative effects would
Involve dust and noise levels as described in the Air Quality and Noise
sections. The marketability of residences in the area surrounding the
cement plant has been judged to be good because of the demand for hous-
ing from industrial workers. The homes which would be subject to the
greatest impact will be taken for the ship channel project or the land
will probably be converted to industrial use. These takings and con-
versions would occur without the proposed cement plant; therefore, the
impact on land values, although of moderate magnitude to some remaining
residences, 1s considered to be of low significance in the area. These
reversible effects will be short-term during construction and long-term
during the operation of the plant.
MITIGATING MEASURES
An aspect of the construction phase which will minimize social impact
will be the recruitment of local construction workers rather than
utilization of an imported labor force. The feasibility of this policy
is demonstrated by the past success of Ideal's engineering contractor
(Brown & Root, Inc.) in drawing upon the Mobile area labor force for
other local projects. An important action associated with permanent
operations will be the orderly transfer of workers from the existing
Ideal Basic Industries plant in Mobile to the new facility at Theodore.
An environmental safeguard that will minimize effects of construction
and plant operation upon land use, land value, and residential amenity
will be the preservation of a vegetated buffer strip at least 90 meters
(300 feet) wide along the eastern margin of the property and the
20-meter (65-foot) high limestone storage area between the facility and
this greenbelt.
Possible mitigating actions that could be undertaken by Ideal pertain to
traffic impacts; for example, construction shifts and cement deliveries
conceivably could be scheduled to avoid peak-hour traffic flows on
nearby highways.
114
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SOCIOECONOMICS (PLANT SITE)
ALTERNATIVES
The no-action alternative would result in the loss of substantial eco-
nomic benefits to be generated by the cement plant project, with only
marginal gains in terms of avoiding adverse socioeconomic impacts.
Other than the site location alternatives discussed in the Site Selec-
tion section, there are no practical alternatives for the socioeconomic
aspects of the proposed cement plant.
115
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QUARRY SITE
-------
SITE LOCATION/DEVELOPMENT (QUARRY SITE)
QUARRY SITE
LOCATION
The Gaillard tract, proposed as the limestone quarry site, is located on
the Alabama River approximately 180 kilometers (110 river miles) north
of the Theodore plant site. This 1,633-hectare (4,035-acre) tract con-
sists of two land parcels under different ownership (see Figure 18).
The 739-hectare (1,826-acre) northern portion was purchased by Ideal
Basic Industries in 1953 and 1959, and until recently consisted of
timberland. The southern portion of 894 hectares (2,209 acres) is owned
by Mr. Howard McWilliams, a cattle rancher. Recent agreements between
the two owners have allowed Mr. McWilliams to harvest timber and develop
most of the Ideal Basic Industries property as improved pasture, while
Ideal Basic Industries has acquired quarrying rights to the McWilliams
property. The conversion of land to improved pasture, which is already
underway, is an independent action not covered by this Environmental
Impact Statement.
The quarry site is on the eastern bank of the Alabama River in Monroe
County, approximately 5 kilometers (3 miles) southwest of the intersec-
tion of Stockton Road (Monroe County Road No. 1) and U.S. Highway 84
(see Figure 19). The site is very isolated relative to other developed
land uses. Except for a few houses situated along Stockton Road, the
only land uses found within 5 kilometers (3 miles) of the central
portion of the site are agriculture and woodland. The geology of the
area is characterized by layers of limestone overlaid by sand and gravel
deposits of varying thicknesses. The northern portion of the tract is
currently being clear cut and converted to improved pasture, whereas the
southern portion already consists primarily of pasture with a few
planted fields.
On the proposed quarry site, there are four large creeks which flow into
the Alabama River. In descending order from north to south they are:
McGirts Creek, Thompson Mill Creek (also known as MarshalIs Creek),
117
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IDEAL BASIC
INDUSTRIES
PROPERTY
McWILLIAMS
PROPERTY
I RESIDENTIAL
| IMPROVED PASTURE
1 AND CROPLAND
FOREST
I IMPROVED PASTURE
' TRANSITION STATE
1 THINNED HARDWOODS
' AND WOODLAND PASTURE
Figure 18
PRESENT LAND USE IN THE VICINITY OF THE
PROPOSED IDEAL-BASIC INDUSTRIES QUARRY SITE
0 0.5 1
SCALE IN KILOMETERS
SOURCE: Environmental Science and Engineering, Inc., 1977.
118
-------
Figure 19
QUARRY SITE VICINITY
SOURCE: Environmental Science and Engineering, Inc., 1977.
0 5 10
SCALE IN KILOMETERS
REGION IV
U.S. ENVIRONMENTAL PROTECTION
AGENCY ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
PROPOSED GAILLARD QUARRY
MONROE COUNTY, ALABAMA
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SITE LOCATION/DEVELOPMENT (QUARRY SITE)
Hoi linger Creek, and Randons Creek. They are shallow creeks which have
sand and gravel bottoms and flow in a southwest direction.
Bluffs and outcrops occur along the western boundary of the property
adjacent to the river. Relief moderates considerably to the east as
well as north and south of the site.
120
-------
PROJECT DESCRIPTION (QUARRY SITE)
PROJECT DESCRIPTION
CONSTRUCTION
Construction of the limestone quarry facility will last 18 months. The
construction project will cost $12,000,000 in 1977 dollars and will
employ an average of 133 persons, with a peak employment of
250 workers.
About 40 hectares (100 acres) will be cleared initially for construction
of the access road, main buildings, and stockpile area. Approximately
570,000 cubic meters (750,000 cubic yards) of material will be moved
during the grading of the cleared areas. The limestone will be stock-
piled, and most of the overburden (supplemented by clay materials from
several on-site deposits) will be utilized to construct earthen dams for
clarification basins. Final grade will slope toward the clarification
basins. Prior to construction of the basins, temporary measures such as
berming and terracing will be used to control sediment. Roadways and
work areas at the site will be kept moist to suppress dust. Land-
clearing wastes will be disposed by chipping for mulch and/or by pit
burning. Other construction debris will be hauled to the Monroe County
Landfill.
Conveyors and limestone breakers will be set up in the immediate vicin-
ity of the limestone storage area. Construction of the docking facility
will not require dredging, as the depth of the Alabama River in the dock
area is already adequate. The access road to the quarry site will be
surfaced in order to minimize dust emissions and will be constructed
with bridges and culverts to maintain natural drainage of existing
creeks. The project will include construction of a 38,000-liter
(10,000-gallon) underground diesel fuel tank and an underground gasoline
storage tank of approximately 23,000 liters (6,000 gallons).
121
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PROJECT DESCRIPTION (QUARRY SITE)
QUARRYING PROCESS
The proposed quarry will extract 2.4 million metric tons (2.7 million
tons) of limestone (wet basis) per year from an average of 14 hectares
(35 acres) of land. Up to 80 percent of the site can be mined econo-
mically with present quarrying techniques; the recoverable reserves
exceed 136 million metric tons (140 million tons). Thus, the effective
life of the facility is greater than 50 years. The overall quarrying
process will involve the following six types of activities, which are
diagrammed in Figure 20:
1. Overburden removal
2. Quarrying
3. Crushing
4. Storage
5. Barge loading
6. Reclamation.
Soil overburden will be removed by dozers and scrapers in order to
expose the underlying layers of limestone. The overburden will be taken
to storage areas, used directly in land reclamation, or used to con-
struct dams for the clarification basins which will provide stormwater
runoff control. Overburden storage areas will be seeded where practical.
Depending upon the mining sequence chosen, material may accumulate in
these areas for up to 5 years until an equilibrium between mining and
reclamation is reached. Thereafter, quarrying and land reclamation will
proceed at equivalent rates in terms of acreage and the quantities of
overburden handled.
The material quarried will be a combination of Glendon, Marianna, Red
Bluff, and upper Ocala limestones. Limestone deposits vary up to
28 meters (95 feet) in thickness. The limestone will be quarried to a
level just above the bottom of the lower Ocala limestone layer (see
Figure B.G.14 in Appendix B, Baseline). Quarry activities will begin
with the processing of material stockpiled during construction and will
move progressively away from the stockpile area. Dozers with special
122
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1 ) VEGETATION AND OVERBURDEN REMOVAL
2) QUARRYING
3) CRUSHING
4 ) STORAGE
LIMESTONE PILE
5) BARGE LOADING
6) RECLAMATION
Figure 20
STEPS OF PROPOSED QUARRY PROCESS
REGION IV
US ENVIRONMENTAL PROTECTION
AGENCY ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
SOURCE: Environmental Science and Engineering, Inc., 1977.
PROPOSED GAILLARD QUARRY
MONROE COUNTY, ALABAMA
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PROJECT DESCRIPTION (QUARRY SITE)
ripping equipment will be used to loosen the limestone and push it down
slope; blasting is not anticipated. A total of up to 120 hectares
(300 acres) will be involved in active quarrying and overburden storage
at any given time.
The limestone's natural moisture content of 22 percent should reduce
potential fugitive dust emissions during quarrying operations; however,
a dust suppression system is planned. In order to control sedimentation
problems, all stormwater runoff from land affected by quarrying,
overburden storage, or unvegetated reclaimed lands will be directed to
clarification basins. Figure 21 shows the quarry areas and the basins
that could be used during the First 15 years of operation. The basins
will be formed by constructing earthen dams across low-lying areas.
Front-end loaders, rippers, and dozers will convey the limestone to a
portable breaker located near the quarry face, which will reduce the
material to a size less than 15 centimeters (6 inches). The crushed
limestone will be conveyed either to storage or directly to the barge
loading facility. Barge loading (see Figure 22) will be accomplished by
a conveyor with a telescoping boot for control of dust emissions. Every
20.5 hours a set of four barges will leave for the cement plant. Unlike
the quarrying operations, which normally will be limited to a 40-hour
work week, barge loading may require two 8-hour shifts per day in order
to keep pace with the arrival of a new set of barges. On an average
basis, the quarry will supply 7,788 metric tons (8,585 tons) of wet
limestone per day.
RECLAMATION
The objective of the reclamation program will be to grade and vegetate
the area for use as pastureland. The most significant aspects of the
reclamation plan are:
1. Controlling soil erosion;
2. Controlling water runoff;
3. Developing wildlife habitat;
4. Monitoring environmental quality.
124
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CLARIFICATION \
BASIN 4
CLARIFICATION
BASIN 3
QUARRY PLANT
AREA
CLARIFICATION
BASIN 2 —
CLARIFICATION
BASIN 1
III
IV
CLARIFICATION^
X BASIN 5
VII
ACCESS,
VI
Figure 21
MINING AREAS
(FIRST FIFTEEN YEARS)
0 0.5 1
SCALE IN KILOMETERS
SOURCE: Environmental Science and Engineering, Inc., 1977.
REGION IV
US ENVIRONMENTAL PROTECTION
AGENCY ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
PROPOSED GAILLARO QUARRY
MONROE COUNTY, ALABAMA
125
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UNDERGROUND
FUEL TANKS
MAINTENANCE
BUILDING
FLOATING
DOCKS
I
i
BARGES<
CONVEYOR TO
| /BARGES
Figure 22
SCHEMATIC LAYOUT OF WATERFRONT DEVELOPMENT
0 1000
SCALE IN METERS
SOURCE: Brown & Root, Inc., 1977.
REGION IV
U.S. ENVIRONMENTAL PROTECTION
AGENCY ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
PROPOSED GAILLARD QUARRY
MONROE COUNTY, ALABAMA
126
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PROJECT DESCRIPTION (QUARRY SITE)
After the fifth year of quarrying, approximately 14 hectares (35 acres)
will be reclaimed each year. Soil on reclaimed land will be compacted
to ensure soil stability and graded to minimize erosion. Contour
grading will be used on the steeper slopes when necessary. Reclaimed
areas will be seeded and will be drained into clarification basins until
the area is revegetated.
The removal of limestone will lower the land elevations in quarried
areas by an average of 7.6 meters (25 feet), and the cumulative effect
of quarrying and reclamation will be a moderate reduction in land sur-
face gradients. Transitional zones between disturbed and undisturbed
areas will be graded to minimize slope differences, with no slopes
exceeding 3 to 1.
RESOURCE UTILIZATION
Up to 80 percent of the 1,633 hectares (4,035 acres) may be quarried
during the active life of the project. Quarrying will constitute a
temporary use of the land, in that the land will be returned to its
previous use—improved pasture. However, some slope and elevation
characteristics will be altered.
The quarry will have 4.18 kilovolt electric service supplied by the
Alabama Electric Cooperative or the Alabama Power Company and will uti-
lize 3.0 megawatts of electricity. An aboveground transmission system
is planned to be located within the access roadway corridor. Potable
water for sanitary facilities will be supplied by a deep well with a
pumping capacity of 40 liters (10 gallons) per minute. Water for dust
suppression will be obtained from the clarification basins. The quarry
will generate about 1,800 liters (475 gallons) per day of sewage which
will be disposed on site by means of a septic tank and soil absorption
system. Quarry operations will employ a total of 19 persons and will
generate about $400,000 per year in direct salaries. The quarried lime-
stone will be transported to the cement plant at the average rate of
7,788 metric tons (8,585 tons) per day.
127
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PROJECT DESCRIPTION (QUARRY SITE)
TRANSPORTATION
The limestone will be loaded onto barges for transportation down river
to the cement plant. A tow consisting of four barges will leave the
site each day and will follow a seven-day-per-week schedule.
128
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LAND USE (QUARRY SITE)
LAND USE SETTING
PRESENT LAND USE
As shown In Figure 18, the present land use In the vicinity of the
proposed quarry site consists of forested lands, Improved pasture and
croplands, Improved pasture (transitional state), thinned hardwoods, and
woodland pasture. There are several single family residences in the
area, but by comparison to the other land uses, they represent a very
small proportion of the total land area.
Most of the residential units are located along Stockton Road. All
dwellings on this road are at least 1 kilometer (0.6 mile) from the
closest proposed areas which will be quarried during the next 15 years.
The property is presently devoted to agricultural use. Much of the
southern half is improved pasture with some fodder crops. The north-
central portion of the site has been recently cleared and is in the
transitional state to improved pasture. North of this area and along
the bank of the river are thinned hardwoods. Although some of the hard-
wood areas have been harvested more than others, they are all fenced and
accessible to grazing cattle. Improved pasture and croplands are scat-
tered around the perimeter of the property to the north, east, and
south. All other lands within a 2- to 3-kilocneter (1- to 2-mile)
radius of the Ideal property are heavily forested.
FUTURE LAND USE
Present land use trends are expected to prevail in the future (1992),
with most lands in the vicinity remaining predominantly in agricultural
and forest uses.
129
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AIR QUALITY (QUARRY SITE)
AIR QUALITY
BASELINE CONDITIONS
The quarry site Is located in a remote area of western Monroe County
which has very little industrial activity. Several small stationary
air pollution sources are in operation in Monroe County; however, none
of these sources is in the immediate vicinity of the quarry site, and
only very small quantities of particulate matter are emitted. Several
small sources of sulfur dioxide and particulate matter emissions are
located in Clarice County, to the east of the quarry site. None of
these sources is located within 24 kilometers (15 miles) of the site.
Because of the lack of major industrial activity near the quarry site,
ambient sulfur dioxide levels at the quarry site should be near zero.
Ambient total suspended particulate matter (TSP) levels should be
between 20 and 30 ug/m3, approaching natural background levels for
the southeastern United States. Figure 23 plots the suspended particu-
late concentrations at the two ambient air quality monitoring stations
closest.to the quarry site. These are stations located at Evergreen in
Conecuh County and at Grove Hill in Clarke County. No significant pat-
terns are indicated other than relatively low concentrations overall.
In the future, sulfur dioxide and TSP levels at the quarry site will
probably increase slightly due to the influence of the pulp mill being
constructed approximately 11 kilometers (7 miles) north of the site.
RELEVANT PROJECT CHARACTERISTICS
Construction activities such as land clearing, grading, roadway con-
struction, excavation, and other heavy machinery operations, are
potential sources of fugitive dust. Other pollutant sources during
construction are burning of vegetative wastes and vehicular exhausts.
The emission sources associated with permanent quarry operations
130
-------
n
E
3
z
o
H-
cc
^
•
UJ
o
z
0
UJ
0
cc
UJ
0
UJ
o
UJ
0
DC
UJ
<
120-
110-
100-
90-
80-
70-
60-
50-
40-
30-
20-
10-
PRIMARY STANDA
SECONDARY STAND
•••••••••••••••••••••••••••••••••••••••••I
GROVE HILL
<^ ^*"^^^^^™c^^
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1972 1973 1974 197S
YEAR
I •••••••••••
1976
1977
Figure 23
TRENDS IN AMBIENT TOTAL SUSPENDED PARTICULATE
MATTER CONCENTRATIONS. RURAL ALABAMA IN THE
REGION OF THE PROPOSED IDEAL QUARRY SITE,
1972-1977
SOURCE. Alabama Air Pollution Control Commission, 1978.
REGION IV
US. ENVIRONMENTAL PROTECTION
AGENCY ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
PROPOSED GAILLARD QUARRY
MONROE COUNTY, ALABAMA
131
-------
AIR (QUARRY SITE)
include the processes of quarrying, crushing, conveying, storing, and
loading of limestone. As at the plant site, effective methods of fugi-
tive dust control, such as water sprays, will be utilized during both
construction and operations.
IMPACTS
Construction activities at the proposed quarry site are expected to
have short-term air quality impacts in the immediate vicinity of the
area being developed. The major effects will be fugitive dust from
clearing activities and smoke from burning of land-clearing wastes.
Levels of suspended particulate matter are expected to increase;
however, Ambient Air Quality Standards should not be exceeded. These
impacts are rated low in magnitude and significance because of their
short-term, reversible nature and the isolation of the construction
area from sensitive land uses. The impact of burning is considered
avoidable since other means of disposal are available.
In evaluating the air quality impacts of permanent operations, a dis-
tinction is drawn between dust emissions from the quarrying areas and
emissions from the other areas (i.e., breakers, conveyors, stockpile,
and barge loader). Water sprays can be utilized effectively in the
latter case, but not in the quarry areas. Therefore, the magnitude of
air quality impacts is rated as moderate for quarrying activities and
low for other activities at the site. Significance is considered to be
low in both cases due to the lack of receptors, i.e.» the isolation of
the area. The impacts will be long-term (life of the quarry) but
reversible.
It appears that the PSD requirements will not be applicable to the
quarry operations because the potential emissions are less than 227
metric tons (250 tons per year). A review of the air permit
applications should be completed prior to conducting the public hearing
for this project. If the PSD requirements are determined to be
applicable, it is expected that the associated impacts on air quality
and the selection of control equipment will not be significantly
different than those stated in this document.
132
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AIR (QUARRY SITE)
MITIGATING MEASURES
Aside from the effects of burning during construction, the important
air quality impact associated with the proposed quarry is the emission
of fugitive dust. The inherent moisture content of the wet limestone
rock to be quarried will reduce significantly the potential fugitive
dust emissions. In addition, the use of water sprays and the use of
"boot" type loaders at the barge loading facility will lessen fugitive
dust impacts in the local area. The surfacing of the access road will
limit fugitive dust emissions from that source. The disturbed but
non-active areas will be revegetated to reduce the amount of area with
a dust-generation potential.
The adverse effects of burning will be reduced by conducting this
activity only during periods of favorable atmospheric dispersion. The
use of an air-blower type pit burner will burn the materials more effi-
ciently and with less smoke than typical open burning. Chipping of
some of the wastes for mulch will reduce the amount of material to be
burned.
Mitigating measures that could be taken during construction and
operation are the use of chemical stabilizers and wind breaks to
decrease fugitive dust emissions. These measures are appropriate to
use in inactive areas but are not practical for use in the quarry
areas.
ALTERNATIVES
The expected air quality levels in the area in 1992 (the no-action
alternative) should be similar to present conditions, with a possible
slight increase in particulate matter and sulfur dioxide from the
Parsons and Whittemore pulp mill. The alternative actions related to
air quality impacts are landfilling vegetative wastes either on-site or
at the Monroe County Landfill and enclosing and venting conveyors to a
particulate matter control device (baghouse).
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AIR (QUARRY SITE)
Landfill ing of the wastes would eliminate the expected smoke emissions.
However, on-site burial would disturb additional land areas and would
create an unstable surface contour due to the decomposition of the
waste. This area would not be stable and could not be used for
pastureland. Hauling the wastes to the Monroe County Landfill would
involve approximately an 80-kilometer (50-mile) round trip per load,
and access on-site during the first few months of construction might be
a problem.
Enclosing conveyors and treating dust emissions would achieve a higher
degree of removal than water sprays, but their costs would not be
warranted since the impact of the proposed system is already considered
low.
The proposed actions are considered to be environmentally acceptable
and more practical than the alternatives.
134
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NOISE (QUARRY SITE)
NOISE
BASELINE CONDITIONS
The proposed quarry site Is an uninhabited tract of land that Is being
progressively converted from forest to improved pasture. The only
noise sources are wildlife, natural phenomena such as wind and water,
infrequent river traffic, and a light-duty public road that crosses the
extreme eastern section of the tract. Noise was monitored at three
stations in the southern, central, and northeastern portions of the
site (shown on Figure 24). The levels monitored were low and related
to the natural phenomena mentioned above. These measured noise levels
probably would not increase in the future (by 1992) without the
proposed quarry operation.
RELEVANT PROJECT CHARACTERISTICS
Noise during quarry construction will originate from earthmoving and
building of structures, conveyors, improvement of docking facilities,
roads, and clarification basins. Noise will also be generated by
commuter traffic of the construction workers.
For purposes of projecting noise levels at the quarry site, the effects
of the equipment were combined into nine large theoretical point
sources (see Figure 24 for projected noise levels).
Operational noise from the quarry will originate primarily from the
removal of overburden, quarrying, limestone handling, and barge
loading. Automobile commuter traffic to and from the quarry site and
tugboat traffic due to movement of the limestone barges will be addi-
tional noise sources. However, the primary source of operational noise
will be the equipment used in the active quarry areas. Figure 25
projects the boundary of the 55 dBA sound contour expected during the
first 15 years of operations.
135
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(7) RANDONS CREEK
2 EAST OF QUARRY SITE
NORTH OF QUARRY SITE
Figure 24
EQUAL SOUND LEVEL (Ldn) CONTOURS SURROUNDING
THE QUARRY SITE DURING CONSTRUCTION ACTIVITIES
0 0.5 1
SCALE IN KILOMETERS
SOURCE: Environmental Science and Engineering, Inc., 1977.
REGION IV
U.S. ENVIRONMENTAL PROTECTION
AGENCY ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
PROPOSED GAILLARD QUARRY
MONROE COUNTY, ALABAMA
136
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Figure 25
ESTIMATED BOUNDARY OF SOUND LEVEL, Lrfn of
55 DECIBELS. SURROUNDING THE QUARRY SITE
DURING OPERATION ^^^ES^^^S
0 0.5 1
SCALE IN KILOMETERS
SOURCE: Environmental Science and Engineering, Inc., 1977.
REGION IV
U.S. ENVIRONMENTAL PROTECTION
AGENCY ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
PROPOSED GAILLARD QUARRY
MONROE COUNTY, ALABAMA
137
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NOISE (QUARRY SITE)
IMPACTS
The sphere of noise influence due to quarry construction extends some-
what less than 1 kilometer (0.6 mile) from the construction area, with
somewhat greater noise transmission to the west than elsewhere because
the river does not attenuate noise levels. The only off-site effects
will involve the land directly across the river from the quarry site,
which is an uninhabited floodplain area. The noise impacts of
construction are considered low in magnitude and significance,
short-term and reversible.
The sphere of noise influence due to initial quarrying operations will
be similar to the noise impacts during construction. However, the zone
of influence will migrate along with quarry operations, rather than re-
maining centered near the river. No existing residences are projected
to be impacted by a noise level greater than 55 dBA from the quarrying
activities. Therefore, the magnitude and significance of noise impacts
during permanent operations will be low. Impacts will be long-term but
reversible.
MITIGATING MEASURES
Equipment with noise suppression systems, complying with the Walsh-
Mealy Act and the requirements of the Occupational Safety and Health
Administration (OSHA) and the Mining Enforcement and Safety Administra-
tion (MESA) will be used. There are no feasible mitigating measures
that would reduce noise levels at the quarry site.
ALTERNATIVES
If the quarry is not constructed (the no-action alternative), the 1992
noise levels at the site should be similar to present conditions.
There are no practical alternatives related to noise generation during
construction and quarrying activities.
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SOLID WASTE (QUARRY SITE)
SOLID WASTE
BASELINE CONDITIONS
Only one approved sanitary landfill exists In Monroe County. The site
is located near Monroeville and handles putrescible, non-putrescible,
and bulky wastes. The site, which is approximately 10 hectares
(25 acres) in area, operates a multi-lift system of disposal. The site,
which has been in operation since 1972, has an estimated 2 to 3 years of
capacity remaining. The county plans to use surrounding property for
future operations once the present site is depleted. Since the area is
rural, there is adequate land for well over 15 years use. Burning of
land-clearing wastes is permitted by the Alabama Air Pollution Control
Commission.
RELEVANT PROJECT CHARACTERISTICS
Solid wastes will be generated during the following phases of quarry
construction: land clearing, grading, and erection of structures and
equipment. Approximately 40 hectares (100 acres) will be cleared for
the access road, main building, and stockpile area. The vegetative
wastes, consisting of trees and undergrowth, will be chipped for mulch
and/or burned. The amount of wastes that will be chipped will depend on
the size of the pieces and the related time and expenses. The burning
will be performed in an air-blower type pit burner and conducted only
during favorable dispersion conditions. Grading of the cleared areas
will involve moving 570,000 cubic meters (750,000 cubic yards) of over-
burden and limestone. Most of the removed material will be used for
construction of clarification basin dams and roadways, or stockpiled to
supply limestone for initial crushing operations. The remaining over-
burden will be stored for later reclamation use. Construction debris
from the erection of structures and buildings, consisting of lumber,
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SOLID WASTE (QUARRY SITE)
concrete, paper wastes, and metal scraps, will be disposed off-site in
the Monroe County Landfill.
Operation of the proposed quarry is expected to generate 137 metric tons
(151 tons) of solid waste per year. About 2.5 metric tons (2.7 tons) of
paper and lunchroom waste will be disposed off-site at the county
sanitary landfill. Another 1.7 metric tons (1.8 tons) will consist of
wastes from the equipment maintenance shop. The oil and metal wastes
will be separated and sold for recycling. The remainder of this waste
will be taken to the county landfill. The majority of the solid waste
[132 metric tons (146 tons)] will consist of settled soil and rock
particles that have been removed from the clarification basins in order
to maintain capacities. This sediment will be used for reclamation.
IMPACTS
The impacts of burning of vegetative waste are discussed in the Air
Quality section. Disposal of construction debris at the Monroe County
Landfill should not have undesirable effects except to deplete slightly
the available life of the landfill. These impacts are rated low in
magnitude and significance, long-term, reversible, and avoidable.
No major impacts are expected to result from disposal of the solid
wastes generated during quarry operation. The use of sediment from the
settling basins is consistent with the other reclamation activities and
should have a negligible impact. An advantage of disposal at the county
site is that landfill ing will be performed by a qualified staff working
with quantities of other wastes large enough to promote proper disposal
techniques. The overall magnitude and significance of solid waste
disposal impacts during permanent operations are expected to be low.
The impact is considered long-term but reversible since the land could
be reclaimed to other land uses.
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SOLID WASTE (QUARRY SITE)
MITIGATING MEASURES
No mitigating measures for solid waste disposal have been Identified.
ALTERNATIVES
The alternative of not constructing and operating the quarry would
increase slightly the effective life of the county landfill area. No
significant differences are expected.
Landfill ing, which is the alternative action for chipping and/or burning
of the vegetative wastes, is discussed in the Air Quality section.
The solid wastes generated during construction and permanent operations
at the quarry could be disposed at an on-site landfill area rather than
the county-approved landfill. Because of the large size of the quarry
tract, a suitable disposal area could be found, and ecological problems
are not expected. However, it is not considered very practical for
Ideal Basic Industries to maintain an on-site landfill. The commitment
of heavy equipment and labor necessary for proper operation of a
sanitary landfill would be excessive given the required disposal of only
4.2 metric tons (4.5 tons) of office, lunchroom, and maintenance wastes
per year.
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WATER RESOURCES/GEOTECHNICAL (QUARRY SITE)
WATER RESOURCES AND GEOTECHNICAL ASPECTS
BASELINE CONDITIONS
The Alabama River is formed by the juncture of the Coosa and Tallapoosa
rivers near Montgomery, Alabama, and flows southwest across the state to
join eventually the Tombigbee River and form the Mobile River. The
closest river gage to the proposed quarry site is 37 kilometers
(23 miles) upstream at the Claiborne Lock and Dam. The Alabama River
drains approximately 57,000 square kilometers (22,000 square miles) at
this point and has an annual average discharge of 921 cubic meters per
second (32,540 cubic feet per second). The flow regime of the river is
marked by extreme variability. The recorded maximum and minimum dis-
charges differ by a factor of more than 50, and water surface elevations
at the quarry site can vary as much as 10 meters (30 feet) within a
single year.
Present freight traffic on the Alabama-Coosa river system consists
largely of sand and gravel shipments originating in the lower reaches of
the river. The 1976 traffic through the Claiborne Lock and Dam, which
should reflect conditions at the quarry site, included an average of
only one barge tow and 2.5 other vessels passing either up or down per
day.
The proposed quarry site is situated along the outside of a meander on
the east side of the Alabama River. Elevations on the property range
from 3 meters (10 feet) above mean sea level to over 60 meters
(200 feet), with the greatest relief occurring in the area near the
river. Surface drainage of the site is generally southwest to the river
by way of McGirts Creek, Thompson Mill Creek (Marshalls Creek), Hoi-
linger Creek, Randons Creek, and four small intermittent watercourses
designated as Alabama River Tributaries 1, 2, 3, and 4 (see Figure 26).
142
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—— QUARRY PROPERTY BOUNDARY ^'
_ WATERSHED BOUNDARY
STREAM
1 INTERMITTENT STREAM
\S
Figure 26
WATERSHED MAP: McGIRTS CREEK, THOMPSON MILL CREEK, HOLLINGER CREEK,
RANDOMS CREEK, ALABAMA TRIBUTARIES 1, 2, 3, AND 4
SOURCE: Environmental Science and Engineering, Inc., 1977.
0 2
SCALE IN KILOMETERS
REGION IV
U.S. ENVIRONMENTAL PROTECTION
AGENCY ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
PROPOSED GAILLARD QUARRY
MONROE COUNTY, ALABAMA
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WATER RESOURCES/GEOTECHNICAL (QUARRY SITE)
Thompson Mill (MarshalIs) Creek has an overall drainage area of
1,777 hectares (4,392 acres), which includes 385 hectares (952 acres) in
the northern area of the proposed quarry site. A substantial portion of
this land Is being timbered and cleared for pastureland. The streambed
of Thompson Mill Creek within the quarry site is characterized by a
relatively steep gradient (0.97 percent), a substrate of gravel and
limerock, perennial flow, and very steep banks.
Hoi linger Creek has a smaller overall drainage area [874 hectares
(2,160 acres)] than Thompson Mill Creek, but drains a larger portion of
the proposed quarry site [592 hectares (1,462 acres)]. Present land use
in the watershed consists primarily of pastureland, with ongoing con-
versions of timberland to improved pasture. Relative to Thompson Mill
Creek, Hoilinger Creek has a somewhat lower channel gradient, more
fine-grained bed material, a lower base flow, and a wider floodplain
near the Alabama River.
Randons Creek is much larger than the streams just mentioned in terms of
drainage area [14,324 hectares (35,394 acres)]. Only 4 percent of the
watershed [506 hectares (1,251 acres)] is located within the quarry
site, so that conditions in Randons Creek can be affected to only a
limited degree by land use and land management in this area. The domi-
nant influences in the watershed are agricultural land and urban land
located to the east. Randons Creek has a lower channel slope, a much
wider floodplain, and a bed containing more silt and sand than either
Thompson Mill Creek or Hoilinger Creek.
McGirts Creek is an intermittent creek which flows in a southwesterly
direction into the Alabama River. Part of the creek forms the northern
boundary of the property. The area of the McGirts Creek watershed is
approximately 161 hectares (397 acres); however, only 30 hectares
(73 acres) are within Ideal's property. This area is primarily in
native woodland.
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WATER RESOURCES/GEOTECHNICAL (QUARRY SITE)
Alabama Tributaries 1, 2, 3, and 4 are located adjacent to the Alabama
River between McGlrts Creek and Hoi linger Creek, and have drainage areas
of 17, 42, 27, and 34 hectares (42, 104, 68, and 84 acres),
respectively. These basins are characterized by steep land slopes,
poorly-defined watercourses, and intermittent flows.
Water quality conditions in the Alabama River and the three major
streams on the quarry site have been surveyed as part of the present
study. There is no evidence of serious water quality problems in the
Alabama River other than high levels of suspended solids and turbidity,
which are both influenced by seasonality, rainfall, and the agricultural
cycle.
At base flow, Thompson Mill (MarshalIs) Creek is low in turbidity, sus-
pended solids, nutrients, and organics, but moderately high in hardness,
alkalinity, and nitrate-nitrite. The latter characteristics are typical
of waters that have extensive contact with limestone formations. The
low chlorophyll <± values, high dissolved oxygen, and moderate water
temperatures observed in Thompson Mill Creek are indicative of a water
body that is relatively uninfluenced by human activities. Water quality
in Hoi linger Creek at low flow has been found similar to Thompson Mill
Creek, with the exception that nitrate concentrations are substantially
lower and Kjeldahl nitrogen is higher. Thus, there appear to be no
significant dry-weather sources of organic pollution. Water tempera-
tures, which are higher than in Thompson Mill Creek, reflect a lack of
tree canopy over sections of the streambed where pasture has been devel-
oped. Water quality in Randons Creek differs from the other two major
streams in that alkalinity, hardness, conductivity, total dissolved
solids, and pH are all substantially lower because of less limestone
influence on the stream water. Turbidity, suspended solids, and color
are relatively high in Randons Creek, but no other water quality
problems have been documented.
Some water quality deterioration in these streams can be expected to
occur in the future. In the case of Thompson Mill and Hoi linger creeks,
145
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WATER RESOURCES/GEOTECHNICAL (QUARRY SITE)
the changes would be due primarily to land clearance, pasture develop-
ment, and Increased stock loading. Turbidity, suspended solids
concentrations, and sedimentation of the stream channel would be
Increased In the short run, but eventually would decline as land condi-
tions stabilized. Nutrient enrichment would occur as a result of cattle
grazing and fertilizer application, and there would be increased load-
ings of organic material during storm events.
GEOTECHNICAL CHARACTERISTICS
The geologic formations encountered at the proposed quarry site range
from Yazoo Clay at the base through various Eocene and Oligocene lime-
stones, to Pliocene or Pleistocene sands and clays with various soil
layers. The formations of economic importance, yielding limestones of
commercially acceptable quality, include the upper member of the Ocala
Limestone, the Red Bluff Clay, the Marianna Limestone, and the Byram
Formation. The complete limestone section was originally about
28 meters (95 feet) thick but has weathered to an irregular surface with
varying thicknesses.
The overburden materials (Citronelle Formation and high terrace
deposits) are composed of sand, clay, topsoil, and other materials
varying in thickness from 0 to 33 meters (110 feet). The overburden is
thickest in upland areas and thin or non-existent on the steep slopes
near the river.
Several aquifer systems of local importance occur at the quarry site,
including the Citronelle and Marianna formations, as well as various
Eocene and pre-Eocene units underlying the Yazoo Clay. The Citronelle
Formation has relatively low permeability and is discontinuous in
extent. The limestone units are high in permeability as a result of
solution channeling. Thus, it is likely that the water level in the
limestone aquifer system is drawn down near the Yazoo Clay (an imperme-
able layer) for some distance from the river. This system is actively
discharging into the creeks and river. The 14 wells identified near the
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WATER RESOURCES/GEOTECHNICAL (QUARRY SITE)
quarry site are either water table wells obtaining water from the sur-
ficial sands, or artesian wells tapping the Lisbon Formation and/or
Gosport Sand below the Yazoo Clay. None of the wells surveyed obtained
water from the limestone formations.
RELEVANT PROJECT CHARACTERISTICS
The proposed quarry operations will be confined during the first
15 years primarily to the 739-hectare (1,826-acre) northern property
owned by Ideal Basic Industries. The construction phase of the project,
lasting 18 months, will begin with construction of an all-weather access
road to the loading and storage site at the Alabama River, followed by
construction of clarification basins 1, 2, and 5 (basins 3 and 4 will be
constructed at a later time if they are needed). Clearing and earthwork
will be conducted on the loading and storage site, which will involve
grading a plateau at an elevation of 21 meters (70 feet). The excavated
material will be stockpiled for limestone supply, used as fill in
constructing dams, or moved to the Milkhouse Branch (a tributary of
Thompson Mill Creek) overburden storage area.
A free-standing mooring structure approximately 194 meters (636 feet)
long will be built in the Alabama River so that barges can be secured
for loading. Dredging in the river is not anticipated due to sufficient
existing depths.
The project will also include a deep well, septic tank with soil
absorption system, a 38,000-liter (10,000-gallon) underground fuel oil
tank, and a 23,000-liter (6,000-gallon) underground gasoline storage
tank.
The mining operations will work away from the limestone storage area.
There will be several active quarry areas and at least two active faces
at any given time. Where possible, overburden will not be moved twice,
but instead will be placed in previously quarried areas as a "haulback"
operation (see Figure 27). Overburden which cannot be utilized
147
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YAZOO CLAY
LOWER OCALA LIMESTONE
——^^_
DRAINAGE DITCH
CONVEYOR
TEMPORARY ACCESS ROAD
PAN SCRAPER
-fa
00
DRAWINGS NOT TO SCALE
PAN SCRAPER
..*•'.••§.•• § * ?• • •
' I ' f' I "I ' -"H-^J^-
LOWER OCALA LIMESTONE
Figure 27
CROSS SECTIONS OF A TYPICAL QUARRYING AREA
SOURCE: Environmental Science and Engineering, Inc., 1977.
YAZOO CLAY
TOPSOIL
OVERBURDEN
LIMESTONE
RECLAIMED LAND AND LAND
IN THE PROCESS OF RECLAMATION
PROPOSED GAILLARD QUARRY
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WATER RESOURCES/GEOTECHNICAL (QUARRY SITE)
Immediately in this fashion will be conveyed to the Milkhouse Branch
watershed for long-term or permanent storage. Topsoil will be stock-
piled for up to 5 years at locations where it can be preserved until the
receiving areas have been brought up to grade. All topsoil and other
stockpiled materials will be graded and seeded to resist erosion until
they are used in the reclamation program.
Control of surface runoff from areas affected by mining and reclamation
is required by both EPA and the Alabama Water Improvement Commission
(AWIC). These requirements will be met by the construction of the
clarification basins to treat the runoff from all areas disturbed by
storage, mining, and reclamation activities (see Permit and Approval
section).
The capacities will be sufficient to store the runoff from all disturbed
areas during a 10-year, 24-hour storm event. A settleability study per-
formed on the natural soils and limestones found at the quarry site has
indicated that the suspended solids concentration of basin effluent will
be less than the standard of 30 milligrams per liter, if the detention
time is maintained at 24 hours or greater.
In addition to clarification basins, the erosion controls employed at
the site will include revegetation with chipped mulch and with native
species of grasses, as both a temporary and permanent stabilization
practice; use of contour terracing to reduce velocities of flow across
unvegetated surfaces; and ditches and berms to divert runoff away from
disturbed areas. Also, a 30-meter (100-foot) setback from streambeds
will be maintained for the major creeks and streams.
Land reclamation will involve placement of overburden in thin layers on
the previously quarried areas and compaction of each layer to approxi-
mately natural conditions. When the final grades are reached, topsoil
will be added and compacted, with steps taken if necessary to compensate
for any deterioration of topsoil quality during stockpiling (e.g.,
leaching, loss of micro-organisms). After replacement of soil horizons
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WATER RESOURCES/6EOTECHNICAL (QUARRY SITE)
in a manner to promote revegetation, fertilizer will be added as neces-
sary, and the area will be seeded to the chosen vegetation types. Land
will be returned to improved pasture.
The slope gradients of reclaimed land will not exceed 3 to 1. In
general, the land surface will be more gently sloping and less irregular
than before quarrying. Landforms will be contoured so that there is a
smooth transition from disturbed to undisturbed areas. In the course of
quarrying operations, it will be necessary to change the direction of
surface drainage for some areas. These changes will be due to quarrying
requirements and the need to capture all runoff in clarification basins.
Although natural drainage patterns will be reinstated where possible
during reclamation, there will be a net diversion of surface drainage
from Thompson Mill (MarshalIs) Creek to the Alabama River, amounting to
roughly 10 percent of the on-site land that presently yields surface
runoff to the creek. There may also be some changes in groundwater flow
patterns, but these will be relatively minor.
IMPACTS
The initial clearing, site preparation, and road construction activities
at the proposed quarry will result in erosion of the land surface during
storm events, but sediment transport to surface water bodies will be
limited by the presence of clarification basins. The magnitude of water
resource impacts due to construction site runoff and stockpile runoff is
expected to be low, due to the controls to be implemented. Constructing
the docking facility on the Alabama River will have an impact of low
magnitude because dredging will not be required. The amount of the par-
ti cul ate material cast into suspension by pile driving should be small.
Both of these construction impacts are considered of low significance.
These impacts will be short-term and reversible.
During permanent operations at the quarry site, all stormwater runoff
from disturbed land will be directed to clarification basins for
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WATER RESOURCES/GEOTECHNICAL (QUARRY SITE)
treatment, and there will be erosion/sedimentation controls as discussed
earlier. Because of the proper design of the basins, the total sediment
inputs to Thompson Mill and Hoi linger creeks should not exceed 30 mg/1
except during extreme storm events and should meet the requirements in
the Draft NPDES permit (see the Permit and Approval section). The
erosion/sedimentation impacts of mining and land reclamation are rated
low in both significance and magnitude, long-term but reversible.
Changes in landforms will be irreversible but are not considered signi-
ficant as environmental impacts (low magnitude and significance). The
quarried land will be lowered in elevation by roughly 7.6 meters
(25 feet) on the average, with generally reduced slopes and somewhat
altered drainage patterns. The reclamation procedures described earlier
should leave the land as productive as before, without significant
effects upon water resources or other off-site conditions.
The surficial aquifer system involving the sand/clay layers and perme-
able limestone formations will be disturbed in the immediate vicinity of
active quarrying operations. There should not be appreciable effects
upon the quantity or quality of aquifer discharges to surface waters.
The function of the surficial aquifer will be reinstated as part of land
reclamation. Because of the reduced relief, infiltration may be greater
than before quarrying, leading to more stable base flow of local streams
and reductions in soil loss. The deep aquifer system will not be
affected either by quarrying or by land reclamation, because this system
is isolated from surface conditions by the impermeable Yazoo Clay. The
anticipated impacts will be a localized drawdown in groundwater levels
during active quarrying and possible long-term effects on groundwater
flows due to a change in soil strata. This impact is assigned low
significance and magnitude because it should be confined to areas within
60 meters (200 feet) of each quarry face, and it will not affect wells
in the area. This impact is considered long-term and irreversible.
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WATER RESOURCES/GEOTECHNICAL (QUARRY SITE)
MITIGATING MEASURES
The environmental safeguards employed to lessen water resource Impacts
due to the Ideal Basic Industries quarry project will Include the use of
clarification basins and other sediment controls as described earlier.
Stormwater runoff from,the major sources of sediment (cleared areas,
overburden stockpiles, active quarry areas, and areas being reclaimed)
will comply with effluent standards. The project will be planned to
reduce erosion by minimizing the extent of cleared, unvegetated areas
during both the construction and quarrying phases. Berms, diversion
structures, and contour terracing will be utilized to decrease the
velocity of overland flow and encourage infiltration. The most
important environmental safeguard will be the use of land reclamation
techniques that result in viable soil conditions for rapid
revegetation.
The mitigative measures that could be employed to minimize water
resource impacts would involve even more extensive use of erosion con-
trols such as mulching, seeding, netting, hay bales, sodding, localized
ponding, and vegetated buffer strips.
ALTERNATIVES
The no-action alternative would involve significant short-term
deterioration in water resources at the quarry site, because of the
ongoing land conversion. Moderate improvement would then take place as
land conditions stabilized.
The alternatives to the proposed use of clarification basins are the use
of vegetation buffers or of quarry pits to reduce the solids loading in
the runoff. (These alternative actions could be used alone or could be
used as mitigating measures in addition to the clarification basins.)
Vegetation buffers on the upland and downstream drainage paths could be
used to reduce runoff velocities, stabilize soils, and trap sediment.
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WATER RESOURCES/GEOTECHNICAL (QUARRY SITE)
The vegetation buffers probably would not be as efficient as the clari-
fication basins in controlling the solids levels in the runoff.
The large quarry excavations would be suitable for storing large volumes
of runoff. However, this alternative could not be implemented until
5 or 7 years of quarrying has created a sufficient size pit (assuming no
reclamation activity). The use of quarry depressions for expanding the
water storage capacities of the clarification basins is being studied by
the design consultant.
The proposed use of clarification basins is considered an acceptable
ecological action that will meet effluent requirements.
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ARCHAEOLOGY (QUARRY SITE)
ARCHAEOLOGY
BASELINE CONDITIONS
The archaeological-historical inventory of the Ideal Basic Industries
quarry site included a comprehensive review of historic literature and
previous archaeological surveys in the area. Although none of the pre-
vious surveys or excavations conducted included the Ideal quarry site,
they provided data for predicting the types of sites which might occur
in the area, as well as the chronological framework for the region.
A walk-over surface survey of the site was conducted by the University
of South Alabama. Stream banks, plowed fields, erosional ditches,
recently logged areas, logging roads, and wooded areas were examined for
archaeological/historical sites. A total of 15 sites, 8 archaeological
and 7 historic, were recorded during the survey. Of the 15, two were
determined to merit further investigation—Ideal Site Nos. 6 and 8.
Research and on-site investigations indicated that these sites are of
special archaeological-historical interest. In accordance with the
Ideal Quarry Plan, Site No. 8 will not be disturbed by the quarrying
activities. Site No. 6, however, will probably be disturbed as it is
located in the area expected to be quarried within the first 15 years.
The University of South Alabama Archaeological Lab was contracted to
perform the test excavations and/or salvage operations necessary in
order to receive approval for quarrying activities from the Alabama
Historical Commission. The name of Site No. 6 was changed to Site
No. !Mn57 to conform to the standard system of numbering archaeological
sites in Alabama.
Test excavations revealed that Site !Mn57 is a multi-component site
involving an historic house site, a Mississippian component, a Woodland
component, and an archaic component.
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ARCHAEOLOGY (QUARRY SITE)
The historic component, which was very evident over a large portion of
the site, yielded numerous artifacts (many related to farming activi-
ties) of late 19th to early 20th century origin.
The Mississippian (late prehistoric) component was most obvious in
Feature No. 2. It is less obvious in the area of cultivation with a
few small shell-tempered sherds mixed with sand- and clay-tempered
sherds and many historic artifacts. Evidently, much of the Missis-
sippian component has been destroyed by cultivation and erosion.
The Woodland component is demonstrated by the number of large-stemmed
projectile points, blade tools, sand and sand/clay tempered pottery.
Portions of this component have also been disturbed by cultivation;
however, the majority remains intact.
An archaic (pre-ceramic) component is indicated by the presence of stea-
tite fragments, including a large steatite vessel sherd.
The archaeologist's final report was submitted to the Alabama Historical
Commission in March, 1978, with a complete account of the required test
excavations. Site !Mn57 did not reveal significant archaeological evi-
dence to mandate further investigation, and approval of the Alabama
Historical Commission is pending.
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ECOLOGY (QUARRY SITE)
ECOLOGY
BASELINE CONDITIONS
TERRESTRIAL ECOLOGY
Five major vegetational communities currently exist on the proposed
quarry site: improved pasture and cropland, remnant forest, floodplain,
pine-oak forest, and hardwood bottomland (see Figure 28). The first
vegetational category includes bahia-grass grazing land and fields
planted to row crops and silage, bordered by weedy plant species that
may be important to wildlife. Remnant forests are defined as disturbed
woodland areas surrounded by improved pasture and used by livestock.
These areas are characterized by elevated nutrient loadings, high
insolation, compacted soils, and reduced understory due to grazing.
The Alabama River floodplain, defined by the presence of alluvial soils,
is a relatively small portion of the quarry site extending along the
river bank and into the creek valleys. The floodplain vegetation is
dominated by silver maple, gum, hickories, and ash, and also includes
reed, red maple, titi, and cliftonia. There are cypress along portions
of Hollinger Creek and Randons Creek. Because of a lack of intermediate
age classes for these trees, the Hollinger Creek cypress area is
considered a modified wetland.
Most of the proposed quarry site is essentially upland pine-oak forests
with bottomlands containing hardwood forests. The bottomland hardwood
species are typical of "branch-bottoms," which are defined by Gemborys
(1971) as "alluvial and colluvial areas along small intermittent or
perennial streams." The upland (mesic to xeric) pine-hardwood forest
typically has a loblolly pine overstory which, as described by Quarter-
man and Keever (1962), suppresses the development of a hardwood forest.
Many areas have been opened in the canopy as the result of past and
present agricultural and forestry practices. These activities have
yielded various stages of succession from old field to predominantly
156
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PINE HARDWOODS
HARDWOODS
REMNANT FOREST
3 IMPROVED PASTURE
3 FLOODPLAIN FOREST
-?i FLOODPLAIN FOREST
—J DOMINATED BY CYPRESS
IMPROVED PASTURE r~1 FLOODPLAIN FOREST
TRANSITION STATE WITH MODIFIED CYPRESS
AREAS
THINNED HARDWOODS
ROADS
McWILLIAMS PROPERTY
BOUNDARY
IDEAL BASIC INDUSTRIES
PROPERTY BOUNDARY
Figure 28
VEGETATION MAP OF THE PROPOSED QUARRY SITE
0 O.S 1
SCALE IN KILOMETERS
SOURCE: Environmental Science and Engineering, Inc., 1977,
REGION IV
U.S. ENVIRONMENTAL PROTECTION
AGENCY ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
PROPOSED GAILLARD QUARRY
MONROE COUNTY, ALABAMA
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ECOLOGY (QUARRY SITE)
hardwood areas. The upland forests are composed of cedar, water oak,
and pine with assorted hardwoods. Water oak has the highest Importance
value among the upland stands and is the dominant tree, although it does
not have the highest density.
The understory species on the southeast corner of the property are more
sensitive to changes in soil moisture than the overstory species. Areas
of different species composition can be situated close to one another.
The mesic areas generally contain oak saplings, basswood, hackberry,
dogwood, sweetgum, and hickories, whereas more hydric areas contain
French mulberry, cane, and maples.
Ground cover species include pepper vine, Virginia creeper, poison ivy,
greenbrier, Japanese honeysuckle, oak seedlings, mushrooms, and mosses,
with various grasses also important in open areas. Lianas, such as
grapes and crossvine, were prevalent in the understory of the higher
hardwood areas. The lower stream-side areas generally lacked any lianas
except in the higher strata of the vegetation. Along the river bluffs
there are microclimates characterized by relatively cool air, high
humidity, and low illumination. These areas support luxuriant growths
of ferns.
Many of the animals inhabiting forested areas of the proposed quarry
site are the same as those found in the forested areas of the plant
site; however, there are some exceptions in terms of abundance and
diversity. The forests of the quarry site support a greater abundance
of squirrels and are characterized by the presence of deer and wild
turkey. The hardwood bottomlands and floodplain forest of the quarry
site contain barred owls, hooded warblers, southeastern shrews, cotton-
mouths, southern dusky salamanders -and pickerel frogs, none of which
are present at the plant site. Extensive and active beaver dams have
been found in the lower reaches of Hoi linger Creek. The characteristic
exclusives of the forested area are warblers, chickadees, woodpeckers,
squirrels, tree frogs, and skinks. The ubiquitous types are similar to
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ECOLOGY (QUARRY SITE)
those found at the plant site, e.g., raccoons, shrews, rabbits, and box
turtles.
The pasture and cultivated fields of the quarry site are characterized
by cattle, songbirds, cattle egrets, cotton rats, and mice. Deer,
quail, mourning dove, and turkey also frequent these open areas. The
number of exclusive species (e.g., the meadowlark) are few. A large
number of ubiquitous types (e.g., crows, foxes) are commonly found In
both forested and unforested areas. At the Interface of the forest and
pasture, an edge community provides cover, food, and nesting for a large
variety of species. Some wildlife species utilize edges to such an
extent that they are not often found In more uniform habitats (Johnston,
1947; Johnston and Odum, 1956). Quail and dove are quite common In the
forest edges and remnant forest edges. Seasonal patterns at the pro-
posed quarry site Include spring and fall Increases of migratory species
of birds and spring and summer Increases In all resident populations.
The relationship between ecosystems at the quarry site Is Illustrated In
Figure 29. The present forest vegetation of the quarry site reflects
the history of land use. In the past, the area has been cultivated,
grazed, lumbered, and some portions have been burned and surrounding
areas have been previously cultivated for food crops. During the last
16 years, the property has been managed under an agreement with the U.S.
Department of Agriculture. From 1968 to 1974, about 40 percent of the
Ideal and MeWilliams properties were managed by cutting 1,300 pine trees
per year and thinning uplands to favor pine, while bottomlands were
managed to favor yellow poplar, ash, gum, and various hardwoods.
Approximately 36 hectares (90 acres) were planted in wildlife food
plants (chufu and partridge pea) during this six-year period.
The hardwoods are well-developed because of the opening of the canopy by
the lumbering of pines and the selection of hardwoods in the bottom-
lands. Many areas within the forest are open and typically have young
pine seedlings, greenbrier, blackberry, saplings of various hardwoods,
and some weedy species. The understory varies depending on soil
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ATMOSPHERE
(WATER. NUTRIENTS)
AND EDGE ANIMALS
UPLAND FOREST
HARDWOOD BOTTOMLANDS
PINE-OAK FOREST
RUNOFF. /NUTRIENTS
INCREASED NUTRIENT
LOAD DUE TO CLEARING
AND LIVESTOCK WASTES
FLOODPLAIN FOREST
INCREASED NUTRIENT
LOAD DUE TO CLEARING
REMNANT FOREST
ALABAMA RIVER
INCREASED NUTRIENT LOAD
DUE TO LIVESTOCK WASTES
INCREASED NUTRIENT
LOAD DUE TO CLEARING
AND LIVESTOCK WASTES
PASTURE/OLD FIELDS
PASTURE/ OLD FIELD ANIMALS
BIOTIC RELATIONSHIPS
ABIOTIC RELATIONSHIPS
Figure 29
ECOLOGICAL RELATIONSHIP OF THE ECOSYSTEMS
OF THE PROPOSED QUARRY SITE
REGION IV
U.S ENVIRONMENTAL PROTECTION
AGENCY ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
SOURCE: Environmental Science and Engineering. Inc.. 1977.
PROPOSED GAILLARD QUARRY
MONROE I
, ALABAMA
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ECOLOGY (QUARRY SITE)
moisture and the degree of light penetration. Lianas are prevalent in
the understory of the upland areas, especially Vitis spp. on the moder-
ately elevated regions. The most common understory species are oaks and
maples, and they would form the future climax forest if the area were
not disturbed. The managed bottomlands would reach the climax state
relatively soon (80 years) while the uplands would take longer (160 to
170 years). The uplands have many clearings which might require a
somewhat longer period to reach climax.
Animal succession proceeds with the same general pattern as plant suc-
cession, involving increases in the diversity and specialization of
organisms over time. A decline in overall animal diversity at the site
is expected, however, with the implementation of the latest management
plan. There will be a reduction of forest, edge, and shrub communities
and an increase in pastures and old fields, leading to an increase in
grassland species such as mice, meadowlarks, and grasshopper sparrows.
The overall homeostasis of the proposed quarry site is low and is
similar to the conditions of very early succession. The conversion of
forest systems to pasture is creating early successional attributes such
as poor nutrient conservation (erosion, sedimentation, and increased
need for fertilization); simplified food chains; low diversity in both
plants and animals; and relatively great microclimate variation (tem-
perature, wind, rain, etc.). In general, biotic regulation is giving
way to abiotic regulation (and human regulation). This lower overall
homeostasis of the site is not new. It has happened a number of times
in the last two hundred years with cultivation, abandonment, and
recultivation.
The present quarry site ecosystems have a number of uses. The primary
commercial uses are timber and livestock production. The woodland
ecosystems of the site also provide important services in terms of soil
retention and erosion control. The site has a high productivity for
small game species such as bobwhite quail, mourning dove, snipe, and
cottontail rabbit. Wood ducks have also been observed on the site.
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ECOLOGY (QUARRY SITE)
There is a harvestable population of deer (estimated at 115 to 200 ani-
mals), and some trappable populations of upland, bottomland, and
riverine species of fur-bearing mammals can be expected. Turkey and
squirrel populations are present but declining because of the loss of
hardwood forests. In terms of recreational and aesthetic value, the
site is not unique but has a number of important natural features,
including the riverfront bluffs and the scenic lower reaches of Thompson
Mill (MarshalIs), Hoi linger, and Randons creeks.
Sixteen species of plants and animals which are endangered, threatened,
or of special concern in Alabama have ranges that include the proposed
quarry site. The only plant on this list is a pogonia (Isotria
spectabilis) which has been observed growing on the hardwood slopes of
the site.
Three "endangered" species are the golden eagle, bald eagle, and Red
Hills salamander. Eagle populations have declined in recent years
because of pesticide poisoning, illegal shooting, and other human
disturbance. The bald eagle is considered likely to occur along the
Alabama River at the quarry site, although no nests have been found. A
recent killing of a bald eagle near the quarry site was reported. Golden
eagles are sighted regularly in Alabama during the winter and may occur
occasionally at the Ideal property.
The quarry site is just outside the known range of the Red Hills sala-
mander, but likely habitat does occur in some of the wooded ravines of
the site. Field reconnaissance has revealed no Red Hills salamanders
nor their characteristic burrows, so that the likelihood of occurrence
is considered marginal.
Two "threatened" species are the American alligator and the gopher
tortoise. In sections of the Alabama River adjacent to the proposed
quarry site, the occurrence of the American alligator is very limited
(Boone, 1977). A few alligators are sighted each year near the con-
fluence of Randons Creek and Lovetts Creek. The gopher tortoise occurs
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ECOLOGY (QUARRY SITE)
commonly on the lower Coastal Plain but is threatened by loss of
suitable habitat. This burrowing animal apparently was present at the
quarry site in the past, but recent disturbances of the land have
lowered its likelihood of occurrence.
Three species of "special concern" that have been positively identified
at the quarry site are the wood stork, red-shouldered hawk, and little
blue heron. The wood stork is the only American representative of the
stork family (Ciconiidae). Although locally common in swamps, marshes,
and ponds, the wood stork population appears to be declining throughout
Alabama (Imhof, 1976; Keeler, 1976). The wood stork is frequently
reported in Monroe County and has been observed in the hardwood bottom-
lands of the quarry site. The red-shouldered hawk, which is a permanent
breeding resident throughout Alabama, favors large tracts of forested
land, especially bottomland hardwoods. One red-shouldered hawk was
observed at the quarry site. The little blue heron nests in colonies
and feeds primarily upon aquatic animals. This heron was observed in
pool areas of the quarry site and is also likely to occur in the
floodplain forest and hardwood bottomlands.
AQUATIC ECOLOGY
Introduction
Aquatic habitats at the proposed quarry site consist of the Alabama
River, which forms the western boundary of the property, and four per-
manent streams, which empty into the Alabama River. Water quality and
the streambeds have been described in the Water Resources section, and
the vegetation in Terrestrial Ecology. To summarize this information,
McGirts Creek, Thompson Mill (MarshalIs) Creek (Figure 30), and
Hoi linger Creek (Figure 31) have good-quality hard water. Flow gradient
is rather steep (approximately 0.9 percent), and streambeds consist of
sands or coarser materials. Randons Creek (Figure 32) is the largest
and has a gradient of only 0.45 percent, with some silt near the mouth.
Water is soft and generally of good quality, but it shows some effects
of runoff from agricultural and urban development at Frisco City. It is
163
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Figure 30
PHOTOGRAPHS OF THOMPSON MILL CREEK
REGION IV
U.S. ENVIRONMENTAL PROTECTION
AGENCY ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
SOURCE: Environmental Science and Engineering, Inc., 1977.
PROPOSED GAILLARD QUARRY
MONROE COUNTY, ALABAMA
164
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Figure 31
PHOTOGRAPHS OF HOLLINGER CREEK
REGION IV
U.S. ENVIRONMENTAL PROTECTION
AGENCY ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
SOURCE: Environmental Science and Engineering, Inc., 1977.
PROPOSED GAILLARD QUARRY
MONROE COUNTY, ALABAMA
165
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Figure 32
PHOTOGRAPHS OF RANDOMS CREEK
REGION IV
U.S. ENVIRONMENTAL PROTECTION
AGENCY ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
SOURCE: Environmental Science and Engineering. Inc., 1977.
PROPOSED GAILLARD QUARRY
MONROEi
, ALABAMA
166
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ECOLOGY (QUARRY SITE)
expected that the present rapid conversion of most of the site to
improved pasture will lead to some deterioration of water quality,
especially in the two smaller creeks.
The property is on the convex side of a bend in the Alabama River. High
bluffs overlook the river, and there is very little floodplain either on
the river or the tributary creeks. There is no permanent standing water
on the site.
Aquatic Fauna
Fishes
Fishes of the lower Alabama River system are quite similar to those of
the Tombigbee/Mobile/Tensaw Rivers systems with the exception of those
marine or estuarine forms which inhabit the lower reaches. Like the
Tombigbee River, the Alabama is populated by larger, current-loving
species in the main channel, numerous small fishes along the banks and
in sheltered locations, and a great number of small stream or brook
forms in the tributary streams. Normally many forms which inhabit tri-
butaries such as those found on the quarry site are similar to headwater
or upper Alabama River forms. The mouths of all of the streams on site
could have any of the listed species (see Table B.A.E.3 in Appendix B,
Baseline), depending upon the season and the existing water conditions.
Tributary streams to the Alabama at the level of the quarry site were
examined during a low-water period following extensive spring flooding
and general high water conditions. Hoi linger and Thompson Mill
(MarshalIs) creeks had insufficient water to maintain large riverine
species, and the young of larger river fishes, such as carp, carp-
suckers, catfish, buffalo, sturgeon, or drum, were not observed.
Data for these tributaries are quite limited for this stretch of the
Alabama River. Hoiley Creek and several by-pass loops, as well as the
mainstream Alabama (south of the quarry site), were examined as part of
a special study of the Tennessee-Tombigbee Waterway (Shipp and Hemphill,
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ECOLOGY (QUARRY SITE)
1974). The results of this rather exhaustive sampling effort help to
clarify the relative abundance of fishes which might commonly be
expected from the Alabama River below Claiborne Lock and Dam (see
Table B.A.E.3 in Appendix B, Baseline).
Numerical abundance for the 20 most prevalent species was examined for
both the unaffected portion of the river and the by-passed loops.
Minnows and shad dominate the top ten species, whereas catfishes and
centrarchids were the most significant contributors to the next ten
species.
In Holley Creek there is an array of species typical of moderate-si zed,
mid-south and southern streams. All trophic levels are represented, and
every available creek habitat is used by such an assemblage of fishes.
With few exceptions, any of these fishes may use the stream throughout
their entire life history.
All of these fishes might be expected to be found in the lower reaches
of Randons Creek, and at high water conditions in Hollinger and Thompson
Mill (MarshalIs) creeks. Fishes actually observed or seined from these
last two creeks consisted of minnows, sunfish, bass, and darters. Under
observed streamflow conditions in June, there was not sufficient water
to support larger fishes.
The only species encountered which is not present in these lists was the
Alabama hogsucker, Hypentilinum etowenum. Other than numerous minnows,
the centrarchids, both bass and Lepomis sp., were the most prevalent.
Sunfish nests were observed in every suitable soft-bottomed habitat.
Although much of the habitat looked as if it would be suitable for dart-
ers, these fishes were never very abundant in the collections taken.
Rare and Endangered Fishes
Several species of fishes have been listed by the Alabama Committee for
the Identification of Rare and Endangered Species. Although previously
168
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ECOLOGY (QUARRY SITE)
listed, the Alabama shad, Alosa alabamae. and the blue-spotted sunfish,
Enneacanthus gloriosus, are no longer regarded as being in these criti-
cal categories. No special status fishes have been observed at the
site. Species which could occur include: atlantic sturgeon Acipenser
oxyrhynchus (Rare); shovel nose sturgeon Scaphirhynchus platorynchus
(Endangered); blue sucker Cycleptu elongatus (Status Undetermined);
crystal darter Ammocrypta asprella (Threatened); and the freckled darter
Percina lenticula (Threatened).
Benthic Macroinvertebrates
Data concerning the aquatic invertebrate populations of the waters in
the vicinity of the quarry site are quite limited. Dredging along the
quarry site side of the Alabama River, as well as transects across the
river, failed to produce identifiable benthic macroinvertebrates. Even
though there were isolated pockets of finer materials, species of the
burrowing mayflies (such as Hexagenia sp.) were not detected.
Benthic macroinvertebrates which might be expected from this level of
the Alabama River may be inferred from a previous study and compilation
of existing data from various sources for the Tombigbee and Mobile
rivers (see Table B.A.E.4 in Appendix B, Baseline). The apparently
greater numbers and variety of forms is a reflection of the finer sub-
strates and pockets of fines and mixed organic matter encountered in
those streams as compared to the Alabama River at the quarry site
vicinity.
The animals tentatively identified in the field are common to woodland
gravel, sand, riffle/pool streams found throughout the midwest and
southeastern United States. Some expected forms were not found; how-
ever, it is possible that some forms were missed because not all sites
were sampled. It was expected that many more chironomids and annelids
and a different assortment of mayflies would be found. Experiences at
the same level on the Tombigbee River suggested that Sphareriid and
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ECOLOGY (QUARRY SITE)
Corbiculid clams would be found, but these were conspicuously absent
from the samples. Gastropods were locally abundant, however.
Several species of pearly naiads from the Alabama River system are
listed as rare or endangered. However, no beds or mussel shoals were
found In the Immediate vicinity of the quarry site.
If the quarry were not developed, the land would continue to be con-
verted to pasture with only small areas of forest remaining in 1992.
This conversion could lead to a change in streamflow characteristics
because water tends to run off more quickly from pasture than from well-
developed forest. Water quality and aquatic ecosystems would be affected
by high sediment loadings in the short run due to ongoing land clearance
activity. Without the proposed quarry project, sediment loadings might
decline after 1980 as the pastureland reaches stable condition. However,
nutrient loadings might continue to increase due to higher stock-loading
rates. Cattle would have access to the streams and would disturb the
stream bottoms and would create organic and nutrient loadings.
For about 1 kilometer (0.6 mile) from the Alabama River, forest would be
left along the streams, but in the gently rolling terrain farther
upstream all trees probably would be cleared. The resulting exposure
would lead to greater temperature fluctuations; perhaps of most concern,
water would be warmer in the summer.
As a result of all these perturbations, there would be major changes in
faunal composition in the upper parts of the stream. How well the fauna
could be maintained in the lower portions, where forest cover is pre-
served, cannot be estimated precisely, but some alteration would be
probable.
RELEVANT PROJECT CHARACTERISTICS
The effects of the proposed quarry project on terrestrial and aquatic
ecosystems have been described in the discussion of water resources.
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ECOLOGY (QUARRY SITE)
The initial phase will involve clearance of a 40-hectare (100-acre)
area, including the access roadway. The construction project will
include preparing an area in the Milkhouse Branch drainage basin for
overburden storage; developing the access road, haul road, and conveyor
alignments; and constructing the docking and loading facilities on the
Alabama River.
Quarrying will proceed in the areas around clarification basins 1 and 2
and will then extend to the east, south, and north of the starting
point. Land reclamation of each area will begin as soon as there is
enough overburden and land to make reclamation practical. Erosion
controls will be utilized for all aspects of the project that involve
land disturbance.
Quarrying and reclamation will proceed at an average rate of about
14 hectares (35 acres) per year. As much as 80 percent of the 1,633-
hectare (4,035-acre) site could be quarried over the 50-year life of the
project. However, the total area of land which is disturbed at any one
time, excluding stable reclaimed land, should not exceed 120 hectares
(300 acres).
IMPACTS
Land disturbance at the quarry site will alter significantly the present
ecological functions and attributes of the site. The initial disturbance
of existing vegetation in the first 15 years represents a loss of 120
hectares (296 acres) of cultivated croplands or pasture1ands, 139 hec-
tares (343 acres) of hardwoods, and 30 hectares (74 acres) of remnant
forests.
Any forests which are left on the site during the quarrying activities
may be affected by the quarry. Some of the lower floodplain forest may
remain; however, the increased surface runoff, insolation, and airflow
will cause changes in composition and production of these remnant areas.
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ECOLOGY (QUARRY SITE)
Insolation of the remnant forests will Increase and will cause increased
temperatures within the forests. The opened areas will develop more
weedy species and primary woody invaders. Most of the forest areas
remaining after excavation will be hardwood bottomlands, since the
pine-oak upland areas will have been destroyed during the quarrying.
The magnitude of these impacts is considered low because of the abun-
dance of the existing forested areas in the area. The significance is
low because these actions will probably not affect subsequent land use
(pasture). The impacts are considered long-term, but reversible.
In addition to the innate value of plant communities destroyed, the
first 15 years of the project will involve losses of at least
56 hectares (138 acres) of most favorable rabbit and quail habitat,
93 hectares (230 acres) of most favorable turkey habitat, and 21 hec-
tares (51 acres) of most favorable squirrel habitat. The animal
populations inhabiting these areas will be displaced.
In general, the impact of the quarrying activities will be the change in
wildlife populations from forest types to old field/pasture types; how-
ever, the magnitude of these changes is low because of the relatively
small amount of affected area in comparison to the areawide abundance of
available forest habitat. The significance of this wildlife habitat
loss is low because of the frequent occurrence of the species involved
in the surrounding area. All the populations in the area are currently
self-sustaining. This impact is considered long-term, but reversible.
The major impact of these activities on rare and endangered species will
be reduced habitat for those animals which inhabit forest or forest/
field communities. The magnitude of this disturbance of sensitive fauna
inhabiting aquatic environments will be low, and the significance should
be low because of the small areas to be affected and the availability of
suitable habitat in nearby areas. This impact will be long-term, but
reversible.
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ECOLOGY (QUARRY SITE)
Erosion and stormwater will be controlled by berms, grading, and
clarification basins; however, it is expected that some moderate net
Increases in the loads of participate material carried by tributary
streams will occur. The presence of this material could be detrimental
to aquatic organisms and could reduce primary productivity. In addi-
tion, settling of particulate material on the substrate could smother
bottom-dwelling organisms. These impacts are considered of limited
significance because erosion controls will limit sediment loads and the
ecological adjustment to elevated turbidity levels should have already
occurred during the conversion of the site to improved pasture.
The overall effect of sedimentation, organic loadings, and land
clearance will be to increase the prevalence of facultative aquatic
organisms. Siltation can be expected to create more soft-bottomed habi-
tats which would favor burrowing forms (worms, chironomids, burrowing
mayflies) over root, rubble, sand, or gravel inhabitants. The removal
of trees and their detrital components, such as leaves, twigs, and bark,
may eliminate the larger grazers and carnivores of the present system
(mayflies, elmid beetles, stoneflies, dragon and damsel flies, and
members of the Megaloptera).
The net sedimentation effects of the quarrying project alone would
probably not be sufficient to cause pronounced changes in ecological
conditions. These impacts are considered of low magnitude based on the
erosion/sedimentation controls planned and of low significance. The
impacts should be long-term (life of the quarry) and mostly reversible.
As presented in the Air Quality section, limestone dust may enter the
atmosphere from quarry operations. The results of Brandt and Rhodes
(1972) Indicate the possibility of reduced productivity of the remaining
forest species at the perimeter of the quarry. The effects are consi-
dered to be of low significance and magnitude because of the commonness
of the species involved and the relatively few trees to be affected.
These impacts will be long-term but reversible when the quarry area is
reclaimed.
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ECOLOGY (QUARRY SITE)
Noise resulting from construction and quarrying (see Noise section) will
have adverse effects on some species of wildlife, such as the turkey,
which requires a fairly high degree of isolation. This disturbance
could contribute to the reduction of some wildlife populations remaining
on the site. It is not considered significant to the area and region
because of the frequent occurrence of the species. This impact is con-
sidered of low magnitude and long-term, but highly reversible.
The increased barge traffic from the quarry could disturb activity pat-
terns of water-associated birds, such as eagles and waterfowl, and could
affect alligators in the area. In all cases, the disturbed species will
relocate or adapt to the conditions. These impacts are of low magnitude
and significance, long-term, and reversible.
The drainage patterns created by the quarrying and reclamation process
could reduce the drainage area of Thompson (MarshalIs) Mill Creek by
about 10 percent. This change could reduce the base flow of the stream,
the extent of flushing, the size and depth of pools, and the length of
stream reaches containing water during dry-weather conditions. However,
since major effects on base flow should not occur, the related impacts
to aquatic communities are estimated to be of low magnitude and
significance, but irreversible and long-term.
After active quarry slopes are no longer drained into the clarification
basins, these basins will have the positive impact of creating addi-
tional habitat for aquatic-related species such as herons and waterfowl.
This positive impact is considered to be of low significance and low
magnitude for the area because of other existing ponds.
MITIGATING MEASURES
The environmental safeguards employed to lessen impacts upon terrestrial
and aquatic ecosystems will include all of the measures described ear-
lier in connection with water resources, noise, and air quality. Among
the most prominent measures will be the stormwater clarification basins,
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ECOLOGY (QUARRY SITE)
on-site erosion controls, 30-meter (100-foot) setbacks from major creeks
and streams, and steps during reclamation to recreate productive soil
conditions.
There are no mitigating measures available to reduce the immediate ecol-
ogical impacts of land clearance, given the necessary characteristics of
quarry operation. However, a number of options exist with regard to the
revegetation of reclaimed land and other areas requiring stabilization.
A program could be established to develop healthy biologic communities
as a wildlife asset, particularly at the edge of mined areas. These
"blend" zones would become ecotones between biotic communities and would
be managed to produce more varied assemblages of plants and animals than
would be possible for either community alone. A variety of wildlife
food and cover plants are available from public sources. Other species
which would naturally volunteer and produce significant browse would
include woody species such as maples, persimmon, sassafras, and oak, and
herbaceous natural plants such as beggar ticks, vetch, lespedeza, and
sumac.
Since the reclaimed land will be utilized as pasture, the area for which
beneficial wildlife plantings will be feasible is rather small, con-
sisting of: (1) blend zones between quarried and undisturbed land;
(2) potentially difficult areas such as drainageways where erosion may
occur; and (3) other areas requiring stabilization such as faces of
retention dams.
ALTERNATIVES
Ecosystem conditions at the proposed quarry site would be only moder-
ately different under the no-action alternative than under the project
alternative. The no-action alternative would involve somewhat greater
recovery of aquatic conditions from the effects of land conversion, and
somewhat more forest cover would remain for the benefit of terrestrial
organisms. The no-action alternative obviously would not involve per-
manent changes in topography and drainage.
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ECOLOGY (QUARRY SITE)
Alternatives relating to ecological Impact Involve land reclamation.
Instead of reclaiming to pasture, the project could Include the creation
of a connerclal pine forest or an old field condition leading by natural
succession to a mixed deciduous woodland. These alternatives would lead
to a different mix of faunal species and possibly greater ecosystem
diversity than the pasture alternative, and generally would benefit
aquatic conditions.
The property could also be used as an Industrial area because of Its
favorable location with good water access and a small flood potential.
The decision for reclamation to pastureland provides flexibility In
long-range land use since timbering, agriculture, or some other land use
could easily be established at a later time.
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SOCIOECONOMICS (QUARRY SITE)
SOCIOECONOMICS
BASELINE
PRESENT CONDITIONS
The socioeconomic Impact area of the proposed quarry operation Includes
Monroe, Clarke, and Conecuh counties, with the most significant Impacts
limited primarily to Monroe County. Historically, the region around
Monroe County has been characterized by declining populations and stag-
nant economic conditions. Population losses between 1940 and 1970
amounted to 29.3 percent In Monroe County, 38.6 percent In Conecuh
County, and 3.3 percent In Clarke County. However, the populations of
these counties have been either stable or rising since 1970. Monroe
County contained 20,883 residents In 1970, 21,200 persons In 1975, and
an estimated 21,700 persons In 1977.
Past population losses In the three Impact area counties primarily
Involved out-migration of farm workers and their families, In response
to the low profitability of agriculture and the Increased opportunities
elsewhere. The principal economic support now Is manufacturing
activity, which accounts for more than 40 percent of total employment
In each of the three counties. Two-thirds or more of the manufacturing
employment In each case Is concentrated In three Industrial categories:
wood products, textile products, and pulp and paper products. Growth
In manufacturing employment has provided the major stimulus for recent
population gains In Monroe and Clarke counties. Monroe County has also
benefltted by substantial employment growth In retail trade and
services, Involving the emergence of Monroevllle as the commercial
center for a sizable area.
Average Income levels are relatively low for Monroe, Clarke, and
Conecuh counties. Per capita Income remains between 72 percent and
81 percent of the average for the State of Alabama, although there has
been a recent narrowing of the gap In Monroe and Conecuh counties.
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SOCIOECONOMICS (QUARRY SITE)
In 1970, between 30 percent and 35 percent of the families In the three
counties had incomes below the poverty level.
Housing in Monroe County is currently in somewhat short supply, partic-
ularly in the Monroeville area. This circumstance is related to the
general increases in employment and population, and to the construction
of the Parsons and Whittemore, Inc., pulp mill facility at Claiborne.
It is estimated that the housing market in Monroe County currently can
absorb at least 50 percent more dwelling units per year than were con-
structed on the average between 1960 and 1970. Active steps are being
taken by the city administration of Monroeville to alleviate the
present shortage, particularly with regard to rental units and the
availability of sites for mobile homes.
Community facilities in Monroe County presently are being expanded and
will be generally adequate to accommodate future growth. Public school
enrollment has declined in recent years (due to an expansion of enroll-
ment at Monroe Academy), but can be expected to increase in the future.
The major health care facility in the county, Monroe County Hospital,
was expanded in 1974 and will increase in capacity by 50 percent over
the next 10 years according to current plans.
A public sewer system serving Monroeville, Frisco City, and adjacent
areas is presently under construction. Public water supply systems are
currently being expanded by the Monroeville Water Board and the Excel
Water Board. There has been improvement in the public recreation
facilities provided by Monroeville and other communities, but the
overall level of recreation opportunities in the county has been
described as "lacking" in the Monroe County Preliminary Comprehensive
Development Plan.
Existing highway facilities in Monroe County are more than adequate to
accommodate the low volumes of traffic found in the county. There are
no public transportation facilities other than intercity bus service.
The Monroeville Fire Department provides fire protection service to
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SOCIOECONOMICS (QUARRY SITE)
most of the county. No special problems in providing police or fire
protection to the county's expanding population have been reported.
Planning assistance to Monroe County is provided actively by the
Alabama-Tombigbee River Regional Planning and Development Commission,
which has recently prepared a preliminary comprehensive development
plan for the county. The City of Monroeville enforces zoning regula-
tions and building codes within its corporate limits and exercises
subdivision review within the police jurisdiction [extending
2.5 kilometers (1.5 miles) beyond the corporate boundary]. There is no
regulation outside police jurisdiction of municipalities.
FUTURE CONDITIONS
The most important single development affecting Monroe County is the
$266 million Parsons and Uhittemore pulp mill project. Permanent opera-
tion at this pulp mill will generate more than $5,000,000 in Income for
350 employees. More than $2,000,000 annually will be spent for wood
purchases in Monroe County alone, creating roughly 125 new forest-
related jobs. Several other industrial development projects in Monroe
County have either been announced or are under construction. A new
Scotch Plywood plant in Beatrice will employ 125 to 130 persons, with a
payroll of approximately 1.6 million dollars. Another wood products
plant is to be constructed by Georgia Pacific at Peterman. These and
other expansion plans could add close to 1,000 Industrial and related
jobs in Monroe County over the next 5 years.
Employment projections for Monroe County in 1977, 1985, and 1992 are
presented in Table 7. The 1985 forecasts assume only that the
developments just mentioned will take place and that there will be a
multiplier effect on non-manufacturing activity. The forecasts for
1992 assume a slowdown in industrial growth but continued expansion In
the services-producing sector. Table 8 presents two population
forecasts for Monroe County: the OBERS Series E Projection and an
alternative forecast series which is consistent with the employment
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SOCIOECONOMICS (QUARRY SITE)
Table 7. Forecasts of Nonagricultural Wage and Salary Employment in
Monroe County
Manufacturing
Nonmanufacturing
TOTAL
April
1977
3,250
2.990
6,240
Change
1977-1985
850
850
1,700
1985
4,100
3,840
7,940
Change
1985-1992
300
750
1,050
1992
4,400
4.590
8,990
Source: Environmental Science and Engineering, Inc, 1977, utilizing
information from the Alabama Department of Industrial Rela-
tions, Research and Statistics Division, 1977.
Table 8. Comparison of Population Forecast for Monroe County with OBERS
Series. E Projections
Monroe County
Population
1970
1977
1980
1985
1990
1992
Increase, 1977-1992
Alternative
Forecast
20,900
21,700
22 ,400*
23 ,600
24 ,600*
25,000
15.2%
OBERS
20,900
21,600*
21 ,900
22,300
22,600
22,500*
4.2%
Deviation
from OBERS
Number/Percent
0 0
100 0.5
500 2.3
1,300 5.8
2,000 8.8
2,500 11.1
* Denotes interpolated values.
Sources: U.S. Department of Agriculture, Economic Research Service,
1975.
Environmental Science and Engineering, Inc., 1977.
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SOCIOECONOMICS (QUARRY SITE)
estimates just described. The alternative forecast, which exceeds
OBERS by 11.1 percent in 1992, is believed to be more accurate as an
extrapolation of very recent trends in the county. The projected
average population growth rate of roughly 1 percent per year is not
considered sufficient to produce serious stress upon housing, community
facilities, or social stability.
RELEVANT PROJECT CHARACTERISTICS
The construction phase of the proposed Ideal Basic Industries quarry
project will involve an average of 133 employees for 18 months and a
peak labor force of 250 workers. The total wages paid will exceed
$3,000,000. Permanent operations at the quarry will employ 19 persons
and will generate an annual payroll of approximately $400,000 in 1977
dollars. The project will involve temporary changes in land use from
improved pasture to mineral extraction and back to pasture in each
successive area of the site that is quarried. There will be major
increases in waterway traffic on the Alabama River, as discussed in the
Water Resources section, and very slight increases in traffic on high-
ways near the quarry site.
IMPACTS
The multiplier effects of construction employment at the quarry site
will generate approximately 60 additional jobs in Monroe County, and
$1,000,000 or more in additional income. The total employment effect
will thus average nearly 200 workers during the 18-month duration of
the project. This economic stimulus to Monroe County and surrounding
areas is rated moderate in significance and magnitude as an impact.
The labor force buildup at the quarry may coincide with the phasing out
of the nearby Parsons and Whittemore project. This situation would
allow some direct shifts of personnel and would permit the quarry
construction workers to utilize housing and public facilities that
currently are used by the Parsons and Whittemore labor force.
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SOCIOECONOMICS (QUARRY SITE)
The construction labor force residing in Monroe County is somewhat
limited because of the small scale of the local economy. Therefore, a
majority of the workers on the quarry project will necessarily live
elsewhere. Some of these workers will commute to Monroe County on a
daily or weekly basis, and a few will establish residence in the area
for the duration of the project or longer. The current shortage of
transient accommodations and rental housing units in Monroe County is
expected to ease by the time the quarry project is under way, so that
construction workers should not have difficulty in finding suitable
lodgings. Very few of the workers will bring dependents to the area.
Given the generally favorable experience of the Parsons and Whittemore
project, the construction phase at the proposed quarry should not have
adverse impacts upon public services or social conditions.
Permanent operations at the proposed quarry will involve 19 employees
and will generate 25 additional jobs in Monroe County due to a multi-
plier effect. This favorable economic impact is considered moderate in
magnitude and high in significance to the community. Of the 44 jobs
attributable directly or indirectly to the quarry operation, it is
estimated that the number held by Monroe County residents will be
approximately 32 in 1985 and 38 in 1992. The project will increase the
Monroe County population by about 92 persons in 1985 relative to base-
line conditions and by 102 persons in 1992. Population increments of
this size clearly can be assimilated by the Monroe County community
without overburdening public facilities or creating social
disruptions.
The isolation of the Ideal Basic Industries quarry site relative to
other developed land uses will limit greatly the possibility of off-
site impacts upon land use, land value, or residential amenity. The
project is not expected to have significant impacts involving noise or
air quality.
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SOCIOECONOMICS (QUARRY SITE)
MITIGATING MEASURES
The proposed quarry project will not yield adverse socioeconomic
impacts which would require mitigation.
ALTERNATIVES
Alternate quarry locations are discussed in the Site Selection section.
There are no other project alternatives which would have a significant
influence upon socioeconomic impacts.
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PERMIT AND
APPROVAL SECTION
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DRAFT NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM
(NPDES) PERMIT (PLANT SITE)
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Permit No AL0028801
Application No
AUTHORIZATION TO DISCHARGE UNDER THE
NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM
In compliance with the provisions of the Federal Water Pollution Control Act, as amended,
(33 U.S.C. 1251 et. seq; the "Act"),
Idea]. Basic Industries
Cement Division
Theodore Cement Plant
DRAFT
is authorized to discharge from a facility located at
Theodore Industrial Park
Theodore, Alabama
to receiving waters named
Theodore Ship Channel - Discharge 001
North Fork of the Deer River - Discharge 002
in accordance with effluent limitations, monitoring requirements and other conditions set forth
in Parts I, II, and III hereof.
This permit shall become effective on
This permit and the authorization to discharge shall expire at midnight.
Signed this day of
Paul J. Traina, Director
Enforcement Division
EPA Form 33:0.4 (10.73)
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A. EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS
1. During the period beginning on effective date and lasting through the term of this permit,
the permittee is authorized to discharge from outfall(s) serial number(s) 001-material stockpiles run-off, cooling
tower blowdown, vehicle and floor wash wastewaters and fuel storage area dike drainage.
Such discharges shall be limited and monitored by the permittee as specified below:
-a
rvs
Effluent Characteristic
Discharge Limitations
kg/day (Ibs/day) Other Units (Specify)
Daily Avg Daily Max Daily Avg Daily Max
Flow-m3/Day (MGD) - - - -
Total Suspended Solids shall not exceed 50 mg/1 for any one (1) day
Monitoring Requirements
Measurement
Frequency
Dally
I/week
Sample
Type
Recorder
Composite
—n
The pli shall not be less than 6.0 standard units nor greater than 9.0 standard units and shall be monitored once per
week by grab sample.
There shall be no discharge of floating solids or visible foam in other than trace amounts.
Samples taken in compliance with the monitoring requirements specified above shall be taken at the following location(s):
nearest accessible point after final treatment but prior to actual discharge to or mixing with
the receiving waters.
O H-
O t->
to
00
00
O
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2. During the period beginning on effective date and lasting through the term of this permit,
the permittee is authorized to discharge from outfall(s) serial number(s) OOla, fuel storage dike area only.
Such discharges shall be limited and monitored by the permittee as specified below:
Effluent Characteristic Discharge Limitations Monitoring Requirements
kg/day (Ibs/day) Other Units (Specify)
Measurement Sample
Daily Avg Daily Max Daily Avg Daily Max Frequency Type
Flow—m3/Day (MGD) _ _ — — I/month Estimate
-o Oil and Grease — — 30 mg/1 60 mg/1 I/month Grab
W
Where dike drains discharge into an oil-water separator, effluent limitations and monitoring
requirements apply to the effluent from the oil-water separator. However, the discharge from BS-V"!
dike drains shall not be subject to the monitoring and effluent requirements of the permit if T|
all of the following are true: *
1. The dike drain discharge does not go to an oil-water separator and
2. The facility has a valid SPCC Plan pursuant to 40 CFR 112
and
3. Best management practices (BMP) are used in draining the diked area. BMP is defined
as use of a portable oil skimmer or similiar device or the use of abosorbent material
to remove oil and grease (as indicated by the presence of a sheen) immediately prior
to drainage.
Samples taken in compliance with the monitoring requirements specified above shall be taken at
the following location(s): nearest accessible point after final treatment but prior to actual
discharge to or mixing with all other waste waters.
Z U) —
o
> -
O H-
O I-
oo
o
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3. During the period beginning on effective date and lasting through the tern of this permit,
the permittee is authorized to discharge from outfall(s) serial number(s) 002, uncontaminated storm'water run-off.
Such discharges shall be limited and monitored by the permittee as specified below:
Effluent Characteristic Discharge Limitations
kg/day (Ibs/day) Other Units (Specify)
Daily Avg
Daily Max
Daily Avg
Daily Max
Flow-m3/Day (MGD)
Monitoring Requirements
Measurement
Frequency
1/month
Sample
Type
Estimate
Best Management Practices (BMP)
*
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PARTI
Page 5 ,,f 11
Perm,. No AL0028801
B. SCHEDULE OF COMPLIANCE
1. The permittee shall achieve compliance with the effluent limitations specified for
discharges in accordance with the following schedule:
Operational Level Attained Effective Date of permit
2. No later than 14 calendar days following a date identified in the above schedule of
compliance, the permittee shall submit either a report of progress or, in the cas? of
specific actions being required by identified dates, a written notice of compliance or
noncompliance. In the latter case, the notice shall include the cause of noncomplianiv.
any remedial actions taken, and the probability of meeting the next scheduled
requirement.
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PART I
PJFI- 6 -f 11
PcrmilN., AL0028801
C. MONITORING AND REPORTING
1. Representative Sampling
Samples and measurements taken as required herein shall be representative of the volume
and nature of the monitored discharge.
2. Reporting
Monitoring results obtained during the previous 3 months shall be summarized for
each month and reported on a Discharge Monitoring Report Form (EPA No. 3320-1),
postmarked no later than the 28th day of the month following the completed reporting
period. The first report is due on . Duplicate signed copies of
these, and all other reports required herein, shall be submitted to the Regional
Administrator and the State at the following addresses:
Environmental Protection Agency Alabama Water Improvement Commission
Water Enforcement Branch State Office Building
345 Courtland Street, N.E. Montgomery, Alabama 36130
Atlanta, Georgia 30308
3. Definitions
a. The "daily average" discharge means the total discharge by wsight during a calendar
month divided by the number of days in the month that the production or
commercial facility was operating. Where less than daily sampling is required by this
permit, the daily average discharge shall be determined by the summation of all the
measured daily discharges by weight divided by the number of days during the
calendar month when the measurements were made.
b. The "daily maximum" discharge means the total discharge by weight during any
calendar day.
4. Test Procedures
Test procedures for the analysis of pollutants shall conform to regulations published
pursuant to Section 30-J(g) of the Act, under which such procedures may be required.
5. Recording of Results
For each measurement or sample taken pursuant to the requirements of this permit, the
permittee shall record the following information:
a. The exact place, date, and time of sampling;
b. The dates the analyses were performed;
c. The person(s) who performed the analyses;
P-6
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PARTI
I'jto 7 »i 11
ivr.mi NM AL0028801
d. The analytical techniques or methods used: and
e. The results of all required analyses.
6. Additional Monitoring by Permittee
If the permittee monitors any pollutant at the location(s) designated horein more
frequently than required hy this permit, using approved analytical methods as specified
above, the results of such monitoring shall be included in the calculation and renortmp of
the values required in the Discharpe .Monitoring Report Form (EPA No. 3320-1). Such
increased frequency shall also be indicated.
7. Records Retention
All records and information resulting from the monitoring activities required by this
permit including aJl records of analyses performed and calibration and maintenance of
instrumentation and recordings from continuous momtOi-.-q instrumentation shall he
retained for a minimum of three (3) years, or longer if requested by the Resional
Administrator or the State water pollution control agency.
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PART II
Page 8 "I 11
Permit No. AL0028801
A. MANAGEMENT REQUIREMENTS
1. Change in Discharge
All discharges authorized heroin shall be consistent with the terms and conditions of this
permit. The discharge of any pollutant identified in this permit more frequently than or
at a level in CXCPSS of that authorized shall constitute a violation of the permit. Any
anticipated facility expansions, production increases, or process modifications which will
result in new, different, or increased discharges of pollutants must be reported by
submission of a new NPDES application or, if such changes will not violate the effluent
limitations specified in this permit, by notice to the permit issuing authority of such
changes. Following such notice, the permit may be modified to specify and limit any
pollutants not previously limited.
2. Noncompliance Notification
If, for any reason, the permittee does not comply with or will be unable to comply with
any daily maximum effluent limitation specified in this permit, the permittee shall
provide the Regional Administrator and the State with the following information, in
writing, within five (5) days of becoming aware of such condition:
a. A description of the discharge and cause of noncompliance; and
b. The period of noncompliance, including exact dates and times; or. if not corrected,
the anticipated time the noncompliance is expected to continue, and steps being
taken to reduce, eliminate and prevent recurrence of the noncomplying discharge.
3. Facilities Operation
The permittee shall at all times maintain in good working order and operate as efficiently
as possible all treatment or control facilities or systems installed or used by the permittee
to achieve compliance with the terms and conditions of this permit.
4. Adverse Impact
The permittee shall take all reasonable steps to minimize any adverse impact to navigable
waters resulting from noncompliance with any effluent limitations specified in this
permit, including such accelerated or additional monitoring as necessary to determine the
nature and impact of the noncomplying discharge.
5. Bypassing
Any diversion from or bypass of facilities necessary to maintain compliance with the
terms and conditions of this permit is prohibited, except (i) where unavoidable to prevent
loss of life or severe property damaae, or (11) \\herc* excessive storm drainage or runoff
would daniuge any facilities necessary for compliance with the effluent limitations and
prohibitions of this permit. The permittee shall promptly notify the Regional
Administrator and the .Slate in writing of each such diversion or bypass.
P-8
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PART II
Page 9 of 11
Permit No. AL0028801
6. Removed Substances
Solids, sludges, filter backwash, or other pollutants removed in the course of treatment or
control of wastewaters shall be disposed of in a manner such as to prevent any pollutant
from such materials from entering navigable waters.
7. Power Failures
In order to maintain compliance with the effluent limitations and prohibitions of this
permit, the permittee shall either:
a. In accordance with the Schedule of Compliance contained in Part I, provide an
alternative power source sufficient to operate the wastewater control facilities;
or, if such alternative power source is not in existence, and no date for its implementation
appears in Part I,
b. Halt, reduce or otherwise control production and/or all discharges upon the
reduction, loss, or failure of the primary source of power to the wastewater control
facilities.
B. RESPONSIBILITIES
1. Right of Entry
The permittee shall allow the head of the State water pollution control agency, the
Regional Administrator, and/or their authorized representatives, upon the presentation of
credentials:
a. To enter upon the permittee's premises where an effluent source is located or in
which any records are required to be kept under the terms and conditions of this
permit; and
b. At reasonable times to have access to and copy any records required to be kept under
the terms and conditions of this permit; to inspect any monitoring equipment or
monitoring method required in this permit; and to sample any discharge of pollutants.
2.. Transfer of Ownership or Control
In the event of any change in control or ownership of facilities from which the authorized
discharges emanate, the permittee shall notify the succeeding owner or controller of the
existence of this permit by letter, a copy of which shall be forwarded to the Regional
Administrator and the State water pollution control agency.
3. Availability of Reports
Except for data determined to be confidential under Section 308 of the Act, all reports
prepared in -accordance with the terms of this permit shall be available for public
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PART II
10 of 11
PermnNo. AL0028801
inspection at the offices of the State water pollution control agency and the Regional
Administrator. As required by the Act. effluent data shall not be considered confidential.
Knowingly making any false statement on any such report may result in the imposition of
criminal penalties as provided for in Section 309 of the Act.
4. Permit Modification
After notice and opportunity for a' hearing, this permit may be modified, suspended, or
revoked in whole or in part during its term for cause including, but not limited to, the
following:
a. Violation of any terms or conditions of this permit;
b. Obtaining this permit by misrepresentation or failure to disclose fully all relevant
facts; or
c. A change in any condition that requires either a temporary or permanent reduction or
elimination of the authorized discharge.
5. Toxic Pollu tan ts
Notwithstanding Part II, B-4 above, if a toxic effluent standard or prohibition (including
any schedule of comoliance specified in such effluent standard or prohibition) is
established under Section 307(a) of the Act for a toxic pollutant which is present in the
discharge and such standard or prohibition is more stringent than any limitation for such
pollutant in this permit, this permit shall be revised or modified in accordance with the
toxic effluent standard or prohibition and the permittee so notified.
6. Civil and Criminal Liability
Except as provided in permit conditions on "Bypassing" (Part II, A-5) and "Power
Failures" (Part II, A-7). nothing in this permit shall be construed to relieve the permittee
from civil or criminal penalties for noncompliance.
7. Oil and Hazardous Substance Liability
Nothing in this permit shall be construed to preclude the institution of any legal action or
relieve the permittee from any responsibilities, liabilities, or penalties to which the
permittee is or may be subject under Section 311 of the Act.
8. State Laws
Nothing in this permit shall be construed to preclude the institution of any legal action or
relieve the permittee from any responsibilities, liabilities, or penalties established pursuant
to any applicable State law or regulation under authority preserved by Section 510 of the
Act.
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PART II
Paw 11 of 11
Permit No. ALOO28801
9. Property Rights
The issuance of this permit does not convey any property rights in either real or personal
property, or any exclusive pnvtlpges, nor does it authorize any injury to private property
or any invasion of personal rights, nor any infringement of Federal, State or local laws or
regulations.
10. Severability
The provisions of this permit are severable, and if any provision of this permit, or the
application of any provision of this permit to any circumstance, is held invalid, the
application of such provision to other circumstances, and the remainder of this permit,
shall not be affected thereby.
PART III
OTHER REQUIREMENTS
1. For the purpose of this permit, a calendar day is defined as any
consecutive 24-hour period.
2. In accordance with Section 306(d) of the Federal Water Pollution
Control Act (PL92-500) the standards of performance for conventional
pollutants as contained in this permit shall not be made any more
stringent during a ten year period beginning on the date of completion
of such construction or during the period of depreciation or amortization
of such facility for the purposes of section 167 or 169 (or both) of
the Internal Revenue Code of 1954, whichever period ends first. The
provisions of Section 306(d) do not limit the authority of the Environ-
mental Protection Agency to modify the permit to require compliance
with a toxic effluent limitation promulgated under BAT or toxic
pollutant standard established under Section 307(a) of the FWPCA, or
to modify, as necessary, to assure compliance with any applicable
State Water Quality Standard.
3. Control of runoff from site construction shall be consistent with sound .
engineering practices such as thocc contained in "Guidelines for Erosion
and Sediment Control Planning and Ir.plctr.cntation," EPA-R2-72-015 (August,
1972) or "Processes, Procedures and Methods to Control Pollution Resulting
from all Construction Activity," EPA-430/9-73-007 (October, 1973). Prior
to start of construction, the permittee shall submit to the Regional
Administrator for review and approval, a detailed erosion and sediment
control plan. An approved plan shall be implemented prior to start of
construction.
4. Any overflow which is discharged from facilities designed, constructed
and operated to treat to the applicable limitations for pH and total
suspended solids, the precipitation and run-off resulting from a 10-year,
24-hour precipitation event shalL not be subject to the limitations sec
forth in Part I, A of this permit.
P-ll
-------
DRAFT NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM
(NPDES) PERMIT (QUARRY SITE)
-------
Pcrinil N,, AL0028819
AUTHORIZATION TO DISCHARGE UNDER THE
NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM
In complianre with the provisions of the Federal Water Pollution Control Act, as amended,
(33 U.S.C. 1251 et. seq; the "Act").
Ideal Basic Industries
Cement Division
Gaillard Quarry
FT
is authorized to discharge from a facility located at
Monroe County, Alabama
to receiving waters named
Alabama River
in accordance with effluent limitations, monitoring requirements and other conditions set forth
in Parts I, II, and III hereof.
This permit shall become effective on
This permit and the authorization to discharge shall expire at midnight,
Signed this day of
Paul J. Traina, Director
Enforcement Division
EPA Farm 1320.4 (10-73}
P-13
-------
A. EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS
During the period beginning on effective date andjasting through the term of this permit,
the permittee is authorized to discharge from all point sources associated with active mine dewatering activities
indicated on the area map (Attachment I).
Such discharges shall be limited and monitored by the permittee as specified below:
Effluent Characteristic
Discharge Limitations
kg/day (lbs/da"y) OtKeir Units (Specify)
Daily Avg Daily Max
Daily Avg
Daily Max
Flow-m3/Day (MGD)
Monitoring Requirements
Measurement
Frequency
I/month
Sample
Type
Instantaneous
Total Suspended Solids shall not exceed 30 mg/1 for any one (l) day
I/month
Composite
The pH shall not be less than 6.0 standard units nor greater than 9.0 standard units and shall be monitored once per
month by grab sample.
There shall be no discharge of floating solids or visible foam in other than trace amounts.
Samples taken in compliance with the monitoring requirements specified above shall be taken at the following location(s):
nearest accessible point after final treatment but prior to actual discharge to or mixing with
the receiving waters.
»
a
3
- -
o
o so
IS)
00
00
-------
PARTI
Page 3 of 9
Permii No. AL0028819
B. SCHEDULE OF COMPLIANCE
1. The permittee shall achieve compliance with the effluent limitations specified for
discharges in accordance with the following schedule:
Operational Level Attained Effective Date of Permit
2. No later than 14 calendar days following a date identified in the above schedule of
compliance, the permittee shall submit either a report of progress or, in the case of
specific actions being required by identified dates, a written notice of compliance or
noncompliance. In the latter case, the notice shall include the cause of noncompliance,
any remedial actions taken, and the probability of meeting the next scheduled
requirement
P-15
-------
PART I
pjpc 4 of 9
PermilNo AL0028819
C. MONITORING AND REPORTING
1. Represen ta five Samp ling
Samples and. measurements taken as required herein shall be representative of the volume
and nature of the monitored discharge.
2. Reporting
Monitoring results obtained during the previous 3 months shall be summarized for
each month and reported on a Discharge Monitoring Report Form (EPA No. 3320-1),
postmarked no later than the 28th day of the month following the completed reporting
period. The first report is due on . Duplicate signed copies of
these, and all other reports required herein, shall be submitted to the Regional
Administrator and the State at the following addresses:
Environmental Protection Agency Alabama Water Improvement Commission
Water Enforcement Branch g Qff± Building
345 Courtland Street, N.E. M^«i--« «-,, Aia*.ama -umn
.... . tn^no Montgomery, Alabama 36130
Atlanta, Georgia 30308 ° *
3. Definitions
a. The "daily average" discharge means the total discharge by weight during a calendar
month divided by the number of days in the month that the production or
commercial facility was operating. Where less than daily sampling is required by this
permit, the daily average discharge shall be determined by the summation of all the
measured daily discharges by weight divided by the number of days during the
calendar month when the measurements were made.
b. The "daily maximum" discharge means the total discharge by weight during any
calendar day.
4. Test Procedures
Test procedures for the analysis of pollutants shall conform to regulations published
pursuant to Section 304(g) of the Act, under which such procedures may be required.
5. Recording of Resu Its
For each measurement or sample taken pursuant to the requirer.ients of this permit, the
permittee shall record the following information:
a. The exact place, date, and time of sampling;
b. The dates the analyses were performed;
c. The person(s) who performed the analyses;
P-16
-------
PARTI
?w 5 oi 9
PcrmuNo. AL0028819
d. The analytical techniques or methods used; and
e. The results of all required analyses.
6. Additional Monitoring by Permittee
If the permittee monitors any pollutant at the location(s) designated herein more
frequently than required by this permit, using approved analytical methods as specified
above, the results of such monitoring shall be included in the calculation and reporting of
the values required in the Discharge Monitoring Report Form (EPA No. 3320-1). Such
increased frequency shall also be indicated.
7. Records Retention
All records and information resulting from the monitoring activities required by this
permit including all records of analyses performed and calibration and maintenance of
instrumentation and recordings from continuous monitoii"^ instrumentation shall be
retained for a minimum of three (3) years, or longer if requested by the Regional
Administrator or the State water pollution control agency.
P-17
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PART 11
Page 6 of 9
Permit No. AL0028819
A. MANAGEMENT REQUIREMENTS
1. Change in Discharge
All discharges authorized herein shall be consistent with the terms and conditions of this
permit. The discharge of any pollutant identified in this permit more frequently than or
at a level in excess of that authorized shall constitute a violation of the permit. Any
anticipated facility expansions, production increases, or process modifications which will
result in new, different, or increased discharges of pollutants must be reported by
submission of a new NPDES application or, if such changes will not violate the effluent
limitations specified in this permit, by notice to the permit issuing authority of such
changes. Following such notice, the permit may be modified to specify and limit any
pollutants not previously limited.
2. Noncompliance Notification
If, for any reason, the permittee does not comply with or will be unable to comply with
any daily maximum effluent limitation specified in this permit, the permittee shall
provide the Regional Administrator and the State with the following information, in
writing, within five (5) days of becoming aware of such condition:
a. A description of the discharge and cause of noncompliance; and
b. The pehod of noncompliance, including exact dates and times; or, if not corrected,
the anticipated time the noncompliance is expected to continue, and steps being
taken to reduce, eliminate and prevent recurrence of the noncomplying discharge.
3. Facilities Operation
The permittee shall at all times maintain in good working order and operate as efficiently
as possible all treatment or control facilities or systems installed or used by the permittee
to achieve compliance with the terms and conditions of this permit.
4. Adverse Impact
The permittee shall take all reasonable steps to minimize any adverse impact to navigable
waters resulting from noncompliance with any effluent limitations specified in this
permit, including such accelerated or additional monitoring as necessary to determine the
nature and impact of the noncomplying discharge.
5. Bypassing
Any diversion from or bypass of facilities necessary to maintain compliance with the
terms and conditions of this permit is prohibited, except (i) where unavoidable to prevent
loss of life or severe property damage, or (ii) where excessive storm drainage or runoff
would damage any facilities necessary for compliance with the effluent limitations and
prohibitions of this permit. The permittee shall promptly notify the Regional
Administrator and the State in writing of each such diversion or bypass.
P-18
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PART II
Page 7 of 9
Permit No. AL0028819
6. Removed Substances
Solids, sludges, filter backwash, or other pollutants removed in the course of treatment or
control of wastewaters shall be disposed of in a manner such as to prevent any pollutant
from such materials from entering navigable waters.
7. Power Failures
In order to maintain compliance with the effluent limitations and prohibitions of this
permit, the permittee shall either:
a. In accordance with the Schedule of Compliance contained in Part I, provide an
alternative power source sufficient to operate the wastewater control facilities;
or, if such alternative power source is not in existence, and no date for its implementation
appears in Part I,
b. Halt, reduce or otherwise control production and/or all discharges upon the
reduction, loss, or failure of the primary source of power to the wastewater control
facilities.
B. RESPONSIBILITIES
1. Right of Entry
The permittee shall allow the head of the State water pollution control agency, the
Regional Administrator, and/or their authorized representatives, upon the presentation of
credentials:
a. To enter upon the permittee's premises where an effluent source is located or in
which any records are required to be kept under the terms and conditions of this
permit; and
b. At reasonable times to have access to and copy any records required to be kept under
the terms and conditions of this permit; to inspect any monitoring equipment or
monitoring method required in this permit; and to sample any discharge of pollutants.
2. Transfer of Ownership or Control
In the event of any change in control or ownership of facilities from which the authorized
discharges emanate, the permittee shall notify the succeeding owner or controller of the
existence of this permit by letter, a copy of which shall be forwarded to the Regional
Administrator and the State water pollution control agency.
3. Availability of Reports
Except for data determined to be confidential under Section 308 of the Act, all reports
prepared in accordance with the terms of this permit shall be available for public
P-19
-------
PART II
Page 8 of 9
Permit No. AL0028819
inspection at the offices of the State water pollution control agency and the Regional
Administrator. As required by the Act, effluent data shall not be considered confidential.
Knowingly making any false statement on any such report may result in the imposition of
criminal penalties as provided for in Section 309 of the Act.
4. Permit Modification
After notice and opportunity for a hearing, this permit may be modified, suspended, or
revoked in whole or in part during its term for cause including, but not limited to, the
following:
a. Violation of any terms or conditions of this permit;
b. Obtaining this permit by misrepresentation or failure to disclose fully all relevant
facts; or
c. A change in any condition that requires either a temporary or permanent reduction or
elimination of the authorized discharge.
5. Toxic Pollutants
Notwithstanding Part II, B-4 above, if a toxic effluent standard or prohibition (including
any schedule of compliance specified in such effluent standard or prohibition) is
established under Section 307(a) of the Act for a toxic pollutant which is present in the
discharge and such standard or prohibition is more stringent than any limitation for such
pollutant in this permit, this permit shall be revised or modified in accordance with the
toxic effluent standard or prohibition and the permittee so notified.
6. Civil and Criminal Liability
Except as provided in permit conditions on "Bypassing" (Part II, A-5) and "Power
Failures" (Part II, A-7), nothing in this permit shall be construed to relieve the permittee
from civil or criminal penalties for noncompliance.
7. Oil and Hazardous Substance Liability
Nothing in this permit shall be construed to preclude the institution of any legal action or
relieve the permittee from any responsibilities, liabilities, or penalties to which the
permittee is or may be subject under Section 311 of the Act.
S. State Laws
Nothing in this permit shall be construed to preclude the institution of any legal action or
relieve the permittee from any responsibilities, liabilities, or penalties established pursuant
to any applicable State law or regulation under authority preserved by Section 510 of the
Act.
P-20
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PART M
Page 9 of 9
Permit No. AL0028819
9. Property Rights
The issuance of this permit does not convey any property rights in either real or personal
property, or any exclusive privileges, nor does it authorize any injury to private property
or any invasion of personal rights, nor any infringement of Federal, State or local laws or
regulations.
10. Severability
The provisions of this permit are severable, and if any provision of this permit, or the
application of any provision of this permit to any circumstance, is held invalid, the
application of such provision to other circumstances, and the remainder of this permit,
shall not be affected thereby.
PART III
OTHER REQUIREMENTS
1. For the purpose of this permit, a calendar day is defined as any
consecutive 24-hour period.
2. Any untreated overflow which is discharged from facilities designed,
constructed and operated to contain or treat as applicable all process
generated waste water and the surface runoff to the treatment facility,
resulting from a 10-year, 24-hour precipitation event shall not be
suject to the limitations set forth in Part I, A of this permit.
3. In accordance with Section 306(d) of the Federal Water Pollution Control
Act (PL92-500) the standards of performance for conventional pollutants
as contained in this permit shall not be made any more stringent during
a ten year period beginning on the date of completion of such construction
or during the period of depreciation or amortization of such facility for
the purposes of section 167 or 169 (or both) of the Internal Revenue Code
of 1954, whichever period ends first. The provisions of Section 306(d)
do not limit the authority of the Environmental Protection Agency to
modify the permit to require compliance with a toxic effluent limitation
promulgated under BAT or toxic pollutant standard established under
Section 307(a) of the FWPCA, or to modify, as neccessary, to assure
compliance with any applicable State Water Quality Standard.
4. Control of runoff from site construction shall be consistent with sound
engineering practices such as those contained in "Guidelines for Erosion
and Sediment Control Planning and Implementation," EPA-R2-72-015 (August,
1972} or "Processes, Procedures and Methods to Control Pollution Result-
ing from all Construction Activity," EPA-430/9-73-007 (October, 1973).
Prior to start of construction, the permittee shall submit to the Regional
Administrator for review and approval, a detailed erosion and sediment
control plan. An approved plan shall be implemented prior to start of
construction.
P-21
-------
ATTACHMENT I
AL002R819
/ HIUlMOVSe CLARIFICATION
~ tKAMCM yX BASIN 5
CLARIFICATION \
BASIN 4
CLARIFICATION
•ASIN 3
OUARRY PLANT
AND DOCK AREA
CLARIFICATION
BASIN 2
CLARIFICATION
BASIN 1
1111111II AREAS TO BE MINED
CLARIFICATION BASINS
0 0.3 1
SCALE IN KILOMETERS
PROPOSED GAILLAflO OUAftNY
MOMWOC COUNTY. ALABAMA
SOURCE W«lB,wiBdu,tri.,.1977.
P-22
-------
JOINT PUBLIC NOTICE--U.S. ARMY CORPS OF ENGINEERS AND
ALABAMA WATER IMPROVEMENT COMMISSION (PLANT SITE)
-------
TO
ATTENTION O Pi
DEPARTMENT OF THE ARMY
MOBILE DISTRICT. CORPS OF ENGINEERS
f. 0. BOX 2288
MOBILE. ALABAMA 38628
JOINT PUBLIC NOTICE
U. S. ARMY CORPS OF ENGINEERS
SAMOP-S
PUBLIC NOTICE NO.
AND
STATE OF ALABAMA
WATER IMPROVEMENT COMMISSION
AL78-00057-E
27 April 1978
PROPOSED DREDGING, FILL, BARGE DOCK, AND OUTLET STRUCTURE,
THEODORE SHIP CHANNEL AND NORTH FORK DEER RIVER,
ADJACENT TO MOBILE BAY, MOBILE COUNTY, ALABAMA
TO IJHOM IT HAY CONCERN:
This District has received an application for a Department of the Army
permit pursuant to Section 10 of the River and Harbor Act of 1899
(33 U.S.C. 403), and Section 404 of the Federal Water Pollution Control
Act (PL 92-500, 33 U.S.C. 1344), as described below:
APPLICANT; Ideal Basic Industries
G. M. Lochhead, P. E., Chief Engineer
P. 0. Box 8789
Denver, CO 80201
WATERWAY; Theodore Ship Channel, North Fork Deer River
Mobile County, Alabama
WORK; Perform dredging to a depth of -40.0 MSL, by hydraulic dredge, of an
area approx. 300 ft. x 2300 ft. along the shoreline of applicant's property as
shown. Approximately 650,000 CY native soil, including sands, silts and clays
will be removed. It is presently anticipated that dredging operations will be
conducted concurrently with the dredging of the Theodore Industrial Canal and
that the removed material will be disposed of in a site approved for use in
connection with the Theodore Industrial Canal.
Approximately 2300 ft. of concrete trestle type dock structures will be con-
structed adjacent to the dredged area. The dock facilities will extend approx.
80 ft. from the shoreline into the dredged area. The dock facilities will be
operated to receive raw materials utilized in the manufacture of cement and to
support equipment utilized in loading cement transport vessels.
Fill will be placed in the wetland area as shown adjacent to an existing road-
way in order to construct an access road to the plant site. Approx. 4450 CY
fill will be required to bring the grade of the plant access road to elevation
10.0 MSL, the top of the.proposed bridge across North Fork Deer River. The
earth fill will cover a lineal distance of approximately 500 feet with an
average height of fill about 5 feet.
P-23
-------
SAMOP-S 27 April 1978
PUBLIC NOTICE NO. AL78-0057-E
Fill will also be placed in two wetland areas within the plant site itself in
order to bring the plane grade to elevation lo.O MSL. Concrete sheet pilings
will be driven along the northeast corner of the plant site along the edge of
the fill to minimize construction in the wetland area.
A concrete outlet structure, with riprap, will be constructed at the southwest
corner of the plant site adjacent to the Theodore Ship Channel. The outlet
structure will serve as a discharge point for the settling basin as shown on
the attached plan.
The trestle for the railroad and the bridge within the plant access road
have not been included in this Public Notice since they are currently being
processed by the Eighth Coast Guard District, New Orleans. If the Coast Guard
declines jurisdiction at a later date, an additional public notice will be
advertised.
AIL work to be performed on or adjacent to the applicant's property within the
Theodore Industrial Park, off Theodore Ship Channel, Mobile Bay, Mobile County
Alabama. Plans submitted by the applicant are attached to this notice.
PLANS SUBMITTED BY THE APPLICANT ARE PRELIMINARY AND BASED ON CONCEPTUAL
ENGINEERING STUDIES, NOT DETAILED DESIGN. ANY SUBSTANTIAL DEVIATIONS WILL BE
RE-ADVERTISED.
The applicant has applied for certification from the State of Alabama in
accordance with Section 401(a)(l) of the Federal Water Pollution Control
Act Amendments of 1972; and upon completion of the required advertising,
a determination relative to certification will be made.
The Environmental Protection Agency has determined that an Environmental
Impact Statement (EIS) is necessary. An EIS is currently being prepared
for Ideal Basic Industries' entire operation, both at the Theodora Site and
the Quarry Site, Monroe County.
This public notice is baing distributed to all known interested persons
in order to assist in developing facts on which a decision by the Corps
of Engineers can be based. For accuracy and completeness of the record,
all data in support of or in opposition to the proposed work should be
submitted in writing setting forth sufficient detail to furnish a clear
understanding of the reasons for support or opposition. The decision
whether to issue a permit will be based on an evaluation of the probable
impact of the proposed activity on the public interest. That decision
will reflect the national concern for both protection and utilization of
important resources. The benefit which reasonably may be expected to
accrue from the proposal must be balanced against its reasonably foresee-
able detriments. All factors which may be relevant to the proposal will
be considered; aniong those are conservation, economics, aesthetics, general
environmental concerns, historic values, fish and wildlife values, flood
damage prevention, land use classification, navigation, recreation, water
supply, water quality and, in general, the needs and welfare of the people.
No permit will be granted unless its issuance is found to be in the public
interest.
P-24
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SAMOP-S 27 April 1978
PUBLIC NOTICE NO. AL78-00057-E
Any person who has an interest which nay be adversely affected by the issuance
of a permit may request a public hearing. The request must be submitted in
writing to the District Engineer within 30 days of the date of this notice and
oust clearly set forth the interest which may be adversely affected and the
manner in which the interest may be adversely affected by the activity.
You are requested to communicate the information contained in this letter to
any other parties whom you deem likely to have interest in the matter.
Evaluation of the probable impacts involving deposits of dredged or fill
material into navigable waterways will include the application of guidelines
established by the Administrator of the Environmental Protection Agency.
No properties listed in the National Register of Historic Places are known to
be near the proposed work. The possibility exists that the proposed work may
damage or destroy presently unknown archeological, scientific, prehistorical
or historical sites or data. Copies of this notice are being sent to the State
Archeologist, State Historical Preservation Officer and the National Park
Service.
Correspondence concerning this Public Notice should refer to Public Notice No.
AL78-00057-E and should be directed to the District Engineer, U. S. Army
Engineer District, Mobile, Corps of Engineers, P. 0. Box 2288, Mobile,
Alabama 36628, ATTN Regulatory Functions Branch, in time to be received
prior to 26 May 1978.
If you have any questions concerning this application, you may contact this
office, P. A. Flanagan , telephone number (205) 690- 2650
Please refer to the above Public Notice number.
MOBILE DISTRICT
U. S. Army Corps of Engineers
P-25
-------
HOLLINGERS
/ISLAND
THEODORE INDUSTRIAL
PARK
/^
ADJACENT PROPERTY:
(T) AIM REDUCTION COMPANY
^/s
f X"S>
££• IDEAL BASIC "N
gtf INDUSTRIES
If
.PROPOSED DOCK
DREDGING
TURNING
BASIN
1
1
(|) HIGHWAY R.O.W.
FROM: uses OUAO SHEET (THEODORE, ALA.)
LOCATION MAP
O 500 IOOO 200O 3OOO
SCALE IN FEET
Sfe-
UkT.
•-:-?/
FROM: US. C.S. MAP (MOBILE, ALABAMA; MISS.; LA.)
PROPOSED SHIP a BARGE DOCK
IN THE
THEODORE SHIP CHANNEL
MOBILE COUNTY
STATE OF ALABAMA
APPLICATION BY
IDEAL BASIC INDUSTRIES
• 977
P-26
-------
250'
1400
CONCRETE DECK
SUPPORTED BY PILES*/ P
V
NEW PIERHEAD LINE ft BREASTING LINE
X"~
AREA TO BE DREOOEO
TO M.S.L. EL.(-)40
TOE OF CHANNEL
THEODORE SHIP CHANNEL
TOE OF CHANNEL
PLAN
0 50 100
200
300
s
r
CD
H
(/> B
H O
> 2 O
H O O
^ 9? $
-o
3
o
TJ
o
CO
m
o
CO
SCALE IN FEET
5
F553S ¥5i
\ * ^ ^j^ ^J|
= i > o -D g »
g a r O o m
w * 5 5 > 2
-j 1* ~j Z O
^ 5C -< 2 m
*** ^. r-r^
m o
CO O
o
200*
i UOOHINU
BREASTING DOLPHIN
NOTE;
INFORMATION PRESENTED ON THIS DRAWING
IS PRELIMINARY AND BASED ON CONCEPTUAL
ENGINEERING STUDIES NOT DETAILED DESICN
DATUM: UEAN SEA LEVEL M.S.L.
NOTE;
NEW PIERHEAD LINE
ft BREASTIN6 LINE
. TOE OF
^ CHANNEL
M.S.L. EL.0.01
EXISTING
GRADE
DREDGE TO
H 40' M S L
Z_
SECTION A-A
,0
20
40
60
L.
80
100
-------
HOLLINGERS
/
ISLAND
XHEOOORE INDUSTRIAL
PARK
•>•».
vi//.
SETTLING
BASIN
TUSHIHG
BASIN
IDEAL -BASIC
INDUSTRIES
.OUTLET
STRUCTURE
'•WE
ADJACENT PROPERTY.
0 A»* REDUCTION COMPANY
(I) HIGHWAY HO W.
(D ALABAMA STATE DOCKS
FKOM> U30S OUAO 3HEET (THEODORE, ALA.)
: USG5 MA>(MO§ILt. ALABAMA; Ml S3 i LA.)
LOCATION MAP
O 300
3OOO \o
SCALE IN FEFT
LAT
••v
VICWITY MAP
a ; * "i «~"">
iCALI IN MIUES"
LOCATION MAP
THEODORE PLANT
MOBILE COUNTY
STATE OF ALABAMA
APPLICATION BY
IDEAL BASIC INDUSTRIES
JANUARY 13, 1978
P-28
-------
EXISTING
ROAD
EXISTING
CULVERTS
AIR REDUCTION
COMPANY PROPERTY
PROPERTY-
UNE
NOTE: Information
preliminary
engineering
APPROXIMATE LIMIT
OF MARSH EL. 4
PROPOSED RAILROAD BRIDGE
H
PROPOSED ROAD BRIDGE
NOTE:
Mean High Water and
Mean Low Water levels
are not known
for Marsh area.
200
SCALE IN FEET
presented on this drawing is
and based on conceptual
studies not detailed design.
P-29
PROPOSED BRIDGES
OVER
NORTH FORK DEER RIVER
MOBILE COUNTY
STATE OF ALABAMA
APPLICATION BY
IDEAL BASIC INDUSTRIES
JANUARY 13, 1978
-------
2 SPANS X 25'= 50*
TOP OF SLAB
\EL. lo.o
NATURAL
GROUND
?. PROFILE
FILL
NOTE'-
Mean High Water and
Mean Low Water levels
ore not known
for Marsh area.
ELEVATION
O 5 LO 20 30
SCALE IN FEET
30'
PILES DRIVEN
TO REFUSAL
i 1
ui H r
L^
.«:
EL. IO.O
1 H
{••L,
:|
^i
>^~
PRECAST CONCRETE
STRINGERS
CONCRETE PILES
SECTION A-A
10
SCALE IN FEET
20
NOTES:
I. Elevations shown refer to Mean Sea Level.
2. Approximately 4450 cubic yards of select
granular material will be used for fill.
NOTE: Information presented on this drawing
Is preliminary and based on conceptual
engineering studies not detailed design.
PROPOSED ROAD BRIDGE
OVER
NORTH FORK DEER RIVER
MOBILE COUNTY
STATE OF ALABAMA
APPLICATION BY
IDEALBAS£ INDUSTRIES
JANUARY 13, 1973
P-30
-------
Ween High V/atar and
Mson Lo* Wo fur lev
for ?jtarso Arao.
RAILROAD
SPUR
ACCESS
ROAD
AREA OF FU
NORTH FORK
DEEH RIVER
A R A
(PLANT GRADE = EL. IS.Oi)
THEODORE SHIP CHANNEL
HO I
500
1,000
SCALE IN FEET
Information presented on this drawing is
preliminary and based on conceptual
engineering studies not detailed design,
P-31
V/ETLAND FILL
THEODORE PLANT
MOBILE COUNTY
STATE OF ALABAMA
APPLICATION BY
IDEAL BASIC INDUSTRIES
FEBRUARY 14, 1973
-------
L-9A"
24 DIA. PIPE
PLAN
INV EL. 0.0
EL 0.0
MEAN HIGH WATER EL. 0.7
IEAN LOW WATER EL-B07
•MHW EL. 0.7
EL.H0.7
CONCRETE
OUTLET
STRUCTURE
PROFILE
SCALE IN FEET
NOTES:
I. Elevations shown refer to Mean Sea Level.
NOTE: Information presented on this drawing is
preliminary and based on conceptual
engineering studies not detailed design.
PROPOSED OUTLET STRUCTURE
IN THE
THEODORE SHIP CHANNEL
MOBILE COUNTY
STATE OF ALABAMA
APPLICATION BY
IDEAL BASIC INDUSTRIES
JANUARY 13,1978
P-32
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JOINT PUBLIC NOTICE—U.S. ARMY CORPS OF ENGINEERS AND.
ALABAMA WATER IMPROVEMENT COMMISSION (QUARRY SITE)
-------
DEPARTMENT OF THE ARMY
MOBILE DISTRICT. CORPS OF ENGINEERS
f. 0. BO! 2288
•OBIIE. ALABAMA 38B28
JOINT PUBLIC NOTICE
U. S. ARMY CORPS OF ENGINEERS
AND
STATE OF ALABAMA
WATER IMPROVEMENT COMMISSION
SAMOP-S ,, . .. 1Q7R
PTTWT Tr MrtTTrr M« ^ APril 1978
PUBLIC NOTICE NO. AL78-00056-E
PROPOSED BARGE DOCK .AND FILL ASSOCIATED WITH CLARIFICATION BASINS. ALABAMA
RIVER, APPROXIMATELY MI. 54, MONROE COUNTY, ALABAMA
TO WHOM IT MAY CONCERN:
This District has received an application for a Department of the Army
permit pursuant to Section 10 of the River and Harbor Act of 1899
(33 U.S.C. 403), and Section 404 of the Federal Water Pollution Control
Act (PL 92-500, .33 U.S.C. 1344), as described below:
APPLICANT; Ideal Basic Industries
c/o Mr. G. M. Lochhead, P.E., Chief Engineer
P.O. Box 8789
Denver, CO 80201
WATERWAY: Alabama River, Approximately Mile 54
Monroe County, Alabama
WORK; Construct a barge dock, adjacent to the shoreline, on the Alabama River,
approximately Mile 54. The dock , 636 ft. long, will extend approximately 100
ft. beyond the MHW line. A conveyor sys tern ,loca ted at the center of the dock,
will connect to on shore facilities and will extend an additional 80' into the
Alabama River. The barge dock will provide water access to Ideal Basic Industries
quarry, site. Additionally, clarification basins and outlet facilities will be
constructed to provide effective storage capacities for stormwater runoff. These
basins will provide a sediment trap for all runoff from the disturbed quarry and
limestone storage area. Only those basins adjacent to the Alabama River which
are below the OHW will be required to have Department of Army Permits. All work
to be performed adjacent to the applicant's property on the Alabama River,
approximately mile 54, Monroe County, Alabama. Plans submitted by the applicant
are attached to this notice.
PLANS SUBMITTED BY THE APPLICANT ARE PRELIMINARY AND BASED ON CONCEPTUAL
ENGINEERING STUDIES NOT DETAILED DESIGN. ANY SUBSTANTIAL DEVIATIONS
WILL BE RE-ADVERTISED.
P-33
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SAMOP-S 10 April 1978
PUBLIC NOTICE NO. AL78-00056-E
The applicant has applied for certification from the State of Alabama in
accordance with Section 401(a)(l) of the Federal Water Pollution Control
Act Amendments of 1972; and upon completion of the required advertising,
a determination relative to certification will be made.
A preliminary assessment of environmental, social and other factors indicates
that an environmental impact statement is not required. Permit assessment
is a continuing process. This preliminary determination of EIS requirement
will be changed if data or information brought forth in the coordination
process is of a significant nature.
This public notice is being distributed to all known interested persons
in order to assist in developing facts on which a decision by the Corps
of Engineers can be based. For accuracy and completeness of the record,
all data in support of or in opposition to the proposed work should be
submitted in writing setting forth sufficient detail to furnish a clear
understanding of the reasons for support or opposition. The decision
whether to issue a permit will be based on an evaluation of the probable
impact of the proposed activity on the public interest. That decision
will reflect the national concern for both protection and utilization of
important resources. The benefit which reasonably may be expected to
accrue from the proposal must be balanced against its reasonably foresee-
able detriments. All factors which may be relevant to the proposal will
be considered; among those are conservation, economics, aesthetics, general
environmental concerns, historic values, fish and wildlife values, flood
damage prevention, land use classification, navigation, recreation, water
supply, water quality and, in general, the needs and welfare of the people.
No permit will be granted unless its issuance is found to be in the public
interest.
Any person who has an interest which may be adversely affected by the issuance
of a permit may request a public hearing. The request must be submitted in
writing to the District Engineer within 30 days of the date of this notice and
must clearly set forth the Interest which may be adversely affected and the
manner in which the interest may be adversely affected by the activity.
You are requested to communicate the information contained in this letter to
any other parties whom you deem likely to have Interest in the matter.
Evaluation of the probable impacts Involving deposits of dredged or fill •
material into navigable waterways will include the application of guidelines
established by the Administrator of the Environmental Protection Agency.
No properties listed in the National Register of Historic Places are known to
be near the proposed work. The possibility exists that the proposed work may
damage or destroy presently unknown archeological, scientific, prehlstorical
or historical sites or data. Copies of this notice are being sent to the State
Archeologist, State Historical Preservation Officer and the National Park
Service.
P-34
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SAMOP-S 1° AP*11 1978
PUBLIC NOTICE NO. AL78-00056-E
Correspondence concerning this Public Notice should refer to Public Notice No.
AL78-00056-E and should be directed to the District Engineer, U. S. Amy
Engineer District, Mobile, Corps of Engineers, P. 0. Box 2288, Mobile,
Alabama 36628, ATTN Regulatory Functions Branch, in time to be received
prior to 3 May 1978.
If you have any questions concerning this application, you may contact this
office, p. A. Flanagan • telephone number (205) 690-2658
Please refer to the above Public Notice number.
MOBILE DISTRICT
U. S. Army Corps of Engineers
P-35
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GAILLARD QUARRY
CLARIFICATION BASINS ALONG ALABAMA RIVER
As the limestone quari*y area is being developed, the open faces
of limestone and other subsurface soil subject to stormwater surface
runoff will erode and could create a turbidity and sediment problem in
nearby streams and wetland areas. Storm runoff from all of the process
operations will contain suspended solids of varying concentrations.
During the operating life of the quarry at least five clarification
basins will be required for controlling sediment and water quality of the
storm runoff from the disturbed areas. However, during the first five
years of quarry operation it is anticipated that only Clarification Basins
Nos.l,2&5 will be needed and therefore are the only ones which are to be
included as part of the initial construction of the quarry facilities.
Since detailed design engineering for these clarification basins has not
been completed, the information presented herein represents only the best
available based on conceptual engineering studies.
The embankment for Clarification Basin No. 5 may not require the
issuance of a fill permit from the Department of Army since the streambed
elevation at this location is considerably higher than the established
ordinary high water elevation of 3*».0 feet MSL for the Alabama River at
the Gail lard Quarry site.
The clarification basin embankment will be an earthfill dam with an
impervious clay core. The preliminary information for each clarifica-
tion basin embankment is as shown in the following table:
P-36
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Page 2
Gai1 lard Quarry
Clarification Basins Along Alabama River
fi cat ion
is in
1
2
5
Streambed
Elevat ion
MSL
23
23
55
Top
Elevation
MSL
60
75
105
Length of
Embankment
FEET
270
1*75
J.85
Earthwork
Volume
CY
18,790
80,650
69,100
All clarification basins would have a flood storage volume to
storm the storm runoff from a 10-year 2^-hour rainfall on top of the
storage volume allocated for sedimentation. Two discharge structures
will be provided for each basin. One discharge structure will be
utilized as a decanting facility while the other will serve as an
emergency spillway sized to accommodate flood flows resulting from a
100 year storm. The suspended solids concentration discharging from
the basins into the Alabama River, under the normal conditions, will
be limited to 25 mg/1 or less.
V-37
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ttCAL BASIC
MDUSTMIES
PROPOSED BARGE DOCK
IN THE
ALABAMA RIVER
MONROE COUNTY
STATE OF ALABAMA
APPLICATION BY
IDEAL BASIC INDUSTRIES
1977
SHEET I OF 2
P-38
-------
CONyfVOft SYSTEM
TO ONSHORE FACILITIES
HI8M
WATCH €L-(+»»*'
LOW
WATCH EL.(+) •'
•ftCASTING LINE
ALAB A MA
FLOW
NOTE:
INFORMATION PRESENTED ON THIS DRAWING IS
PRELIMINARY AND BASED ON CONCEPTUAL
CNOINEEMN8 STUDIES NOT DETAILED DESISN
.. «. _ X" WATCH CL.U) •'
PLAN
0 90 100
200
300
SCALE IN FEET
OATUMl MEAN SCA LEVEL
100*
TO DOCK IL (*) «0'
NI«N
LOW
SECTION A -A
0 fS 9O 100 ISO
• CALI IN FCCT
P-39
PROPOSED BARGE DOCK
IN THE
ALABAMA RIVER
MONROE COUNTY
STATE OF ALABAMA
APPLICATION BY
IDEAL BASIC INDUSTRIES
ItTT
•MEET t OF 2
-------
CLARinCATiai
BASIN
QUARRY
PLANT AREA
XARIFICATON
BASIN
NOTE =
Mop bdtt it 71/2* USGS Ouodronqlt Sheet*.
Elevation* shown art in feet Datum is
Mean Sea ktvtl.
6AILLARD QUARRY
SITE MAP
MONROE COUNTY
STATE OF ALABAMA
APPLICATION BY
IDEAL BASIC INDUSTRIES
JANUARY 13,1978
SHEET 2 OF 5
P-40
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IDEAL BASIC
INDUSTRIES
'McWILLIAMS
PROPERTY
(LEASED)
LOCATION MAP
0 LDOO &OOO
f*0* UMS OUAD **CET (ri.TI.Ni LMtf
SCALE IN FEET
ITOTf HIGHWAY MAP
P-41
LOCATION MAP
6AILLARD QUARRY
MONROE COUNTY
STATE OF ALABAMA
APPLICATION §Y
IDEAL BASIC INDUSTRIES
JANUARY 13, 1378
SHEET I OF 8
-------
NATURAL
'GROUND
14' (20f-
EL_ (see table sheet 4)
DISCHARGE
CHANNEL
I-48TDIA. PIPE-
SECTION AT EMERGENCY OUTLET
10'
NATURAL
Y~ GROUND
6 SOIL-CEMENT-
DISCHARGE CHANNEL SECTION
SCALE IN FEET
NOTE: Information presented on this drawing 1s
preliminary and based on conceptual
engineering studies not detailed design.
PROPOSED EMBANKMENTS
8 OUTLET FACILITIES
NEAR THE
ALABAMA RIVER
MONROE COUNTY
STATE OF ALABAMA
APPLICATION BY
IDEAL BASIC INDUSTRIES
JANUARY 13,1978
SHEET 5 OF 6
P-42
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INLET
EL. \ STRUCTURE
VARIES
14* (20'-BASN I)
(see table)
—
SLIDE
GATE
EARTH FILL
EMBANKMENT
DISCHARGE
CHANNEL
NATURAL •GROUND-^
1-36 DlA. PIPE
OUTLET
STRUCTURE
SECTION AT MAIN OUTLET FACILITY
SCALE IN FEET
6 SOIL-CEMENT
10'
DISCHARGE CHANNEL SECTION
5
SCALE IN FEET
NATURAL
AGROUND
*^*f/wfti^
BASIN
NUMBER
1
2
S
4
TOP OF EMB.
EL.
75
60
70
105
NOTE: Information presented on this drawing 1s
preliminary and based on conceptual
engineering studies not detailed design.
PROPOSED EMBANKMENTS
a OUTLET FACILITIES
NEAR THE
ALABAMA RIVER
MONROE COUNTY
STATE OF ALABAMA
APPLICATION BY
IDEAL BASIC INDUSTRIES
JANUARY 13, 1978
SHEET 4 OF 5
P-43
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ERA'S AUTHORITY TO CONSTRUCT (EPA REGULATIONS FOR THE
PREVENTION OF SIGNIFICANT DETERIORATION OF AIR QUALITY, 40 CFR 52.21
CEMENT PLANT
[The limestone quarry is not included in this authority. Prior to the
public hearing for this project, a final determination will be made
concerning the applicability of 40 CFR 52.21 to the quarry operation.]
-------
UNITED STATES ENVIRONMENTAL PROTECTION AGENCY
v> REGION IV
343 COURTLAND STREET
ATLANTA, GEORGIA 30308
MAR 3 0 1978
Mr. Robert J. Castelli
Director of Environmental Quality
Ideal Basic Industries
Post Office Box 8789
Denver, Colorado 80201
Dear Mr. Castelli:
'This letter refers to the Ideal Basic Industries applying on
November 20, 1977, to the Mobile County Board of Health for a
permit to construct a cement plant in Theodore Industrial Park,
Theodore, Alabama.
The Mobile County Board of Health performed the Prevention of
Significant Deterioration (PSD) Mew Source Review (40 CFR 52.21)
which Includes an engineering and air quality analysis.
The preliminary review of the'application for permit to
construct was subject to a 30-day public comment period beginning
January 12, 1978. EPA made comments during that period concerning
Best Available Control Technology (3ACT) for the cement plant. On
February 22, 1978, the Mobile County Board of Health submitted to
EPA their final determination for the cement plant including copies
of Draft County Permits to Construct.
Because the authority for enforcement of PSD regulations 1n
Alabama presently rests with the EPA, we have reviewed the final
determination. On the basis of our review, we have determined,
subject to the enclosed conditions of approval, that the operation
of the cement plant will not cause a violation of National Amoient
Air Quality Standards and the Class II PSD increments for sulfur
dioxide and particulates and will meet the Federal requirements
concerning BACT for particulate and sulfur dioxide emissions as
amended in the Clean Air Act on August 7, 1977*
P-45 ,
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This Authority to Construct is hereby issued to Ideal Basic
Industries for the cement plant described in your county application
as numbers 503-8026-0001 thru 0028, with permit conditions (enclosed)
which are hereby made a part of this approval.
Also please note that the Mobile County Board of Health
must review and approve specifications for the selected air pollution
control devices prior to your issuance of a purchase order.
Therefore, we require a monthly progress report to be submitted by
your company beginning with this Authority to Construct and ending
when the purchase of all control equipment is approved by the Alabama
Air Pollution Control Commission.
Please be advised that violation of any condition issued as a
part of this approval as well as construction at variance with the
permit will be subject to enforcement action. Also, this Authority
to Construct applies only to PSO requirements and not to other
Federal, State, or local agency permitting requirements.
Authority to Construct shall take effect on the date of this
notice. Any questions concerning this approval may be directed to
Eliot Cooper of the Air Programs Branch, 404/881-3286.
inoerely yours,
John A. White '
jional Administrator
Attachment
cc: Mr. James Cooper
Alabama Air Pollution Control Commission
Mr. Johnny Sanders
Mobile County Board of Health
This Approval to Construct would be issued this date Ffb- Z7, • -•ru,
but for the order entered in Environmental Defense Fund v. Environmental
Protection Agency, No. 78-281 (D.D.C.) (entered on February , 1978).
P-46
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Penalt Conditions
1. This permit is Issued on the bnsls of rules rnd relations existing en Ihc
date oC issuance. In the event addliia:wl rules and reflations are r.JoPctd.
it shall be the pcrait holders responsibility to r.onply vith such rules,.
2. This.permit is not transferable. Upon sale er.lcc.nl transfer, the ncv owner
or operator must apply for a pcrnic vichin 30 days.
3. This permit is tc be kept on file or on display at all tlv.cs at the facility
where the permitted article, machine, pr equipricr.t is used. It is to be wade
readily available for inspection by any and all persons who ray request to
see it.
4. Nothing in this ponr.it or conditions thereto shall negate any authority granted
to the Mobile County Board of Health; Division of Air Pollution Control or Health
Officer pursuant :o the Alabama Air Pollution Control Act or regulations issued
thereunder.
5. Additions end revisions to the conditions of this rrrnit vill be made ii necessary to
insure tltnl (he Mobile County Air Pollution Control Rules and Regulations arc not
violaled.
6. Additional cenitorJng, records and reporting My be rocuired as Authorised by Fart 1.5
of the Mobile County Alt i'ollutlon Control Rules nr.d Regulations.
7. The approved episode plan for particular natter, sulfur dioxide, nitrogen oxide and
hydrocarbons is hereby eace * p.-.rt of and a condition to this permit.
8. A ncu pcnalt cppllc.-.tion uyst bs e.-.de for new sources, .as defined in Fart 1.3.2" of
the Mobile County Afr Pollution Control Rules and Foliations, or for any roaJffcation
of *» existing source, as modification Is defined In Pare 1.3.?6 of said Rales and
Reflation*.
9. The Health Officer or his authorized reprcscntniive any enter &r.rt Inspect any f-opcrty.
premises or place on or at which tn cir conC>JBlnant source Is located cr is being con-
structed, installed or established at any ree&oi:.-.hlc lime for '.ho purpose cf .i-.sortan;-
•ing the state of cc-.rli.-ntce with these rci-ular'.ons. N'o person shall refuse entry or
access to the Health Cfiiccr or his authorized rcpicstnt.itivc who reqxtests entry lor
purposes of inspection, and who presents apprcnrlr.ro crciloncinls; nor fhall any 7«ir=-jr.
ebstnict, hamper or Interfere with any such inspection. If requested, cho owner or
Operator of the preai&etf shall receive a report setting Jorth .-,11 facts found v'.iiclt
relate to coxpliance.sttf.tua.
10. This source may not be oporitcd until a Teaporary Pt-ratt to Operate hits b-?on obtaJncd
froa this office as spc.-ifled in Part 3.10 of the Mobile County Air Pollution CYatrol
Kales and P.cr.ulctions. T.ils request should be made, in vritins at lo.ist 10 days F'.MoT
to planned ctart-up.
P-47
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11. Any change* or deviation fron the plans and specif icatlo is r.uhnlttrd in the i'f»"l *«MSl"n
frr llils remit ruse be .improved by this Division LI' sail changes or dsviaci.cn say cj'tr.u
an increase in die anounc of air concanin.incs cr.icr.cd.
12. The methods for report in* nainten.tnce or oalfunetloninc sf equip-scnt rhall be in jcr.v-
dancc vitli Part 1.12 of the Mobile County Air Politician CimtroL Rules and Ri*;juJ.-;tlcr..5.
13. In case of rhutdovn of. lir pollution control cqttfcnonc far scheduled ealntrn.-incfl f;-r
a period greater th.in 4 hour?, ihr intone Co shucOovrs sh-ill l»o reported to ihc 'Jivivin.i
of Air Pollution Control at least 24 hours prior to the planned shucJcvn.
14. In the event there is 'a breakdown of e^ulpnent *" "'ch a Winner .is Co cause c!io l:ier«.txr
of omission of Mr coremln.incr. for a period f.rpatcr Chan 4 hours, the pcrsi-t r/^ronsli'U-
for such oqnipaent sfcill notify the Division of Air Pollution Concrol viihi". 2* 'inirs .IMC
provide 9. sJntO'wnt jjK-lns ulJ p«?rtli«o:i'. f-ictJ:, ancludirt^ tt'.a -luraeton -Jl t!i- hi p^I.da-.ii.
The Division of Air 1'ollution Concrol shall also bu contacted when riio br«-nk-jv<«'n has I 0.1-1
corrected.
IS. During construction rha r^olicant rast take all prcrnuclcr.3 to Halt the snrunt of ?.u-
Clculac-2 anctcr In elf nlr. Tiicsr vill include, but an: not Halted co. the •..-.'tci-i-.'. of
all dirt rondii on a srh-»JuicJ b.ir.ls durlr.R any dry partods and the «««c of the hrsr
In the burning of vr^ot.ition at thr plnnt sice. A burning pcmli r.u.Jt he
jir'or to any ooen burninr..
16. The three total suspended patticulatc nonilorlng sites vill rcxaln in oporatlon at
their present locacio:i or at other locations approved by die Mantle County Hca'.rh
Hepartrcnc. The site dnta cust be collected on .in every 6 days b.isis ,ini/:he roJ lec-
tion anil analysis rust follov all approved cviidcllr.es. A seal -annual rcjjor: o.f tlj-j"
data will be required.
17. After construction the relieving measures sust be tancn to assure the adequate con-
trol of fugitive dust caisslons:
a. The application of wafer, or suitable chcr.lcals on e-atcrlal stockpiles or
other surfaces which may create fugitive dust.
b. All paved surf&cca shall be cleaned as necessary.
e. Paving of all utilized auto or truck traffic rands ?r areas.
d. Any spillage clean up Is to be done vith a vacuum type system or other
appropriate cquipncnc as necessary.
e. The removal frrn the plant sice of all waste materials in a aanner Co
prevent fugitive euiir-sivns.
f. Adequate controls during any unloading cr loading operations to air.imlrc
cplllagc and fugicivc emissions.
18. I'articulate ealsalons from the conl dryer shall be subject to whichever ct the
condition!: Is norc stringent:
a. 'The participate caisnicn rate shall not exceed 21.1 Ibs/hr; or
b. The pnrtlculntc caissicna shall be United to 0.031 pr/dscf a.t
In the U. S. Environmental Protection Armey's Standnrds c; Fcc'onuncc
for Coal Preparation I'lants.
In addition the .ipplicnnt shill not cnusc to be discharged Inro tl'C atcosphrrc fron
the t her ixi 1 dryer', f.sses which exhibit 20 percent opacity or greater.
P-48
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19. The applicant shell 'not cau.-.e to be dtscli_rr.c>I into the nlr.:or.phere frcn ar.y coal
processing or convey lit*; equip?.. >it, coal stnraf.o syr.tcu, or co.il transfer a:vJ *sr.d
Ing systiie, &ascs which exhibit 10.1 op.iciLy or p.rc.itcv and paniculate rxission
limit r.rcater than 0.01 Rr/dscf.
a. The sulfur dioxide rate froa the- coal dryer shall not exceed the were
etritif.cnt of 60 Ibs/ton of co.il burned or ISO Ibs/hr. Vho applicant
shall conduct tostliir. In order to tirasuic the sulfur dioxicii: erMr::ic-u
rate froa the coal dryer. The rone methods aiirt procedure:; must In:
approved by the Mubllc County Health De?.ii txeut.
20. With roj-.ard to the coal drver, the applicant shall continuously operate
devices for Btc.isurocenc of the i caper.-, it: ro nf cha ».as ft roan at thn exit of t'.-.f coal
dryer on a con: inuou.-- ha:: is; alr.o. the menl tcrir.r. Hevi.-.es are Co bis rocal U'ralcd
annually In accordance vlth procedures uiuiur 40 C"K 60.13(j)(J).
21. With regard LO thu raw allis arid- kilns (anJ the cllnl.cr cooler if ulccrnacivi* r.u-ner 1
is utilized), they vill ncet a partlcul.-itc emission Halt of tSe norc st.'Jnpc.iC oC ^.1
Ibs/hr or of 0.30 Ib/ton of food (dry b^sl.s) to kiln *••. specified by ldu.il Ci >.c:ic !:•..
its pci-r.lt application to the "obilc County Health Dr.p-i:tav.-.t. Tlia 0..50 J«/i ,r. of
feed 1& equal to the U. S. Er4vironr^ntcl Protection Aj-.ensy'n Sr.ar.dard of Perf srrj.vic.-..
In addition, the applicant shall not cause to b« dlschiirced inco '.he .acuria^hrrc thrr«|>
the raw will stack, any gases which exhibit sru.itcr than 20 percent cpr.city.
a. The sulfur dloxiJe omission rate frora the rav mill::, kilns and clay
(and clinker cooler if slcernatlvc- number 1 is utilized) ci>rour.h the ruv
Mill stack shall i.ot exceed iric norc s^rir.^cnt of -SO ]bs/tc;i of coal burvcc
or 2,160 Ibs/hr. Within 150 cays aiicr initial oporatlon of the fas; ;-.?». . or
90 days after tho facility is operating .1: full ca.v-rj cy, rcstinr. vili br
conducted on several occasions to determine che sulfur dior.idc enii-sicii r.-ro
through the raw aill stack. (Tiic test ucthods and prnccduron nsur.t be approved
by the Mobile Cour.cy Health Departr.cr.t.) Tlie Dcpjrtr.cnc »?.y then make vra-
sonablc reductions in tne above cnissio:i rate basc-i upon ch.? results oT tl:ij
testing and the variations in such results aud the possibility of
in the future; tha feasibility, cost and engineer Ing aspects of
with such rerluctiotu, if any are proponc-d; and the process, fuel or rav
aaterial changes necessary to cecply with such reductions, .if any arc pro-
posed .
22. With regard to tha clinker cooler (if alternative number 2 is utilized), it "ill
Beet a partlculat? c-nission limit of the n.->re stringent of 31 Ibs/hr or of 0.10
Ib/ton of feed (dry basis) to kiln as specified by Ideal Cco-rat in its pcrair.
application 'co tha Mobile County Health D.:;-:irtne-it . Th« 0.30 Ib/tcn of 5:-rJ i*
equal to the U. S. Cnvircnscnta] ?rotcctio:i Agency's St^ncsrJ of Pcrforn-T.ee ' In
addition, the applicant shall not cause to l>c discharged into the atrxtsphsro i
the clinker cooler any &zscs which exhibit 10 percent opacity, or greater.
23. With retard to the clay dryer, it will coot a parrictilr.te emission licit of '.ha
stringent of A. 30 ics/hr or 0.01 Rr/dscf as specified by Ideal Ccir.y EJ<^ =?provod true ccthoiis and ::!i.ill not cause to t« aljrhirr.t.J
to the atr.ocphcrc, f.nsv3 which euhlMt 102 opacity or greater.
P-49
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25. Due to the large nur.l-cr of point sources, source test:: wilj In* required er sonrccr.
Chat bslh KPA and Mai-i2e County iU-nlth Pepartncnt L:\ cunrul.tc.icion wi.tii the a^i-i Jca.it
fed arc representative of the fabric filters used at the plant.
26. The applicant cur.t sail 10 cite Mobile County Health Di'partccnc and EfA, juiililu fli-r.
vorkinp. d.iys after sploctlon, and before purchase, co;«i.'c of technical Jain i»ert::in»n.;
Co the selected control Ji-vicou IncluJ!.-;'. fornal bid fvo-.i the vendor, cti.it .:n:crsl i:l f:
elcnry or ccinsion r.it*». and all design pcr.inetcrs. A Hat oi any ac!ultfor:il r.'ijtiv/e.4
information vill lie sent to the .ippllc.tr.t upon ivcolp- of tH:> sul'nltt.il. Altnoui'.l- '
Che type of control ili«-'lccfl which .ire desrrihocl in .'*.ci\( rcv'r*.1 c'..t*
final nalectcd device in order to verify the col.isJon Hulls r-tatod in ti-.-i fs»vc '.li rl:<»
Msbilc. County Heal ih Pcparts.cnt applicant .-.hull rulait to tl'.f Mobile Ccnr.ty !:e.i.'.:l.
Department a runrtcrly status report bricily our.iJuius prepress nr.de on c»;.ir.vcrlii.'j
design and purchase of tujor pieces of equipment, incluJing control equiin».:tii.
28. The applicant i/ill bft requited to operate and o.->intnJr. continu'ju:: In-stJck op.ir.iry
Bonitcrs on the rev r:ill stack (Emission Points "o. -'«5 and /.G) and on t'w ciirki'r
cooler stacha (Emission Points' Ko. 47 and 48) if" altLiTsstivv Number 2 is i-tiitzL'd.
TIic instrument and reporting fonnit aust be approved by die Mobile Couucy lu-.-it!i
Dnpertaent..
29. The total sulfur content in the coal will be asccsured and a r.cnthly report ftf t!:e
content will be requitd. The method of analysis for sulfur anci rcporr.'.v.g foi-ruc
must be approved by the Mobile County Health Department.
30. Testing for partlculnte natter must ba conducted on Emission Points 45, ^5, 4/ &n-J
48. The test methods aisd procedures must be approved by the Mobile County rlcjltli
Department .
31. Test Ins for sulfur dioxide muse be conducted on Enissie-n Points 45 and 4'-. T,ic test
ncthods and procedures nusc be approved by the Mobile County Hoalth DooarCMn. .
32. The applicant vill bo required to operate and naintaln continuous tn-sspci: s-J»fvir.
dioxide wonitors en cho raw mill stack (raisslon ."oints J.'o. 45 and 46). This IIISLTU-
nent and reporting fornat must be approved by the Mobile County Health Dcp;ir:iie:it.
P-50
-------
ALABAMA HISTORICAL COMMISSION (PLANT SITE)
-------
W WARNER FLOYD
EXECUTIVE DIRECTOR
STATE OF ALABAMA
ALABAMA HISTORICAL COMMISSION
726 MONROE STREET
MONTGOMERY. ALABAMA 361O4
August 29, 1977
TELEPHONE NUMBER
832-6621
Ms. Marcia L. Ward
Environmental Planner
Environmental Science and Engineering, Inc.
P. O. Box 1354 University Station
Gainesville, Florida 32604
Re: Proposed Cement Plant
Theodore Industrial Park
Monroe County
Dear Ms. Ward:
Based on the assessment conducted by Archaeologists Noel
R. Stowe and Dan L. Jenkins, the Alabama Historical Commission,
state historic preservation office, concludes that the cement
plant site, Theodore Industrial Park, Monroe County, will have
no adverse affect on any cultural resources included in or
eligible for the National Register of Historic Places.
Sincerely,
W. Warner Floyd
WWF/gcb
xc: Archaeologist Noel R. Stowe
Milo B. Howard, Jr. 6/ "^
State Historic Preservation Officer
-------
ALABAMA HISTORICAL COMMISSION (QUARRY SITE)
-------
w WARNER FLOYD
IXCCUTIVC Dime-Ton
STATE OF ALABAMA
ALABAMA HISTORICAL COMMISSION
729 MONROE STREET
MONTGOMERY. ALABAMA 361O4
April 19, 1978
TELEPHONE NUMBER
832-6621
Ms. Marcia L. Ward
Environmental Planner
Environmental Science and Engineering, Inc.
P. O. Box 13454
Gainesville, Florida 32604
Re: Archaeological Investigations
at the Ideal Basic Industries,
Inc., Perdue Hill Quarry Site
Monroe County
Dear Ms. Ward:
Based on the archaeological investigations conducted by
Archaeologist Noel R. Stowe, the Alabama Historical Commission,
state historic preservation office, concurs in the development
of Ideal Basic Industries, Inc. plant site at Perdue Hill.
However, if during construction or mining activities artifacts
are discovered please notify the Commission immediately.
Sincerely,
W. Warner Floyd
GCB
P-53
-------
ALABAMA STATE DOCKS DEPARTMENT APPROVALS (PLANT SITE)
-------
"fit*
ALABAMA STATE DQCXS DEPARTMENT *"
March 15, 1978
or THE .TAT. or AUA.AMA
TWX810 741.7748
P.O.BOX 1988
MOBILOLABAMA 36601
Ideal Basic Industries
Cement Division
P. O. Box 8789
Denver, Colorado 80201
Attention: Mr. G. M. Lochhead, P. E.
Chief Engineer
Gentlemen:
You are hereby licensed to perform dredging, removing
approximately 650,000 cubic yards of material, on the
Theodore Industrial Canal, near Mobile, Mobile County,
Alabama, in a manner and at the location as described
in your application dated March 3, 1978, and the draw-
ings attached thereto.
This license merely concerns the public's rights of
navigation and has no connection with property rights.
This license is issued subject to the approval of the
U. S. Corps of Engineers, and no work in connection
with this project is to be performed prior to the
issuance of a permit by the Corps of Engineers.
Also, this license is issued subject to the approval
of the Alabama Water Improvement Commission, Alabama
Department of Conservation & Natural Resources, and
Environmental Protection Agency.
For the Director:
W. H. Black, Jr.
Chief Administrative
Officer
. .% . cc; Corps of Engineers
CEMMT
P-55
-------
ALABAMA STATE S3&GKS
*»
OF THC STATS OF ALABAMA
TWX 81O 741-7748
P.O.BOX isaa
MOBILE.ALABAMA 366O1
March 15, 1978
Ideal Basic Industries
Cement Division
P. O. Box 8789
Denver, Colorado 80201
Attention: Mr. G. M. Lochhead, P. E.
Chief Engineer
Gentlemen:
You are hereby licensed to construct access road bridge
and railroad spur bridge, discharge outlet, discharge
catchment area, and fill in wet land, in North Fork
Deer River, near Mobile, Mobile County, Alabama, in a
manner and at the location as described in your appli-
cation dated March 3, 1978, and the drawings attached
thereto.
This license merely concerns the public's rights of
navigation and has no connection with property rights.
This license is issued subject to the approval of the
U. S. Corps of Engineers, and no work in connection
with this project is to be performed prior to the •
issuance of a permit by the Corps of Engineers.
For the Director:
W. H. Black, Jr.
Chief Administrative
Officer
MAR §Si97§°rpS '°f
M CEMENT COMPANY
P-56
-------
ALABAMA STATE DOCKS DEPARTMENT APPROVALS (QUARRY SITE)
-------
ALABAMA STATE D'QGXS E3EPARTZWENT AN AGENCY or TN« .TAT« or ALABAMA
TWX81O 741-7748
P.O.BOX 1588
MOBILE.ALABAMA 366O1
March 15, 1978
Ideal Basic Industries
Cement: Division
P. O. Box 8789
Denver, Colorado 80201
Attention;
Gentlemen:
Mr. G. M. Lochhead, P. E.
Chief Engineer
You are hereby licensed to construct a dock facility
on the Alabama River, near Perdue Hill, Monroe County,
Alabama, in a manner and at the location as described
in your application dated March 3, 1978, and the draw-
ings attached thereto.
This license merely concerns the public's rights of
navigation and has no connection with property rights.
This license is issued subject to the approval of the
U. S. Corps of Engineers, and no work in connection
with this project is to be performed prior to the
issuance of a permit by the Corps of Engineers.
For the Director:
W. H. Black, Jr.
Chief Administrative
Officer
WHB/mh
6NGINEER1NG DEPT.
cc: Corps of Engineers
MAR 21 1978
EMtNT COMPANY
P-57
-------
ALABAMA STATE B&GXS
AN *<*ENCY or THE STATE or ALABAMA
TWX 81O 741-7748
P.O.BOX 1588
MOBILE.Al.AaAM A 36SO1
March 15, 1973
Ideal Basic Industries
Cement Division
P. O. Box 8789
Denver, Colorado 80201
Attention:
Gentlemen;
Mr. G. M. Lochhead, P. E,
Chief Engineer
You are hereby licensed to form clarification basins on
the Alabama River, near Perdue Hill, Monroe County,
Alabama, in a manner and at the location as described
in your application dated March 3, 1978, and the draw-
ings attached thereto.
This license merely concerns the public's rights of
navigation and has no connection with property rights.
This license is issued subject to the approval of the
U. S. Corps of Engineers, and no work in connection
with this project is to be performed prior to the
issuance of a permit by the Corps of Engineers.
For the Director:
W. H. Black, Jr.
Chief Administrative
Officer
WHB/mh
cc: Corps of Engineers
P-58
-------
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-------
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