DRAFT
ENVIRONMENTAL IMPACT STATEMENT
IDEAL BASIC INDUSTRIES
CEMENT PLANT
THEODORE INDUSTRIAL PARK. ALABAMA
LIMESTONE QUARRY
MONROE COUNTY, ALABAMA
APPENDICES
VOLUME I
APPENDIX A PROJECT DESCRIPTION
UNITED STATES ENVIRONMENTAL PROTECTION AGENCY, REGION IV
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TABLE OF CONTENTS
APPENDIX A. PROJECT DESCRIPTION
GENERAL OVERVIEW A-l
PLANT SITE
SITE LOCATION AND DEVELOPMENT A-4
EXISTING CONDITIONS A-4
PLANT SITE DEVELOPMENT A-9
PLANT CONSTRUCTION A-16
INTRODUCTION A-16
CONSTRUCTION ACTIVITIES A-17
Land Clearing and Grading A-17
Access Road A-19
Pile Driving A-20
Dredging and Construction of Docking Facility A-20
Erection of FacilitiesA-21
Catchment Area A-21
Equipment Needs A-22
PLANT OPERATIONS A-24
PROCESS DESCRIPTION A-24
Raw Materials A-25
Raw MillA-32
Regrind Mill A-34
Mix BlendTng A-34
Kiln Suspension Preheaters A-34
KilnsA-38
Clinker Coolers A-39
Finish MilTA-39
CEMENT STORAGE AND HANDLING A-42
ENVIRONMENTAL CONSIDERATIONS A-47
RESOURCES REQUIRED A-47
Limestone A-47
Clay and 'Sand A-47
I-i
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Iron Ore A-49
Gypsum A-49
Coal A-49
Electricity A-49
Water A-50
Labor A-50
Water Transportation A-50
Land Transportation A-50
AIR POLLUTANT EMISSIONS A-52
Stack Emissions A-52
Participate Matter Emissions A-52
Other Emissions A-56
Baghouses A-58
Fugitive Emissions A-60
NOISE A-61
Construction A-61
Operation?A-61
SOLID WASTE A-66
Construction A-66
Land Clearing A-66
Dredging A-67
Grading A-67
Construction and Final Clean-Up A-68
Operations A-68
WATER UTILIZATION AND DISPOSAL A-72
Water Usage Requirements A-72
Industrial WastewaterA-73
General Stormwater Runoff A-83
Summary of Wastewater Flows A-84
Sewage System A-84
ENVIRONMENTAL SAFEGUARDS A-86
Stormwater Runoff Control A-86
Industrial Wastewater Control A-86
Process Air Emission A-87
Fugitive Dust Controls A-87
Noise Controls " A-87
Burning Controls A-88
Fuel Oil Spills A-88
Solid Wastes A-88
Preservation of Natural Communities A-89
Archaeol ogical /H~i storical Measures A-89
Local Community Aspects A-89
PERMITS AND APPROVALS REQUIRED A-90
I-ii
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QUARRY SITE
LOCATION AND DEVELOPMENT A-94
EXISTING CONDITIONS A-94
SITE DEVELOPMENT A-98
CONSTRUCTION A-104
OPERATIONS A-110
QUARRYING SEQUENCE A-110
GENERAL OPERATIONS A-113
ENVIRONMENTAL CONSIDERATIONS A-124
RESOURCES REQUIRED A-124
Labor A-124
Electricity A-124
Hater Supply A-124
Water Transportation A-124
AIR POLLUTANT EMISSIONS A-127
Construction and Operation A-127
NOISE A-128
Construction A-128
Operation?A-128
SOLID WASTES A-131
Construction A-131
Operation?A-131
WATER UTILIZATION AND DISPOSAL A-134
Water Requirement A-134
WastewaterA-134
Construction and Operation A-134
Sanitary Wastes A-138
Water Requirement A-142
ENVIRONMENTAL SAFEGUARDS A-139
Stormwater Runoff Control A-139
Erosion ControlsA-139
Fugitive Dust Controls A-139
Noise ControlsA-139
Burning Controls A-140
I-iii
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Solid Wastes A-140
Preservation of Natural Communities A-140
Archaeological/Historical Measures A-140
PERMITS AND APPROVALS REQUIRED A-141
I-iv
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LIST OF TABLES
PLANT SITE
Table
A.I Equipment Requirements (Plant Site)—30 Months A-23
A.2 Raw Material and Fuel Requirements A-27
A.3 Raw Materials Storage Supply (Wet Basis) A-28
A.4 Finish Mill Requirements and Production Figures A-41
A.5 Cement Shipment Schedule A-45
A.6 Maximum Allowable Atmospheric Emissions from the A-54
Proposed Cement Manufacturing Plant for Particulate
Matter and Sulfur Dioxide and Estimated Quantities of
other Pollutants: Nitrogen, Oxides, Hydrocarbons, and
Carbon foonoxide
A.7 Solid Waste Disposal A-69
A.8 Typical Analysis of Water Supply to Mobile, Alabama A-74
(1969)
A.9 Storage Pile Characteristics A-76
A.10 Preliminary Leachate Study Results A-77
A. 11 Results of Toxicity Test Solution Analyses A-79
A.12 Wastewater Discharge to Settling Basin(s) A-82
A.13 Environmental Permits and Approval Requirements A-91
QUARRY SITE
A.14 Equipment Requirements A-109
A.15 Solid Waste Disposal A-133
A.16 Proposed Storage Capacities of Storage Basins A-136
and Area of Quarry Areas
A.17 Environmental Permits and Approval Requirements A-142
(Quarry Site)
I-v
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LIST OF FIGURES
PLANT SITE
Figure
A.I Typical Portland Cement Process A-2
A.2 The Proposed Plant Site Relative to Mobile, Alabama A-5
A.3 The Theodore Industrial Park Site A-6
A.4 Plant Site - Facing North A-7
A.5 Plant Site - Facing East A-8
A.6 Proposed Plant Plot Plan A-10
A.7 Plant Site and Proposed Right of Way for Channel A-ll
Extension
A.8 Proposed Access Road A-15
A.9 Schedule of Main Construction Tasks A-18
A.10 Flow Diagram Proposed Plant Process A-26
A.11 Raw Materials Handling Flow Diagram A-31
A.12 Raw Mill System A-33
A.13 Regrind Mill and Kiln Feed System A-35
A.14 Preheater and Kiln/Clinker Cooler System A-36
A.15 Sketch of Preheater, Kiln, and Clinker Cooler System A-37
A.16 Finish Cement Mills A-40
A.17 Land Silos Process Flow A-43
A.18 Marine Cement Shipping A-44
A.19 Daily Resources Cycle (Plant Site) A-48
A.20 Cement Manufacturing Process, Ideal Basic A-53
Proposed Plant, Theodore, Alabama
I-vi
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LIST OF FIGURES
(continued)
Figure
A. 21 Schematic of Typical Fabric Filter (Baghouse) A-59
Collector with Pulsed Compressed Air
Cleaning Cycle
A. 22 Equal Sound Level (Ldn) Contours Due to Worst A-62
Case Construction Activities from the Proposed
Plant Only
A. 23 Equal Sound Level (Ldn) Contours Due to Plant A-64
Operations Only
A. 24 Sources of Industrial Wastewater A-75
A. 25 Schematic of Wastewater Flow A-85
QUARRY SITE
A. 26 Proposed Cement Plant and Quarry Sites A-95
A. 27 Quarry Site Vicinity A-96
A. 28 Property Line, Quarry Site A-97
A. 29 Aerial View of Quarry Site A-99
A. 30 Site Development (First Fifteen Years) A-102
A. 31 Schematic Layout of Waterfront Development A-106
A. 32 Typical Section of Waterfront Development A-107
A. 33 Schedule of Main Construction Tasks A- 108
A. 34 Mining Areas (First Fifteen Years) A-lll
A. 35 Steps of Proposed Quarry Process A-114
A. 36 Plan of Typical Quarry Cut A-118
I-vii
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LIST OF FIGURES
(continued)
Figure
A.37 Cross Sections of a Typical Quarrying Area A-119
A.38 Existing Drainage Patterns in Quarry Areas A-121
A.39 Final Drainage Pattern of Reclaimed Areas A-122
A.40 Daily Resources Cycle (Quarry Site) A-125
A.41 Equal Sound Level Contours Surrounding the Quarry A-129
Site During Construction Activities
A.42 Estimated Boundary of Sound Level, Ldn of 55 decibels, A-130
Surrounding the Quarry Site During Operation
I-viii
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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.
I-ix
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PLANT AND QUARRY SITES
APPENDIX A. PROJECT DESCRIPTION
GENERAL OVERVIEW
Ideal Cement Division of Ideal Basic Industries of Denver, Colorado,
plans to construct and operate a 1.4 million-metric-ton-per-year
(1.5 million ton-per-year) portland cement plant and a limestone quarry
near Mobile and Monroeville, Alabama, respectively. The cement plant
will be located in the Theodore Industrial Park along the federally
authorized Theodore Ship Channel. The construction costs will be
$165 million (1977 dollars) over approximately a 30-month period. The
cement plant, which will start operations in late 1980 or early 1981, is
expected to have a 50-year life and a staff of approximately
135 employees.
The quarry will produce about 2.4 million metric tons (2.7 million tons)
per year (wet basis) of limestone for shipment via barge to the cement
plant. The development of the quarry facilities will take 18 months and
will cost more than $12 million (1977 dollars). The quarry, which would
start operating in mid-1980, will have 19 employees.
A portland cement plant produces various types of cement for use in
transportation, pollution control, sewage treatment and water supply,
commercial, residential, and industrial construction. The process re-
quires that the raw materials (limestone, sand, clay, and iron ore) be
ground and mixed in specific proportions; fed into a rotating furnace to
be fused into small balls called clinker; mixed and ground with gypsum
to form cement (see Figure A.I). The end product is a fine powder which
remains loose for bulk shipment or is packed into bags. Approximately
60 percent of the finished cement from the proposed plant is to be bulk
loaded onto barges and oceangoing vessels for shipment to the Ideal
Basic Industries facilities in Louisiana and Florida. The cement plant
will depend heavily on water transportation, since the large volume-to-
weight ratio of the raw materials and cement makes other transportation
very costly. Therefore, a major requirement of the project will be
A-l
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LIME-^
STONE
CLAY
SAND
IRON
ORE
I I I
ROTATING FURNACE
GYPSUM
J FINISH \
\ GRINDING 7
RAILROAD
CAR
TRUCKS
\
7
WATER
TRANSPORTATION
Figure A.1
TYPICAL PORTLAND CEMENT PROCESS
REGION IV
U.S. ENVIRONMENTAL PROTECTION
AGENCY ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
SOURCE: Environmental Science and Engineering, Inc., 1977.
PROPOSED CEMENT MANUFACTURING
PLANT THEODORE INDUSTRIAL PARK
MOBILE. ALABAMA
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PLANT AND QUARRY SITES
adequate water transportation facilities and access to the Alabama River
and Mobile Bay.
The cement plant will be supplied with raw materials from various
sources. The limestone will be quarried from a 1,633-hectare
(4,035-acre) tract located on the east bank of the Alabama River in
Monroe County. Ideal Basic Industries owns 739 hectares (1,826 acres)
and has mineral rights to the remaining 894 hectares (2,209 acres).
The clay and silica sand will be mined at the Ideal Basic Industries
existing quarry at 24-Mile Bend near Axis on the Alabama River.
Approximately 195,000 metric tons (215,000 tons) of clay and 98,000
metric tons (108,000 tons) of sand are needed to meet annual cement
production requirements. The other essential raw materials--iron ore
[20,400 metric tons (22,500 tons)], gypsum [61,000 metric tons
(67,300 tons)], and coal [259,000 metric tons (285,000 tons)]—will be
obtained through outside sources.
The proposed project will affect local air quality and noise levels and
will involve wastewater discharges and solid waste disposal. However,
the project is being designed to minimize adverse impacts and to comply
with the environmental requirements of local, state, and federal
agencies. This appendix describes the environmental and socioeconomic
aspects of the proposed project (both the cement manufacturing plant and
the quarry facility). The impacts, possible mitigating actions, and the
alternatives are discussed in the following appendices.
The information contained in this appendix and used in addressing the
other aspects of an environmental impact statement reflects the latest
plans and best estimates of Ideal Basic Industries. Where information
is uncertain, the worst case is described to provide a conservative
assessment of the project's environmental effects. Final design changes
may occur; however, no future alterations will be incorporated in the
project unless they involve either improvement or no significant change
in environmental quality.
A-3
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SITE LOCATION/DEVELOPMENT (PLANT SITE)
PLANT SITE
SITE LOCATION AND DEVELOPMENT
EXISTING CONDITIONS
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 A.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 (see Figure A.3).
The northern boundary of the Ideal Basic Industries site is established
by the Alabama State Docks Terminal Railway Corridor. Dauphin Island
Parkway forms the eastern boundary. The property lies along the ex-
isting 3.7-meter (12-foot) deep by 90-meter (300-foot) wide barge canal
on the southern end and is adjacent to the Airco Alloys and Carbide,
Inc. plant along its western border.
Figures A.4 and A.5, recent aerial photographs of the site, show that
the property is relatively flat except in the vicinity of the barge
canal. The ground elevations range from just above sea level along the
marsh adjacent to the North Fork Deer River to more than 6 meters
(20 feet) above mean sea level (msl) along the canal. There are remnant
longleaf pine trees on the site, except in the wetland area adjacent to
the North Fork Deer River. Because most of the site has been cleared
periodically by fire or hardwood lumbering, there is a well-developed
understory of hardwoods and a prevalence of weedy plants in open areas.
The area surrounding the industrial park is predominantly rural, with
the population concentrated in Mobile, Theodore, Grand Bay, and Bayou La
Batre. Most of the land to the south is undeveloped, with only minimal
acreage devoted to residential use and small-scale farming. Residential
A-4
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HOLD NG
ISLAND
**£>t*JT^
$
PROPOSED
PLANT
Figure A.2
THE PROPOSED PLANT SITE RELATIVE TO
MOBILE, ALABAMA
PROPOSED CEMENT MANUFACTURING
PLANT THEODORE INDUSTRIAL PARK
MOBILE, ALABAMA
SOURCE: USGS, 1974.
A-5
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Figure A.3
THE THEODORE INDUSTRIAL PARK SITE
(Adapted from Mobile Area Chamber of Commerce, 1976)
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
A-6
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Figure A.4
PLANT SITE - FACING NORTH
- • — • - IDEAL PROPERTY LINE
PROPOSED CEMENT MANUFACTURING
PLANT THEODORE INDUSTRIAL PARK
MOBILE, ALABAMA
SOURCE: Ideal Basic Industries, 1977.
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>
oo
Figure A.5
PLANT SITE - FACING EAST
IDEAL PROPERTY LINE
PROPOSED CEMENT MANUFACTURING
PLANT THEODORE INDUSTRIAL PARK
MOBILE, ALABAMA
SOURCE: Ideal Basic Industries, 1977
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SITE LOCATION/DEVELOPMENT (PLANT SITE)
areas are developing to the north and northeast, particularly along the
southern banks of Alligator Bayou and along Bay Road from Island Road
(Hamilton Boulevard) to Middle Road.
PLANT SITE DEVELOPMENT
The layout of the proposed Theodore plant area, which constitutes
approximately 34.4 hectares (85 acres) of the 70.8-hectare (175-acre)
property, is shown in Figure A.6. The principal ecological features of
the property, the North Fork Deer River and the associated wetlands,
will not be physically disturbed except for the access road and railroad
trestle on the extreme western property boundary. It is not planned to
develop the 36.4-hectare (90-acre) area north of the wetlands. Along
the eastern boundary, a 90-meter (300-foot) wide "greenbelt" zone of
existing trees and vegetation will help preserve the scenic value of the
area.
These boundaries, together with the proposed ship channel, will form a
natural buffer zone from the nearby residential communities. Figure A.7,
which presents the U.S. Army Corps of Engineers proposed right-of-way
lines for their channel expansion project, shows that many of the exist-
ing residential properties along the present canal are within these
taking lines. Therefore, there will be a reduction in the number of
residences surrounding the Ideal Basic Industries property. Addi-
tionally, as described in the Socioeconomics section of Appendix B,
Baseline, the land use in the area surrounding the plant will change as
the area becomes more valuable as industrial property.
A docking facility along the southern boundary will service water trans-
portation of raw materials and fuels to the plant site and bulk cement
from the site. Depending on their draft and size, several vessels could
be berthed at the same time. The facility's depth of water below msl
will vary depending on draft requirements; however, a conservative depth
of 12 meters (40 feet) below msl, the same depth as the federal channel
expansion project, has been projected to estimate the maximum amount of
A-9
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Figure A.6
PROPOSED PLANT PLOT PLAN
0 100
SCALE IN METERS
SOURCE: Ideal Basic Industries, 1977.
REGION IV
US ENVIRONMENTAL PROTECTION
AGENCY ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
PROPOSED CEMENT MANUFACTURING
PLANT THEODORE INDUSTRIAL PARK
MOBILE, ALABAMA
A-10
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IDEAL BASIC
INDUSTRIES
EXISTING STRUCTURES
Figure A.7
PLANT SITE AND PROPOSED RIGHT OF WAY FOR CHANNEL EXTENSION
SOURCE: USGS, 1974.
Rowe Surveying and Engineering Company, Inc., 1977.
0 100
SCALE IN METERS
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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SITE LOCATION/DEVELOPMENT (PLANT SITE)
material to be dredged during plant construction. The pierhead line for
the dock will be determined by an approximately 60-meter (200-foot) hor-
izontal offset from the northern toe of the ship channel bottom. Using
both of these dimensions, the quantity of dredged material has been
estimated to be approximately 500,000 cubic meters (650,000 cubic
yards). The majority of the plant's dredged material is expected to be
stable material since it is from a land cut. It is anticipated that the
dredged material will be deposited in one of the U.S. Army Corps of
Engineers disposal areas for the spoil from the ship channel and barge
canal extension project.
The marine terminal will include two breasting dolphins with a concrete
wharf. The wharf will be constructed to the grade elevation of the
plant site which will be approximately 4.6 meters (15 feet) above msl.
Another important physical aspect of the proposed plant site is the
arrangement of the various storage piles for raw materials and coal.
Basically all the raw materials, except the limestone and wet clay, will
be stored in a covered area approximately 260 meters by 52 meters
(840 feet by 170 feet).
The storage areas shown include:
1. A 230-meter by 52-meter (760-ft x 170-ft) open storage area to
accommodate 20-meter (65-ft) high piles of 110,000 metric tons
(120,000 tons) of crushed limestone;
2. A 39-meter by 20-meter (129-ft x 67-ft) open storage area for
4,200 metric tons (4,600 tons) of wet clay in a 11-meter
(36-ft) high pile;
3. A 260-meter by 52-meter (840-ft x 170-ft) covered storage area
for 27,000 metric tons (30,000 tons) of gypsum (wet basis),
45,000 metric tons (50,000 tons) of coal (wet basis),
3,300 metric tons (3,600 tons) of dried clay, 4,200 metric tons
(4,600 tons) of wet sand, and 4,200 metric tons (4,600 tons) of
iron ore (wet basis).
A-12
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SITE LOCATION/DEVELOPMENT (PLANT SITE)
It is also anticipated that alongside the limestone storage area there
will be a dead-storage pile of 494,000 metric tons (545,000 tons) of wet
limestone; this pile should be approximately 24,200 square meters
(260,200 square feet) in area and approximately 20 meters (65 feet)
high. The stormwater runoff from the uncovered storage areas will be
drained to a settling basin for clarification before being discharged to
the ship channel. The approximate capacity of the basins will be
16 million liters (4.2 million gallons).
Another physical aspect of the plant will be the various buildings and
process equipment that will be clustered in the center of the southern
portion of the property. These major structures will include: an
office and maintenance building and seventeen 60-meter (200-foot) high
finish cement silos (nine for land transport and eight for marine trans-
port). In addition, depending on the final design, there will be one or
two raw mills, suspension kiln preheaters [which will be 76 meters
(250 feet) high], kilns, "clinker" silos, finish mills, and two 90-meter
(300-feet) high exhaust stacks.
It is anticipated that the cement plant will have a 380-cubic-meter
(100,000-gallon) aboveground fuel oil tank, a 38-cubic-meter
(10,000-gallon) underground diesel oil tank, and a 3.8-cubic-meter
(1,000-gallon) underground gasoline tank. The fuel oil tank will store
fuel to be used for kiln start-up, as a pilot flame for the coal
burners, and an auxiliary fuel supply. The diesel and gasoline tanks
will be used for fueling plant vehicles and equipment.
The facility plot plan shows a parking lot for employees and a 7.3-meter
(24-foot) wide access roadway and railroad spur line extending to the
north from the developed portion of the site. The total width of the
roadway and railroad corridor, which is located along the western prop-
erty line, should be about 47.2 meters (155 feet). The access corridor
will follow the western boundary of the Ideal Basic Industries property
A-13
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SITE LOCATION/DEVELOPMENT (PLANT SITE)
to its intersection with the right-of-way of the Alabama State Docks
Terminal Railway. The railroad spur from the cement plant will join
with this railway; the access road will continue straight and meet
Island Road (Hamilton Blvd.) as shown in Figure A.8.
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.
A-14
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NOT TO BE
DEVELOPED
PROPOSED
PLANT SITE
BAKER SORRE . ROAD
CLAUDIA LAN
Figure A.8
PROPOSED ACCESS ROAD
0 0.5
SCALE IN KILOMETERS
PROPOSED CEMENT MANUFACTURING
PLANT THEODORE INDUSTRIAL PARK
MOBILE, ALABAMA
SOURCE: Ideal Basic Industries, 1978.
A-15
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CONSTRUCTION (PLANT SITE)
PLANT CONSTRUCTION
INTRODUCTION
Construction of the cement manufacturing facility is scheduled to start
in the third quarter of 1978. The construction project will last
approximately 30 months and will employ a labor force averaging
360 workers per month. The total construction payroll for the Theodore
project will be approximately $15,000,000 in 1977 dollars. Another
stimulus to the metropolitan Mobile economy will result from the local
purchase of roughly $10,000,000 in construction materials.
Approximately 80 to 85 percent of construction workers involved in the
Theodore project will be local hires, i.e., workers who live in Mobile,
Baldwin, Washington, and Escambia counties, Alabama, and who commute to
the site on a daily basis. This estimate is based on the experience of
Brown and Root, Incorporated, the design and construction engineers for
the project. The current construction of the Bladex Plant for Shell
Chemical Corporation involves a peak employment of 750 workers; 80 per-
cent of these workers come from the counties mentioned above. In
addition, Brown and Root, Inc. was involved in the initial construction
and 12 subsequent expansions of the Ciba-Geigy chemical complex in
Mclntosh, Alabama, during which approximately 85 percent of the workers
were local.
The capital cost of the cement plant at Theodore will be approximately
$165 million in 1977 dollars. The project will be financed through the
sale of Industrial Revenue Bonds by the Mobile Industrial Development
Board. The facility will be leased rather than owned by Ideal Basic
Industries for at least the duration of the bond repayment period, with
lease payments set at a level sufficient to cover debt service on the
bonds. This financing arrangement, authorized by the Wallace-Cater Act
as a means of encouraging industrial development in Alabama, involves
substantial savings in interest and taxes relative to conventional
financing. Interest costs are relatively low because Industrial Revenue
Bonds are municipals and thus their yields are exempt from federal
A-16
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CONSTRUCTION (PLANT SITE)
taxation. Direct tax savings result from the fact that public ownership
of the facility exempts it from sales taxes for construction materials,
as well as from state and local ad valorem taxation.
CONSTRUCTION ACTIVITIES
The phases and the schedule for construction of the facility are
described in the following sections.
Land Clearing and Grading
About 20 hectares (50 acres) of the 34 hectares (85 acres) of the plant
site area will be cleared. The remaining 36 hectares (90 acres) of the
property will not be developed. The access road and facility site will
be clear-cut of the existing longleaf pine and other vegetation, and
the woody debris will be disposed by a combination of chipping and
mulching, burning in an air-blower type pit burner, and landfill ing at
the Irvington Landfill (see the Solid Wastes section of this document
for more detailed information). Since the area was logged in 1974,
there will be a minimal number of large trees to be cleared, and the
operation is expected to take approximately three months (see
Figure A.9). It is anticipated that about 130,000 cubic meters
(170,000 cubic yards) of earth will have to be moved during the grading
period. This material will be utilized for the bermed stormwater
catchment area, roadway embankments, site grading, and other tasks. The
final grade of plant drainage will be northward towards the freshwater
marsh and is designed to balance the cut and fill aspects so that there
will not be any excess excavation material.
A concrete sheet pile wall will be constructed along the eastern and
northeastern boundary of the facility development. Approximately
17,100 cubic meters (22,375 cubic yards) of fill will be required at the
northeastern corner of the plant area.
A-17
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I
I—1
00
LAND CLEARING
AND GRADING
ACCESS ROADWAYS
PILE DRIVING
DREDGING AND
DOCK CONSTRUCTION
ERECTION
OF FACILITIES
AND EQUIPMENT
SETTLING BASINS
I
9
12
15
18
21
I
24
I
27
I
30
MONTHS
Figure A.9
SCHEDULE OF MAIN CONSTRUCTION TASKS
REGION IV
U.S. ENVIRONMENTAL PROTECTION
AGENCY ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
SOURCE. Brown & Root, Inc.. 1977.
PROPOSED CEMENT MANUFACTURING
PLANT THEODORE INDUSTRIAL PARK
MOBILE, ALABAMA
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CONSTRUCTION (PLANT SITE)
Based on the preliminary design of the facilities, the sheet pile wall
and the fill will be outside the brackish marsh area. The plant design
has undergone many changes specifically to minimize disturbance of both
the freshwater and brackish marshes. The only marsh area affected will
be along the access roadway corridor on the plant's western boundary.
Access Road
A 7.3-meter (24-foot) wide access road and railroad spur will be con-
structed in a 47.2-meter (155-foot) wide corridor along the western
boundary of the property. The road will be paved with concrete and will
have a bridge across the North Fork Deer River. The railroad spur will
have a trestle across the river and the marshland. This work is
expected to take the second through fifth months of the construction
period.
During the early months of construction, a temporary roadway from
Dauphin Island Parkway may be used and will enter the plant site near
the southeastern corner of the property. The primary access to the
plant site during construction and plant operation will be along the
permanent access corridor from Island Road (Hamilton Boulevard).
The plant access road will cross over North Fork Deer River with a
15-meter (50-foot) long, 2-span bridge. The wetlands on both sides of
the bridge (north and south) will be filled with approximately
3,400 cubic meters (4,450 cubic yards) to bring the grade of the road to
about 3 meters (10 feet) above msl. This earth fill will cover a lineal
distance of about 150 meters (500 feet) and represent the loss of
approximately 0.2 hectares (0.5 acres) from the 3.0 hectares (7.3 acres)
of freshwater marsh.
The plant access railroad will parallel the access roadway into the
plant site. The total corridor of both road and railroad is about
47.2 meters (155 feet) wide. As with the road, the railroad will bridge
A-19
-------
CONSTRUCTION (PLANT SITE)
the North Fork Deer River, but due to height and grade requirements, it
will also bridge the adjacent wetlands. A 170-meter (560-foot) railroad
bridge consisting of twenty 9-meter (28-foot) spans is planned. About
110 meters (350 feet) of freshwater marshland is to be affected by this
crossing. In addition, about 840 cubic meters (1,100 cubic yards) of
fill will be required to bring the grade of the access railroad to
approximately 5 meters (15 feet) above msl. However, this fill will not
be in the wetland area.
During construction, a small diversion channel will be formed to divert
runoff upstream. Also about 46 cubic meters (60 cubic yards) of earth
will be removed for the concrete casting of the railroad bridge sub-
structures.
Pile Driving
Due to the soil characteristics in the area and to the high bearing
loads of the facility's structures and equipment, it is planned to drive
approximately 14,000 to 16,000 piles. Pile driving will be done during
the third to the fifteenth months of construction and will be restricted
to daylight hours. The contractor will use the best practical equipment
to reduce as much as possible the expected sound levels.
Dredging and Construction of Docking Facility
Construction of the docking facility, which will be located approxi-
mately 60 meters (200 feet) from the toe of the ship channel, will
require dredging along the entire 716-meter (2,350-foot) waterfront.
The actual volume of dredged material will depend on the final depth
specifications for the dock areas. The oceangoing vessels will require
about a 9-meter (30-foot) depth, while the small barges need only about
a 3-meter (10-foot) draft; however, a conservative depth of 12 meters
(40 feet) below msl has been used to compute the volume of dredged ma-
terial as 500,000 cubic meters (650,000 cubic yards). It is
anticipated that this spoil will be taken to one of the Corps spoil
disposal areas, pending approval of the Alabama State Docks Department
A-20
-------
CONSTRUCTION (PLANT SITE)
(see Solid Wastes section). The docking facility, which will require
the use of piles and sheet pilings, will be built at the beginning of
the construction project (months 1 through 15).
Erection of Facilities
Erection of buildings and process equipment, installation of utility
connections for electricity, water, and sewage, and landscaping will be
done during the fourteenth to thirtieth months of construction.
Catchment Area
The general stormwater catchment area just north of the facility and the
wastewater settling basin will be constructed and used as early as pos-
sible in the project schedule (months 1 to 3). Since the majority of
the existing drainage is to the north, the general stormwater catchment
area.will be constructed first, and the area will treat the majority of
the runoff from the construction areas.
The catchment area will be formed by two detention basins with grassy
earthen berms. The berms will vary from .9 to 1.5 meters (3 to 5 feet)
in height and 370 to 580 meters (1,220 to 1,900 feet) in length. A
90-meter (300-foot) section of the berm will be used as an overflow weir
for handling runoff greater than 50 minutes of a 10-year, 1-hour storm
(design capacity). In order to provide this capacity, the basins will
be continuously drained to the freshwater marsh. It is estimated that
the total earthwork of these berms will be about 9,860 cubic meters
(12,900 cubic yards). All construction will be higher than the wetland
vegetation boundary; therefore, the wetland area will not be disturbed
by the construction of the stormwater catchment area.
A-21
-------
CONSTRUCTION (PLANT SITE)
Equipment Needs
Throughout the construction period, there will be a need for various
types of heavy equipment, such as bulldozers, cranes, scrapers, pile
drivers, and front-end loaders. The anticipated requirements and
schedule are shown in Table A.I. The bulk of the equipment will be
used during the first 18 months of the construction phase.
A-22
-------
CONSTRUCTION (PLANT SITE)
Table A.I. Equipment Requirements (Plant Site)—30 Months
Project Duration (In Months)
Equipment
Earth Moving
Push Dozers
Scrapers
Graders
Loaders
Bulldozers
Carry-Alls
Rollers, Compactors
Lifting
Light Cranes
Heavy Cranes
Cherry Pickers
Forklifts
Welding
D & G Welders
Air Compressors
Portable Generators
Paving and Concrete
Backhoes
Portable Mixers
Vibrators
Rollers
Asphalt Distributors
Concrete Finishers
Pile Drivers
Transporters
Light Trucks
Heavy Trucks
Flatoeds; Low Boys
Dump Trucks
3
2
2
2
2
3
1
2
1
-
2
3
2
2
1
3
_
_
_
_
-
_
5
3
. 2
10
3
2
2
2
2
3
1
2
1
1
2
3
5
4
3
5
3
1
1
1
-
3
10
4
2
10
3
1
1
1
3
3
1
1
2
1
3
3
10
8
3
8
4
2
1
1
2
3
10
4
3
10
3
1
1
1
3
2
1
1
3
3
4
5
15
8
3
8
5
5
1
1
5
3
10
6
3
10
3
1
1
1
3
2
-
1
3
3
4
5
15
8
3
5
5
5
1
1
10
3
10
6
3
5
3
_
_
1
2
1
-
-
3
3
4
5
10
6
2
2
2
5
1
1
10
2
10
4
3
1
3
_
_
_
1
1
-
-
3
2
4
4
10
4
1
2
1
3
1
1
5
_
10
3
3
1
3
_
_
_
1
1
-
-
3
1
2
2
5
2
-
1
1
3
1
1
2
_
5
3
2
~
3
_
_
_
1
1
-
-
2
1
1
1
3
1
-
1
_
1
_
-
1
_
5
3
2
™
3
_
_
_
1
1
-
-
1
-
1
1
2
1
-
1
_
_
_
-
-
_
3
2
1
™
Source: Brown & Root, Inc., 1977.
A-23
-------
OPERATIONS (PLANT SITE)
PLANT OPERATIONS
PROCESS DESCRIPTION
The cement plant will be a dry process facility designed to produce
approximately 1.4 million metric tons (1.5 million tons) of cement each
year. A "dry process" plant grinds and feeds the raw materials into the
kiln in a dry state, rather than as a wet slurry. The advantage of the
dry process is basically the 50-percent saving in fuel per unit of
output.
In either process, the raw materials (limestone, clay, sand, and iron
ore, or the chemical equivalents) are mixed and ground in specific pro-
portions. The raw mix is then fed into a rotary kiln and heated to
approximately 1,480°C (2700°F). At this temperature, the materials fuse
and form clinker. The clinker is mixed and ground with gypsum into a
powder called portland cement. If dry limestone is ground with the
clinker and gypsum, a masonry cement is produced.
The Theodore cement plant will produce five types of portland cements
and one masonry cement. Ideal Basic Industries will mine the required
amounts of limestone from a new quarry in Monroe County (see quarry site
section of this appendix), and the necessary quantities of clay and sand
from their existing quarry at 24-Mile Bend on the Alabama River. The
other raw materials (plus the coal that will be used as process fuel)
will be obtained from contractors. The projected supply of limestone is
adequate for at least 50 years, but the clay supply is estimated to last
only through 1985. The future source of clay has not yet been
designated.
This section summarizes the significant aspects of the process design
currently planned by Ideal; however, as previously mentioned, there will
be changes in the final design due to advancements in process technol-
ogy and changes in facility requirements. However, the environmental
assessment presented reflects the "worst case" air, water, noise, solid
waste, and land use impacts which could result from any feasible process
A-24
-------
OPERATIONS (PLANT SITE)
changes. Therefore, this assessment is considered a conservative
evaluation of the environmental effects of the project.
The proposed process is shown schematically in Figure A.10.
Raw Materials
In order to achieve the design capacity of 1.4 million metric tons (1.5
million tons) per year of dry cement, it will be necessary to handle
approximately 3.0 million metric tons (3.4 million tons) per year of wet
raw materials and coal.
The limestone will be shipped by a fleet of seventeen barges and three
tugboats to the Theodore facility. The logistics of this marine opera-
tion will require four barges to be unloading while a tow (one tug and
four barges) is en route, a second tow is returning to the limestone
quarry site, and the last tow is being loaded at the quarry. The transit
distance to the limestone quarry is approximately 180 kilometers (110
miles), whereas the clay and sand quarry is only about 60 kilometers
(40 miles) upriver. The requirements for clay and sand necessitate that
an extra barge be picked up at this quarry site every fourth tow. An
independent contractor will supply iron ore by barge or rail. The
gypsum and coal can be delivered by either railroad cars or vessels.
The raw materials unloading system consists of clamshell gantry cranes
and conveyors to transfer the materials from their vessels to specific
storage piles at a rate of 700 to 900 metric tons (800 to 1,000 tons)
per hour. Since some of these piles (limestone and wet clay) are ex-
posed to the weather, a system is planned to collect stormwater runoff
and drain it into a settling basin. The basin will be designed to
reduce the suspended solids loading prior to discharging the water to
the ship channel. A more detailed description is given in the indus-
trial wastewater section of this appendix.
The raw material requirements for each year are shown in Table A.2, and
their storage supplies are given in Table A.3. The annual raw mix
A-25
-------
RAW MATERIAL
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
PACKHOUSE
RAIL AND
TRUCK
SHIPPING
MARINE
SHIPPING
Figure A. 10
FLOW DIAGRAM OF PROPOSED PLANT PROCESS
REGION IV
U.S. ENVIRONMENTAL PROTECTION
AGENCY ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
SOURCE: Environmental Science and Engineering, Inc., 1977.
PROPOSED CEMENT MANUFACTURING
PLANT THEODORE INDUSTRIAL PARK
MOBILE, ALABAMA
A-26
-------
Table A.2. Raw Material and Fuel Requirements
Total
Material "(Metric Tons)
Weight Per Year
(Wet)
Raw Mix Finish Grinding
(Tons)
(Metric Tons)
(Tons) (Metric Tons) (Tons)
Moisture Percenta
ge of Mix
Content Portland
(%) Raw Mix Cement Masonry
Raw Materials
Limestone
Clay
Sand
Iron Ore
Gypsum
TOTAL
Fuel
Coal
TOTAL (Raw
Materials
and Coal)
2,414,200
194,700
98,000
20,400
61,000
2,788,300
258,500
3,046,800
2,661,200
214,600
108,000
22,500
67,300
3,073,600
284,900
3,358,500
2,341,400
194,700
98,000
20,400
2,654,500
—
2,581,000 72,700 80,100
214,600 -
108,000 - -
22,500 -
61,000 67,300
2,926,100 133,700 147,400
__ _
22 87.6
22 7.3
— 95
10 4.2 (as cl
5 0.9_
MA 0.0 4
50
.5 — 48.2
inker) (as clinker)
.5 1.8
100.0 100.0 100.0
10 -
_
_
o
-o
m
73
O
;z
CO
Sources: H.K. Ferguson and Associates, 1975.
Ideal Basic Industries, 1977.
CO
-------
OPERATIONS (PLANT SITE)
Table A.3. Raw Materials Storage Supply (Wet Basis)
Storage Capacity Plant Usage (tpd) Storage Annual
Metric Metric Supply Operation
Tons (Tons) Tons (Tons) (Days) (Days)
Limestone
(Active)
Limestone
(Dead
Storage)
Clay
Sand
Iron Ore
Gypsum
Coal
110,000
494,000
4,200
4,200
4,200
27,000
45,400
(120,000)
(545,000)
(4,600)
(4,600)
(4,600)
(30,000)
(50,000)
7,788
— —
645
325
68
212
841
(8,585)
_ —
(711)
(358)
(75)
(234)
(927)
14.0
63.5
6.5
12.8
61.3
128.2
53.9
310*
— _
302t
302t
302t
287**
310*
* Based on an average of 85 percent operating time for producing both
Portland and masonry cements.
t Based on only raw mill requirements. The remaining 8 days per year
are for drying limestone to be used in the masonry cement. Due to
the difference in operating days per year between the raw mill
(302 days) and the kiln (310 days), the average usage rates for the
kilns are 0.97 of those shown.
** Based on the capacities of the finish mills.
Source: Ideal Basic Industries, 1977.
A-28
-------
OPERATIONS (PLANT SITE)
materials are approximately double the annual cement production rate
because of losses of moisture and carbon dioxide while processing the
materials in the raw mill and kiln areas. The average moisture content
of the raw materials is approximately 21 percent when received, but is
reduced to less than 1 percent in the raw mill. In addition, 36 percent
of the raw mix feed weight to the kilns is exhausted as carbon dioxide.
The clay material, which will contain about 22 percent moisture, may be
too wet to be compatible with process requirements. Therefore, a clay
dryer is being designed for possible construction and use. Approxi-
mately 125 mtph (138 tph) (wet basis) of clay will be fed into a rotary
dryer which will be fired with about 5 mtph (6 tph) of coal. Hot
combustion gases will dry the clay and will be exhausted through the
No. 2 raw mill stack. About 98 mtph (108 tph) (dry basis) of clay will
exit the dryer and be transferred to a belt conveyor; this transfer
point will be vented to a small baghouse. The conveyor will bring the
dried clay to the clay storage building which also will be vented
through a small baghouse. To meet raw material requirements of 503 mtpd
(555 tpd) of wet clay (7 days per week), the clay dryer will be designed
to operate at least 7 hours per day for 5 days per week.
The coal requirements of the plant will be handled by unloading vessels
or railroad cars at a rate of 600 to 900 mtph (700-1,000 tph). The coal
as received will be stored in a covered area. From storage, the coal
will be screened, crushed, and conveyed to a central drying mill. The
mill will be an air-swept ball mill, with heated air from a small coal
burner. The coal will be swept from the mill to a classifier and cy-
clone for sizing and collection. A baghouse will be used to control the
particul ate matter emissions from the mill exhausts.
The coal grinding and drying system will be designed to supply an
average of about 840 metric tons (930 tons) of dry coal per day. The
coal demand for process operations will generally follow a 24-hour per
day schedule, so the dried coal will be transferred to a central
A-29
-------
OPERATIONS (PLANT SITE)
storage tank to store enough dried coal to supply the entire plant's
coal requirements.
From the tank, the coal will be conveyed to a tank for use in the
following systems:
1. 1 or 2 kiln(s)—about 22 mtph (24 tph), 24 hours/day,
310 days/year
2. 1 coal dryer—about 3 mtph (3 tph), 24 hours/day,
310 days/year
3. 2 raw mills—about 5 mtph (6 tph), 24 hours/day, 310 days/year
4. 1 clay dryer—about 5 mtph (6 tph), 7 hours/day, 260 days/year
The central storage tank and a coal feed tank will be exhausted through
separate baghouse systems. All estimates for coal usages are based upon
coal with 6.7 calories per gram (12,000 Btu/lb) and a maximum sulfur
content of 1.5 percent by weight.
The gypsum, which will be received by water or rail transport, will be
handled by the same system as the coal. The gypsum will be stored in
bulk in the covered stockpile area. Table A.3 shows that a 128-day
supply of gypsum is planned by maintaining 27,000 metric tons
(30,000 tons) in the stockpile.
In the raw materials storage and handling area (see Figure A.11), the
raw materials will be reclaimed from storage and placed on conveyor
belts for transfer to the raw mill circuit. In the first two areas, the
raw mix materials will be exposed to the atmosphere and thus there is
the potential for fugitive dust emissions. However, the majority of the
materials will have a high moisture content (an average of 21 percent)
which will lessen dust emissions. In addition, an extensive water-spray
dust suppression system will be employed at major drop points and trans-
fer points.
A-30
-------
I
GO
TRAVELING BARQE
UNLOADING TOWER
CLAMSHELL
BUCKET
LIMESTONE
1 * "" ™ 1 I-f i-JBB OB U
48 IN. BELT CONVEYOR \
48 IN. BELT
CONVEYOR
IRONORE, CLAY *48 IN. BELT CONVEYOR
OR SILICA STOCKPILE
IRON ORE CLAY SILICA
LIMESTONE BARQES
Figure A.11
RAW MATERIALS HANDLING FLOW DIAGRAM
REGION IV
U.S. ENVIRONMENTAL PROTECTION
AGENCY ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
SOURCE: H.K. Ferguson Associates, 1975.
PROPOSED CEMENT MANUFACTURING
PLANT THEODORE INDUSTRIAL PARK
MOBILE, ALABAMA
-------
OPERATIONS (PLANT SITE)
Raw Mill
Starting in the raw materials circuit, the cement manufacturing process
generally will be divided into two parallel systems, each designed to
handle half the plant's process weight. Figure A.12 shows a flow dia-
gram of the raw mill system's process materials and exhaust gases. The
purpose of this system is to dry the raw materials, grind them to a fine
consistency, and store them for use in the next area. The drying and
grinding will be accomplished in systems using hot exhaust gases from
each kiln and clinker cooler circuit and supplemented by heat from their
own coal furnaces. The systems are air-swept mills that will each han-
dle 185 mtph (204 tph) of wet raw mix plus 11 mtph (12 tph) of material
entrained in the kiln cooler exhaust gases. After grinding, the mater-
ials and the exhaust gases will be passed through a classifier in which
oversized material will be rejected to a vibrating screen for re-entry
into the mill or discharged into a trash bin. The fines, which will be
entrained in the exhaust gases, must be collected by an air pollution
control system consisting of several cyclone collectors followed by a
baghouse. The fines collected in the cyclones and baghouse are the
"product" of each raw mill and amount to about 154 mtph (170 tph).
The exhaust gases and uncoilected dust will be discharged into the
atmosphere through separate 90-meter (300-foot) high stacks. It is
estimated that 45 kilograms (98 pounds) per hour of particulate matter
and, based on 50 percent removal due to process chemistry (see Air
section), 898 kilograms (1,980 pounds) per hour of sulfur dioxide will
be emitted through the stacks. The collected material will be conveyed
to four raw mix storage silos to await further processing in the regrind
mill and the homogenizing and kiln feed system. Since dry limestone is
required for the masonry finish mix, at times the raw mill will process
only limestone, which will be stored in a separate silo in the clinker
storage circuit. Both of these silo systems will be serviced by
baghouses to reduce dust emissions.
A-32
-------
FROM 11 TPH FROM 11TPH
PREHEATER(12TPH)PREHEATER (12 TPH)
AND ~| AND ~ ~ 1
COOLER - COOLER |
NO. 1 ~| NO. 2 ""
t t <* J
^yj^jIRON ORE Si ' S
^SILICA SAND | | 185 TPH 185 TPH
Xifxj-jxIvV I | (204 TPH) (204 TPH)
CLAY
jf&VX-** * » i 1- * % "
LIMESTONE fc ciioiuArc CIIQMAPC
i.'n.'j-— * FURNACE FURNACE
>*X*Vv C°AL N0.1 *~| f^ NO. 2
1 154 TPH 154 TPH
^ V(170TPH) ^ ,r(170TPH]
§ VERTICAL VERTICAL
j~. " riASS'FFR TIASSIFIFR
x*~~ "^v ^r v
/ CYCLONE \ VIBRATING 1 1 VIBRATING
rni i crrnoc 1 S^RFFNS SCRFFNS
\ y \ v ]
— T~C ^ TRASH BIN '
T 1 * ^~ |
/^BAGHOUSE^X^ | 1
V NO 45 S i '
> vi\j. ta — ^^ . ( ^ 30g TpH
/'BAGHOUSEN RAW MIX
V^NO.'X STORAGE
Rll OR ^ r f
(4)
LIMESTON
STORAGE
SILO
(CLINKEF
STORAGE
AREA)
1
I
8CLAY
DRYER
'
I
_»/^BAGHOIJSEN T ^
X^O. 46 S
~~~\
E j
« k.
/^BAGHOUSEN
V NO. 20 /
PROCESS MATERIAL FLOW ~'~"'^~^~
TPH - METRIC TONS PER HOUR
-—--.--(.-..--.—Pjp... ^^^^^ JTDUM PMPIIQUTnMCDCDUr^MD
BSSM^^H
PROPOSED CEMENT MANUFACTURING
PLANT THEODORE INDUSTRIAL PARK
SOURCE: Environmental Science and Engineering, Inc., 1977. MOBILE, ALABAMA
A-33
-------
OPERATIONS (PLANT SITE)
Regrind Mill
The raw mix will be fed from the stor'age silos into a regrind circuit
for fineness and secondary mix control. A single regrind mill, designed
for a production rate of about 360 mtph (400 tph), will be in a closed
circuit with an air separater to allow fines to pass through the
circuit, while oversized material will be reground in the mill and sized
again in the air separator.
Figure A.13 shows the regrind mill and kiln feed system. The regrind
mill will be serviced by two baghouse collectors.
Mix Blending
Fines passing the mill circuit will be passed into two blending silos
for homogenizing the raw mix. Each silo will have a capacity of
3,240 metric tons (3,560 tons), which allows for a total of approxi-
mately 20 hours of regrind production to be blended. The blended
materials will be fed into two 3,520-metric ton (3,880-ton) kiln feed
silos for storage in order to provide a steady state feed into the two
kilns. The blending and kiln feed silos will have a baghouse control
system as shown.
Kiln Suspension Preheaters
The kiln preheaters, kiln systems, and clinker cooler systems are shown
in Figure A.14. Although twin systems are shown in these figures and
described in this document, a single system may be utilized in the final
design. The process parameters of a single system, such as process
rate, fuel burning rates, exhaust volumes, and emissions should be
approximately the same as the total from a "twin" system.
The blended materials will be transported into the preheater system
through a series of air slide conveyors and elevators, which will be
vented through baghouses. As shown in Figure A.15, the preheater will
A-34
-------
RAW MIX
STORAGE
SILOS
(4)
360 TPH
(400 TPH)
AIR
SEPARATOR
I
REGRIND
MILL
BLENDING
SILOS
(2)
i360 TPH
(400 TPH)
KILN FEED
SILOS
(2)
PROCESS MATERIAL FLOW
PROCESS GAS STREAM
TPH - METRIC TONS PER HOUR
(TPH) - ENGLISH TONS PER HOUR
Figure A.13
REGRIND MILL AND KILN FEED SYSTEM
(ENGLISH UNITS IN PARENTHESES)
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
A-35
-------
KILN FEED
SILOS
(2)
ir-id
151 TPH
(167 TPH)
151 TPH
(167 TPH)
PREHEATER
N01
TO RAW MILL
i \j rn-inv IVIII-L.
NO. 1
" TPH
TDLJl
(12 TPH)
PREHEATER
140 TPH
(155TPH)
KILN NO 1
I '
22 TPH
(24 TPH)
COAL
140 TPH
(155 TPH)
11 TPH
(12 TPH)
V>^ TO RAW MILL
NO 2
KILN NO. 2
88 TPH
(97 TPH)
COOLER NO 1
TO RAW MILL
NO. 1
___ J
88 TPH
(97 TPH)
COOLER NO. 2
^ TO RAW MILL
NO. 2
176 TPH
(194 TPH)
CLINKER STORAGE
SILOS
fXBAGHOUSE
NO. 11
PROCESS MATERIAL FLOW
PROCESS GAS STREAM
Figure A.14
PREHEATER AND KILN/CLINKER COOLER SYSTEM
(ENGLISH UNITS IN PARENTHESES)
SOURCE. Environmental Science and Engineering, Inc., 1977.
TPH - METRIC TONS PER HOUR
(TPH) - ENGLISH TONS PER HOUR
REGION IV
U.S. ENVIRONMENTAL PROTECTION
AGENCY ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
PROPOSED CEMENT MANUFACTURING
PLANT THEODORE INDUSTRIAL PARK
MOBILE, ALABAMA
A-36
-------
RAW MIX
PRECALCINER
GASES
KILN BURNER
FAN
BAGHOUSE
EXHAUST
(or
CLINKER COOLER
WVV
KILN _
RAW MIX
FAN
Figure A.15
SKETCH OF PREHEATER, KILN AND CLINKER
COOLER SYSTEM
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
A-37
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OPERATIONS (PLANT SITE)
be a four-stage system that will feed the raw mix down through each
stage, counter to the kiln exhaust flow. The dust-laden gases will
enter tangentially the top portion of each stage and will be spun
downward. In order to be exhausted, the gases must make a sharp turn
upward through the center of the preheater, thereby separating about
90 percent of the particulate matter from the gases. In this
application of a preheater system, the raw mix will be fed into the
entry of the second stage cyclone, suspended with the kiln exhaust
gases, and separated, prior to exiting through a bottom hopper into the
third stage. Likewise, the third stage will feed the fourth stage,
which in turn will feed the kiln. The exhaust gases and dusts from the
second stage will be fed into the first stage for collection of most of
the entrained particulate matter for recycling into the system.
Approximately 11 mtph (12 tph), or 8 percent of the raw mix, will be
exhausted with the kiln gases from the suspension preheaters to the raw
mill system. Each preheater will handle 151 mtph (167 tph) of raw mix
and will be designed to transfer the heat from the kiln's exhaust gases
[about 1,000°C (1,850°F)] to the raw mix. The exhaust gas temperature
from the preheaters should be about 350°C (650° F), and the raw
materials after precalcination should enter the kiln at approximately
840°C (1,550°F). Approximately 140 mtph (155 tph) of raw mix will fall
through each preheater system for feed into a kiln.
Kilns
The dual kiln system will be fired with 22 mtph (24 tph) of coal to pro-
duce the temperatures [about 1,480°C (2,700°F)] required for formation
of the clinker (see Figure A.15). Each kiln system will have a precal-
ciner for greater thermal efficiency in producing the clinker. The raw
mix will enter the precalciner from the third stage of the preheater and
mix with the kiln's hot exhaust gases and with the heat from the pre-
calciner' s coal burner. The gases and the material are separated in the
preheater's fourth stage, and the heated raw mix is fed into the kiln.
The kiln is inclined and rotates so that the material tumbles towards
the discharge end. The kiln will burn about 40 percent of the system's
coal usage; the precalciner will burn the remaining 60 percent. At the
A-38
-------
OPERATIONS (PLANT SITE)
point of exit, the raw mix will form fused, marble-like structures known
as "clinker" [approximately 88 mtph (97 tph)]. An approximate weight
loss of 36 percent is accounted for by the liberation of carbon dioxide
from the limestone and of suspended particulate matter which is recycled
into the system.
Clinker Coolers
The clinker will be dropped from each kiln into separate inclined hori-
zontal grate coolers where it will be reduced to about 93°C (200°F) by
ambient air being blown through the grates. The clinker will then be
conveyed to the clinker storage silos to await finish grinding.
The heated clinker cooler exhaust will be vented to the precalciner and
raw mill circuits to supply heat and combustion air. The hot gases are
supplemented with a coal burner to produce sufficient heat to dry the
raw materials.
The kiln/clinker cooler/raw mill will have a common discharge system
designed to economize on the heating requirements of the total cement
process. ' The expected fuel consumption for the dry cement process is
0.7 million calories per metric ton (2.8 million Btu's per ton) of
clinker.
Finish Mill
The finish grinding mills are diagrammed in Figure A.16. In this area,
the raw materials will be mixed and ground with the gypsum in an approx-
imate 95 to 5 percent ratio to form the portland cement. In addition,
clinker will be mixed and ground with gypsum and dry limestone in a
ratio of 48 to 2 to 50 to produce masonry cement. It is planned that
six different types of cement will be produced at the plant site. Table
A.4 shows the finish mill requirement and the production figure for each
type. Type I cement should account for 74 percent of production, and
masonry cement for 8 percent. The process weight of each mill,
A-39
-------
CLINKER STORAGE
SILOS
118 TPH
(130 TPH)
EACH
MILL
PROCESS MATERIAL FLOW
PROCESS GAS STREAM
Figure A.16
FINISH CEMENT MILLS
(ENGLISH UNITS IN PARENTHESES)
SOURCE: Environmental Science and Engineering, Inc., 1977.
TPH - METRIC TONS PER HOUR
(TPH) - ENGLISH TONS PER HOUR
REGION IV
U.S. ENVIRONMENTAL PROTECTION
AGENCY ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
PROPOSED CEMENT MANUFACTURING
PLANT THEODORE INDUSTRIAL PARK
MOBILE, ALABAMA
A-40
-------
OPERATIONS (PLANT SITE)
Table A.4. Finish Mill Requirements and Production Figures
Mill
Requirements
Annual Production % of
Cement Type
I
IF
II
II MF
III
TOTAL (Portland Cements)
Masonry
Total (All Cements)
Metric Tons
1,047,997
65,450
65,450
65,450
65,450
1,309,797*
113,400t
1,423,197
(Tons)
(1,155,200)
(72,200)
(72,200)
(72,200)
(72,200)
(1,444,000*)
(125,000t)
(1,569,000)
(%) Operating Time
74.0
4.5
4.5
4.5
4.5
8.0
100.0
65
4
4
5
10
88
12
100
* Assuming 1,251,029 metric tons (1,379,000 tons) per year clinker
used for portland cements.
t Assuming 56,700 metric tons (62,500 tons) per year clinker used
for masonry cement.
Source: H.K. Ferguson Associates, 1975.
A-41
-------
OPERATIONS (PLANT SITE)
118 mtph (130 tph), applies to grinding Type I cement, since this will
be the main type produced and will require the maximum grinding rate.
Each mill will be in a closed circuit with its own air separator to
maintain the fineness quality of the finish product. Because of the
heat generated, each mill will have its own cooler to reduce the
cement's temperature prior to conveying to the silo areas. The finish
mills will have a large number of baghouses associated with control of
the dust generated in handling the finely ground cement.
CEMENT STORAGE AND HANDLING
The plant will have two finished product storage areas—the marine silos
for loading of oceangoing cement vessels and the land silos for all
other shipments. The land silos will serve the bulk rail car and truck
leading facilities as well as the packhouse operation (see Figure A.17).
The packhouse is a bagging facility which gives Ideal Basic Industries
an alternative market for its cement since it can be shipped by rail or
truck. About 5 percent of the cement shipment is expected to be bagged;
62.5 percent of the bagged cement is expected to be masonry cement. The
capacity of the two packing systems is 50 bags per minute.
The marine silos will serve the bulk loading of barges for transport to
Louisiana and Florida. Figure A.18 shows the arrangement whereby four
barge spouts can be used to load a vessel at a rate of 1,800 mtph
(2,000 tph). As shown in both Figures A.17 and A.18, all transfer
points and loading facilities will be ducted to baghouses.
The shipping schedule, as presented in Table A.5, is expected to vary
slightly throughout the calendar year. The marine shipments are approx-
imately 50 percent greater than all land shipments combined.
A-42
-------
TRUCK
LOADING
RAIL
LOADING
45TPH
(50 TPH)
45 TPH
(50 TPH)
PACKHOUSE
(MASONRY) (PORTLAND)
I
BAGHOUSE
NO. 30
109 TPH
(120 TPH)
EACH
BAGHOUSE
NO. 29
LAND CEMENT SILOS
FINISH
MILLS
M)TPH
75 TPH)
^
r""
1
r 1
TRUCK
LOADING
BAGHOUSE
NO. 33
PROCESS MATERIAL FLOW
PROCESS GAS STREAM
TPH - METRIC TONS PER HOUR
(TPH) - ENGLISH TONS PER HOUR
Figure A.17
LAND SILOS PROCESS FLOW
(ENGLISH UNITS IN PARENTHESES)
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
A-43
-------
MARINE CEMENT SILOS
454 TPH
(500 TPH)
454 TPH
(500 TPH)
PROCESS MATERIAL FLOW
PROCESS GAS STREAM
Figure A.18
MARINE CEMENT SHIPPING
(ENGLISH UNITS IN PARENTHESES)
SOURCE: Environmental Science and Engineering, Inc., 1977.
A-44
TPH - METRIC TONS PER HOUR
(TPH) - ENGLISH TONS PER HOUR
REGION IV
U.S. ENVIRONMENTAL PROTECTION
AGENCY ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
PROPOSED CEMENT MANUFACTURING
PLANT THEODORE INDUSTRIAL PARK
MOBILE, ALABAMA
-------
Table A.5. Cement Shipment Schedule
>
in
Annual Tonnage
Type of Shipment
Marine
Land: Trucks
Bulk
Packed
SUBTOTAL
Railroad Cars
Bulk
Packed
SUBTOTAL
TOTAL Land
TOTAL Marine & Land
Portland
Metric Tons
751,200
399,200
20,400
419,600
132,500
6,800
139,300
558,800
1,310,000
Cement
Masonry Cement
(Tons) Metric Tons
(828,000)
(440,000)
(22.500)
(462,500)
(146,000)
(7,500)
(153,500)
(616,000)
(1,444,000)
68,000
0
34,000
34,000
0
11,400
11,400
45,400
113,400
(Tons)
(75,000)
0
(37,500)
(37,500)
0
(12,500)
(12,500)
(50,000)
(125,000)
Tot a
Metric Tons
819,200
399,200
54,400
453,600
132,500
18,100
150,600
604,200
1,423,400
1
(Tons)
(903,000)
(440,000)
(60.000)
(500,000)
(146,000)
(20,000)
(166,000)
(666,000)
(1,569,000)
OPERATIONS (PLAN
Note: Truck capacity: 23 metric tons (25 tons) per bulk truck
25 metric tons (28 tons) per packed truck
Railroad car capacity: 91 metric tons (100 tons) per bulk car
86 metric tons (95 tons) per packed car
Source: H.K. Ferguson Associates, 1975.
00
-------
OPERATIONS (PLANT SITE)
The Louisiana fleet will consist of two tows and will take approximately
5.4 days per trip. The Florida fleet will consist of an oceangoing
vessel which will make a round trip in approximately 5.8 days.
The land fleet will consist of trucks and railroad cars. Each truck is
expected to hold 23 metric tons (25 tons) bulk or 25 metric tons
(28 tons) packed, and each railroad car is sized for 91 metric tons
(100 tons) bulk and 86 metric tons (95 tons) packed.
A-46
-------
RESOURCES REQUIRED (PLANT SITE)
ENVIRONMENTAL CONSIDERATIONS
RESOURCES REQUIRED
The resources needed for the daily operation of the cement plant are
depicted in Figure A. 19. The daily resources cycle shows that
approximately 9,900 metric tons (10,900 tons) of wet raw materials
(limestone, clay, sand, iron ore, gypsum, and coal) are required to
produce 4,600 metric tons (b.100 tons) of dry cement.
Limestone
The quarry to be developed in Monroe County will supply the cement plant
by barge transport with approximately 7,788 metric tons (8,585 tons)
of wet limestone per day. This property contains over a 50-year supply
of limestone.
Clay and Sand
The clay and sand will be obtained from an existing quarry located on
the 24-Mile Bend tract along the Alabama River approximately 60 kilo-
meters (40 miles) from the proposed plant site. A tow from the
limestone quarry will periodically as required pick up a loaded barge at
24-Mile Bend to meet the plant's daily requirements of 645 metric tons
(711 tons) of clay (wet basis) and 325 metric tons (358 tons) of sand
(wet basis).
Based upon a 1970 estimate of the acceptable clay and sand reserves,
5 years of quarry capacity remain after start-up of the proposed plant.
Ideal Basic Industries will evaluate other sources of clay and sand to
replace this facility, but investigation of these sources is beyond the
scope of this EIS.
A-47
-------
135 EMPLOYEES
1080 CM (285,0000) WATER
30 MEGAWATTS
(WET BASIS)
7788 (8585) T LIMESTONE
645(711) TCLAY
325 (358) T SAND
68 (75) T IRON ORE
212 (234) T GYPSUM
841 (927) T COAL
CEMENT
PLANT
AIR
1.4(1.5)1 PARTICULATES
17.4 (19.2) T SULFUR DIOXIDE
4591 (5061) T CEMENT
CM - CUBIC METERS
G - GALLONS
T - METRIC TONS (ENGLISH TONS)
2.8 (3.1) T SOLID WASTES
20 CM (5000 G) SEWAGE
341 CM (90,100 G)
WASTEWATER
910 CM (240,300 G)
FRESHWATER SHIP
MARSH CHANNEL
Fiigure A. 19
DAILY RESOURCES CYCLE (PLANT SITE)
REGION IV
U.S. ENVIRONMENTAL PROTECTION
AGENCY ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
SOURCE: Environmental Science and Engineering, Inc., 1977.
PROPOSED CEMENT MANUFACTURING
PLANT THEODORE INDUSTRIAL PARK
MOBILE, ALABAMA
A-48
-------
RESOURCES REQUIRED (PLANT SITE)
Iron Ore
A vendor will fulfill the plant's daily iron ore requirements, 68 metric
tons (75 tons) on a wet basis, via a barge or rail transport system.
The vendor has not yet been chosen, and the specific type of iron ore
will depend on a final materials analysis.
Gypsum
The gypsum, approximately 212 metric tons (234 tons) on a wet basis per
day, will be obtained from a commercial supplier. The gypsum will be
received from an oceangoing vessel or from railroad cars, depending on
the location of supplier and the post'1980 economics of transportation.
Coal
The coal required, approximately 841 metric tons (927 tons) on a wet
basis per day, will be supplied on a contract basis to be negotiated at
a later time with a currently unspecified vendor. Due to process
constraints, the coal must have a sulfur content less than 1.5 percent
by weight. Either railroad or water transportation of the coal will be
acceptable.
Electricity
The electrical service to the plant will be at 13.8 kilovolts with an
on-site substation. Approximately 30 megawatts will be required during
normal operations of the various process equipment. The electricity
will be purchased from Alabama Power Company. Present plans for the
transmission system to service the cement plant indicate that above*
ground power lines will be located within the roadway/rail road spur
access corridor.
A-49
-------
RESOURCES REQUIRED (PLANT SITE)
Water
The daily requirements for potable and process cooling make-up water
will be 1,080 cubic meters (285,QUO gallons), which will be supplied by
the Board of Water and Sewer Commissioners of the City of Mobile.
Labor
The plant will follow a 24-hour per day operating schedule throughout
the year. However, because of the usual operational and maintenance
problems, only an 85 percent (310 days per year) operating rate is pro-
jected for pyroprocess systems (raw mill, preheater, precalciner,
kiln/cooler). A total of 135 employees will be needed to operate the
Theodore facility--109 hourly employees and 26 supervisory employees.
Most of these workers will be transferred from the existing Mobile
cement plant. The annual payroll at Theodore will be approximately
$3,000,000 in 1977 dollars.
In addition, the plant will be supported by the Monroe County limestone
quarry with 19 employees, the 24-Mile Bend Clay and Sand Quarry with
10 employees, and a marine fleet operated by 50 workers. The annual
operating payrolls (in 1977 dollars) are estimated to be: the marine
facilities, $1,000,000; the limestone quarry, $400,000; and the 24-Mile
Bend Quarry, $110,000. (The marine fleet may be operated partially or
totally by a contractor.)
The plant staff will be supported by outside contractors who will be
responsible for the transport of some raw materials to the plant and for
the hauling of bulk and packaged cement by truck and rail.
Water Transportation
Marine operations will be composed of the following vessels:
Inbound
Limestone Barges: 3 tugs, 16 barges
Clay and Sand Barges: 2 barges
A-50
-------
RESOURCES REQUIRED (PLANT SITE)
Outbound
Louisiana Vessels: 2
Florida Vessels: 1
Approximately 819,200 metric tons (903,000 tons) of cement per year will
be shipped by these vessels.
Land Transportation
Annually the plant will ship approximately 604,200 metric tons
(666,000 tons) of portland and masonry cements by land transportation.
Both trucks and railroad cars will be used, in a tonnage ratio of 3:1.
These services will be leased/contracted or provided by the buyers. On
an average day, approximately 55 to 75 trucks and 5 to 7 railroad cars
will be loaded and shipped to customers.
The plant outputs, as shown in Figure A.19, are the conversion products
of the resources already mentioned. These outputs are described in
detail in the remaining sections of this appendix and are typically
based on annual outputs divided by 365 days per year.
A-51
-------
AIR (PLANT SITE)
AIR POLLUTANT EMISSIONS
Stack Emissions
The proposed cement plant, once constructed and operating, will have
controlled air emissions from approximately 62 individual sources.
Particulate matter from the plant processes will be exhausted from raw
materials handling; clay and coal dryers; the combined exhaust from the
raw mill/kiln preheater/kiln/cl inker cooler system; the regrind mill;
finish mills; and the storage and shipping operations. Fuel burning
operations to provide heat to the cement manufacturing operations will
have emissions of sulfur dioxide, nitrogen oxide, hydrocarbons, and
carbon monoxide, in addition to particulate matter. The flow diagram
shown in Figure A.20 illustrates the major cement manufacturing pro-
cesses which will be conducted at the proposed plant and the types of
air pollutants associated with each process.
A summary of the maximum allowable particulate matter and sulfur dioxide
emissions and the estimated quantities of other criteria pollutants is
presented in Table A.6. The allowables (particulate matter and sulfur
dioxide) are based upon the Prevention of Significant Deterioration
(PSD) application approved by EPA (see Permit and Approval section of
the Summary Document). They reflect Alternative I (kiln and clinker
cooler exhausting through the raw mill stacks) and present a worst-case
situation that will not be exceeded.
The pollutants of nitrogen oxides, hydrocarbons, and carbon monoxide,
although not applicable to the PSD regulation for this project, are
estimated based on emission factors (U.S. EPA, 1975) for similar
operations. These emissions represent the remaining criteria pollutants
that have National Ambient Air Quality Standards (NAAQS) and have been
shown or have the potential to be emitted from a dry cement plant.
Particulate Matter Emissions
Particulate matter emissions from the proposed plant will be generated
primarily by the movement of the process gas streams in the presence of
the raw mix and cement dust (such as in drying and grinding processes)
A-52
-------
CLAY
DRYER
RAW MATERIAL
STORAGE PILES
PARTICULATE MATTER
.t-T SULFUR DIOXIDE
RAW MILL
(DRYING AND
GRINDING)
COAL
FURNACE
NITROGEN OXIDES
PARTICULATE MATTER
SULFUR DIOXIDE
NITROGEN OXIDES
PARTICULATE
MATTER
REGRIND MILL
KILN/COOLER
PARTICULATE
PARTICULATE
MATTER
FINISH MILLS
PARTICULATE
PARTICULATE
MATTER
PARTICULATE
MATTER
PROCESS MATERIAL FLOW
PROCESS GAS STREAM
Figure A.20
CEMENT MANUFACTURING PROCESS, IDEAL BASIC
PROPOSED PLANT, THEODORE, ALABAMA
(Adapted from H.K. Ferguson Associates, 1975.)
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
A-53
-------
AIR (PLANT SITE)
Table A.6. 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
Pollutant/Source
Grams/
Sec
(Ibs/
hour)
Particulate Matter
and
Raw Mills/Kilns/Coolers*
Clay Dryer
Regrind Mill
Kiln/Cooler System**
Gypsum Storage and Unloading
Finish Mills
Clay Handling System
Coal Drying System
Shipping
Marine
Land
Packhouse
TOTAL
20.9
98
4
6
2
21
2
23
5
2
3
166
Sulfur Dioxidet
Raw Mi 11/Kiln/Clay Dryer
Coal Dryer
TOTAL
272.1
1,980
180
2,160
A-54
-------
AIR (PLANT SITE)
Table A.6. 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 1,044
Coal Dryer 20.8 165
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.
tCalculated 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.
A-55
-------
AIR (PLANT SITE)
and by the transfer, conveying, and storage of these materials. The
dust-laden exhausts will be passed through high efficiency collection
devices, known as baghouses, before being vented to the atmosphere
through stacks. These emissions are limited by local and State of Ala-
bama standards and by New Source Performance Standards (see the Permit
and Approval section of the Summary Document). Collected dusts from the
air pollution control devices will be recycled into the process,
conserving raw materials and products and eliminating a solid waste
disposal problem.
Particulate matter emissions from all baghouses, except those servicing
the raw mi 11/kiln/cooler exhaust system and the coal dryer, were esti-
mated based upon an outlet dust loading of 0.02 g/dscm (0.01 gr/dscf).
Emissions from these baghouses should exhibit zero opacity and therefore
meet the 10 percent maximum opacity requirement (NSPS) for cement
processing operations. Particulate matter emissions from the raw
mill/kiln/clinker coolers were based upon the New Source Performance
Standards (NSPS) for cement kilns and clinker coolers, respectively,
which specify a limit of 0.15 kg/metric ton (0.3 Ib/ton) of dry feed to
the kiln and 20 percent opacity. Normal dry feed to the kilns will be
140 metric tons (155 tons) per hour each, resulting in an allowable
particulate emission rate of 5.8 grams per second (46.5 Ib/hr) from each
kiln. Particulate matter emissions from the coal dryer are based upon
an outlet dust loading of 0.07 g/dscm (0.031 gr/dscf), which complies
with the applicable NSPS.
Other Emissions
Reduction of sulfur dioxide emissions can be achieved through the con-
tact with the alkaline cement dust. The alkaline nature of the cement
and its major raw material (limestone) allows the direct absorption of
sulfur dioxide into the product. The sulfur dioxide generated in the
cement kiln by combustion of coal will be exhausted through the length
of the kiln and will thereby have contact with the alkaline materials as
they tumble in the reverse direction.
A-56
-------
AIR (PLANT SITE)
In addition, these gases will be exhausted through the preheater tower
and the raw mill's drying and grinding circuit, thereby having addi-
tional contact with alkaline materials. The combustion gases from the
precalciner and raw mill will contain sulfur dioxide which will be
reduced by being combined with the kiln's gases as they are exhausted
through these process systems and finally through the baghouse prior to
being discharged to the ambient air.
When baghouses are used to control particulate matter emissions, overall
reduction of sulfur dioxide is stated to be as high as 75 percent due to
the intimate contact with the alkaline dust coating on the bags
(U.S. EPA, Office of Air Quality Planning and Standards, 1975). As
previously stated, Ideal Basic Industries will use baghouses to clean
all exhaust air streams; therefore, a similar reduction in sulfur
dioxide emissions is expected from the kiln/raw mill systems. (The coal
dryer and clay dryer exhausts will not contact alkaline dust and no
reduction of sulfur dioxide is anticipated).
Coal with an expected maximum of 1.5 percent sulfur content by weight
will be burned in the kilns, clay dryer, coal dryer, precalciners, and
the raw mill furnaces. In estimating sulfur dioxide emissions from fuel
burning, all available sulfur in the coal was assumed to be converted to
sulfur dioxide and no inherent removal of sulfur dioxide was considered.
Laboratory analysis has shown that trace amounts of sulfur (0.03 per-
cent) are present in the raw materials Ideal Basic Industries will
utilize (Ideal Basic Industries, 1975). By controlling the amount of
excess air within the kilns to normal operating conditions, sulfur will
not be liberated from the raw materials in the process. Therefore, the
sulfur dioxide emissions shown in Table A.6 reflect emissions from fuel
burning only.
For estimating emissions of nitrogen oxides, hydrocarbons, and carbon
monoxide from fuel burning, emission factors for cement kilns and coal
combustion (for the raw mill furnaces and coal and clay dryers) were
utilized (U.S. EPA, Office of Air Quality Planning and Standards, 1975).
A-57
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AIR (PLANT SITE)
Baghouses
The baghouses currently under design consideration are the pulse
compressed air type for most smaller gas flows and the shaker pulse
compressed air and reverse air types for the larger and typically hotter
gas flows. When high temperature is not a problem, a dacron polyester
filter material will be used. Hotter gas streams not containing sulfur
emissions will require a DuPont "Nomex" bag material. The hot exhausts
with sulfur compounds must have bags of a fiberglass material which is
more resistant to sulfur compounds than the Nomex. These materials can
provide a filtering performance better than the 0.02 g/dscm (0.01
gr/dscf) grain loading guaranteed for each baghouse servicing raw
cement/raw material production units.
A schematic diagram of a typical pulse compressed air baghouse arrange-
ment is shown in Figure A.21. The exhaust gases will pass through the
filter material, but the dust will be captured by the bag surface and
form a dust coating. In each of the three types of baghouses, this dust
coating must be periodically removed to maintain proper air flows. The
basic concept in any baghouse is to loosen the dust and allow it to fall
into the bottom collection hopper for easy removal. The difference in
baghouses is the way in which this cleaning cycle is accomplished.
The pulse compressed air type uses a blast of compressed air down
through the clean side of a bag to quickly flex the fabric and break up
the dust coat. This is performed while the unit is in full operation.
The shaker type, as the name implies, shakes the bags for dust removal.
This is usually performed with one of several modules of bags off-line,
to prevent re-entrainment problems. The reverse air unit has a multi-
compartment design that shuts off one section of bags and allows clean
air to flow backwards through the bag to slightly flex the material for
dust removal.
A-58
-------
COMPRESSOR
AIR—•» =
PULSED AIR
FLOW CLEANS
BAGS
SOLENOID VALVE
CLEAN GAS
TO STACK
FILTER BAG
BAG SUPPORT
DUST-LADEN
GAS
COLLECTED DUST
SOLIDS
Figure A.21
SCHEMATIC OF TYPICAL FABRIC FILTER (BAGHOUSE)
COLLECTOR WITH PULSED COMPRESSED AIR
CLEANING CYCLE
(Adapted from American Industrial Hygiene Association, 1968.)
SOURCE: Environmental Science and Engineering, Inc., 1977.
REGION IV
US ENVIRONMENTAL PROTECTION
AGENCY ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
PROPOSED CEMENT MANUFACTURING
PLANT THEODORE INDUSTRIAL PARK
MOBILE, ALABAMA
A-59
-------
AIR (PLANT SITE)
Because of the lower gas-to-cloth ratios of the shaker and reverse-air
types, they usually are massive units in comparison to the pulse jet
type, and require hundreds of bags.
Fugitive Emissions
Several operations and storage areas at the proposed plant are potential
fugitive dust sources. These operations include unloading raw materials
such as gypsum, coal, wet clay, wet limestone, silica sand, and iron
ore, and the transfer and storage of these materials. However, because
of their high moisture content, fugitive dust emissions from limestone,
wet clay, and silica sand operations are not expected to be significant.
Generally atmospheric emissions from coal, gypsum, dried clay, and iron
ore unloading, transfer, and storage operations will be controlled by
providing baghouse dust collectors and/or dust suppression water sprays
as required at transfer points.
Several raw material storage piles will also have potential for fugitive
dust emissions: the limestone storage pile, dry clay pile, coal pile,
gypsum pile, iron ore pile, and silica sand pile. Since all these stor-
age piles (except the limestone pile) will be covered, dust emissions
essentially will be eliminated. In addition, the limestone storage
piles will be provided with extensive water spray systems which will
maintain the piles in a wet state at all times and thereby eliminate
dust emissions.
In summary, the potential impacts due to fugitive dust emissions have
been mitigated by designing the process with baghouses and water sprays
at specific points and covers for the stockpiles of the drier
materials.
A-60
-------
NOISE (PLANT SITE)
NOISE
Construction
The activities of land clearing, grading, pile driving, construction of
buildings, and erection of process equipment will be performed with the
machinery previously described in Table A.I. The construction activi-
ties have been estimated to generate the levels of noise shown in
Figure A.22 (see Noise section of Appendix B, Baseline, for an explana*-
tion of noise levels). These levels will be attenuated by natural
barriers, trees, and vegetation, as well as by distance. In order to
lessen the impact of noise on nearby residents, the following actions
are planned:
1. Priority will be given to using equipment with noise sup-
pression devices, complying with the Walsh-Healy Act and
Occupational Safety and Health Administration (OSHA) regu-
lations. Reduced noise levels for workers will also mean
reduced ambient levels.
2. Most construction activities will be restricted to daylight
hours to reduce impacts on residents during normal sleep
periods.
3. The vegetation along the east and north will be retained to
attenuate noise levels.
Since it is anticipated that the plant's construction period will coin-
cide with the U.S. Army Corps of Engineers ship channel project, the
plant will not be the only active noise source. Every effort will be
made to minimize the overlap of the two projects in terms of peak noise
generation.
Operations
The proposed cement plant will generate noise from its various unit
operations, materials handling, raw materials delivery and product
shipping. The major sources will include:
A-61
-------
ROAO
55
60
ROAD
ROAD
HOAD
CLAUDIA LANEV
MOBILE BAY
LAURENOINE ROAD
Figure A.22
EQUAL SOUND LEVEL (Ldn) CONTOURS DUE TO
WORST CASE CONSTRUCTION ACTIVITIES FROM
THE PROPOSED PLANT ONLY
0 0.5 1
SCALE IN KILOMETERS
SOURCE: Environmental Science and Engineering, Inc., 1977.
A-62
REGION IV
U.S. ENVIRONMENTAL PROTECTION
AGENCY ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
PROPOSED CEMENT MANUFACTURING
PLANT THEODORE INDUSTRIAL PARK
MOBILE, ALABAMA
-------
NOISE (PLANT SITE)
1. Tug and barge traffic
2. Material handling and conveying equipment
3. Raw grinding mills
4. Coal dryer and grinder
5. Clay dryer
6. Kilns
7. Finish grinding mills
8. Railroad
9. Trucks
10. Compressors, fans, and machine shops.
The proposed action at the Ideal Basic Industries property at Theodore
Industrial Park will involve these noise sources. The precise noise
characteristics of the proposed plant are not known, but a reasonable
approximation was made from the results of a noise study conducted at
another cement plant which uses the dry process and has roughly one-
third the capacity of the planned Ideal Basic Industries facility.
Since the major elements of each plant are distributed over nearly equal
areas, the values obtained at the smaller plant, once adjusted for the
size differential, could be used for predictions of noise levels at the
larger plant.
Figure A.23 shows the isopleths of noise levels estimated to be
generated by the proposed cement plant. These levels reflect atten-
uating effects from vegetation in the area. Other sources of noise such
as ship channel traffic, road traffic, and surrounding industries are
not included in the values shown.
The sound levels are highest in the off-site areas to the south and west
because of the lack of vegetation to shield these areas. The critical
area is located immediately south of the site along the bank of the
existing barge canal. The impact of these sound levels is discussed in
Appendix C, Impacts.
A-63
-------
Figure A.23
EQUAL SOUND LEVEL (Ldn) CONTOURS DUE TO PLANT
OPERATIONS ONLY
'ROPOSED CEMENT MANUFACTURING
PLANT THEODORE INDUSTRIAL PARK
MOBILE, ALABAMA
SOURCE: Environmental Science and Engineering, Inc., 1977.
A-64
-------
NOISE (PLANT SITE)
In order to lessen these estimated noise levels, Ideal Basic Industries
will:
1. Enclose most of the process equipment (except for parts of the
kilns as required for heat dissipation);
2. Review the recommendations of their design consultant con-
cerning possible design changes that will generate less noise
by utilizing latest techniques in equipment design and plant
layout.
3. Retain a 90-meter (300-foot) wide greenbelt along its eastern
boundary and not develop the forested area north of the
facility site;
4. Locate roads and railroads as far away as practicable from
residential areas.
5. Locate a 20-meter (65-foot) high dead storage limestone pile to
the east of the facility.
In summary, the cement plant will increase the ambient noise level by
its construction and operation activities. Levels are estimated to be
highest in the areas immediately south and west of the plant site.
Ideal Basic Industries is taking the steps described above to mitigate
the estimated impacts.
A-65
-------
SOLID WASTE (PLANT SITE)
SOLID WASTE
Construction
The generation of solid wastes during the construction phase of the
proposed project will involve land clearing, dredging, grading,
construction, and final cleanup.
Land Clearing
The land clearing aspects will involve about three months of cutting and
removing the existing trees and stumps. It is expected that approxi-
mately 20 hectares (50 acres) will be clear-cut. Because the area was
timbered in 1974, few large trees remain. Typically, the trees are less
than 8 centimeters (3 inches) in diameter. Three types of disposal
methods are under consideration for partial use and combination or
exclusive use: chipping and mulching, controlled burning, and
landfill ing.
The vegetative wastes will be chipped on site and used for mulch along
the buffer strip between the disturbed and non-disturbed areas. This
method would be helpful in stabilizing the soil to lessen erosion and in
revegetating the land.
The contractor will apply for a burning permit from the Mobile County
Board of Health in order to utilize an air-blower type pit burner for
disposing of the wood wastes. This device is basically an outdoor fur-
nace that combusts the vegetation in a more efficient manner and thus
creates less smoke and particulate matter than "open burning." A pit is
dug and the wastes are piled in it and burned. The pit is encircled by
a manifold which blows air down into the burning material and which thus
provides more oxygen for the combustion process. Burning would be
conducted under favorable atmospheric conditions that would tend to
disperse the smoke. In addition, a fire watch would be maintained
during the burning period.
A-66
-------
SOLID WASTE (PLANT SITE)
The other method of disposal Is reducing the waste to an acceptable size
for burial at the Irvington Landfill. This method requires access to
the site by vehicles to haul the wastes to the landfill.
The actual use of any one or all of these methods would be based on the
practical application of each method within the time constraints of the
construction schedule. All the methods are believed to be environ-
mentally acceptable. However, the chipping and mulching is the most
desirable since it does not create localized smoke conditions or utilize
a portion of a landfill that could be best used for burial of higher-
priority wastes.
Dredging
The plans for the ship channel allow for a side slope that extends
approximately 60 meters (200 feet) inland from the channel's toe.
Assuming a conservative case of a 12-meter (40-foot) depth below msl,
the amount of dredging required for the docking facility at the cement
plant has been estimated to be 500,000 cubic meters (650,000 cubic
yards). It is anticipated that permission will be given by the Alabama
State Docks Department to place this dredged material in one of the two
approved spoil disposal areas to be established for the ship channel
project—a land site southwest of the area or the spoil island in Mobile
Bay. The construction schedules of both the Corps ship channel project
and the cement plant involve similar time frames (start at the end of
1978).
Grading
Grading the site location for surface drainage to the north and con-
struction of a berm for the stormwater catchment area will balance the
cut and fill so that disposal of excess material will not be necessary.
A-67
-------
SOLID WASTE (PLANT SITE)
Construction and Final Clean-up
The construction wastes generated from erection and final site clean-up
will be brought to the Irvington Landfill by a private contractor.
These wastes are expected to be quantities of lumber, concrete, brick,
cardboard, and metal scraps.
Operations
The cement manufacturing operation will produce approximately 1,043
•
metric tons (1,150 tons) of solid wastes per year. Table A.7 shows the
various sources of these wastes and their estimated quantities and
disposal methods.
A local disposal firm will be contracted for hauling most of the wastes
from the plant site to the Irvington Landfill. On-site industrial
landfill ing is not proposed by Ideal Basic Industries; therefore, all
solid wastes that cannot be recycled into the process or sold to a
reclaiming operation (such as a dealer in scrap metal or waste oils)
must be disposed at this landfill. Each process area recognized to be a
source of solid waste will use a trash bin system for storing the wastes
until removed by the contractor.
The kilns and their suspension preheaters are refractory-lined to retain
heat. During the course of normal operations, portions of the
refractory brick lining will deteriorate. These sections must be
cleaned and re-bricked; the debris is estimated to be a total of
667 metric tons (736 tons) of refractory bricks per year.
The packhouse produces bags of cement at the rate of 50 bags per minute.
When an upset or bag breakage occurs, the cement product will be
reclaimed and the paper bags discarded. This operation has been esti-
mated to contribute about 14 metric tons (16 tons) of paper waste per
year.
A-68
-------
Table A.7. Solid Waste Disposal
Quantity
Area
Kilns
Packhouse
Office
Maintenance
Raw Mill
Coal Mill
Settl ing
Basin
TOTAL
Metric Tons/
Type Year (Tons/ Year)
Refractory Bricks 667
Broken Paper Bags 14
Papers, Lunchroom 11
Trash
Rags, Oil , Grease, 34
Solvents
Rejected Material 166
Metals 82
Sediment 68
1,043
(736)
(16)
(12)
(37)
(183)
(91)
(75)
(1,150)
Kilograms/ (Pounds/
Day Day*)
1,830 (4,030)
40 (90)
30 (60)
90 (200)
450 (1,000)
220 (500)
190 (410)
2,850 (6,290)
Disposal
Method
Off -site
landfill
Off -site
landfill
Off -site
landfill
Off -site
landfill
Off -site
landfill
Off -site
landfill
Off -site
landfill or
recycl ed
into process
g
r~
1—4
0
s
VI
— 1
rn
^0
r""
* Based on 365 days per year.
Source: Environmental Science and Engineering, Inc., 1977.
-------
SOLID WASTE (PLANT SITE)
The plant will have approximately 20 office employees and will provide a
lunchroom for all of the 135 employees. Typical paper wastes generated
from these two areas are estimated to be 11 metric tons (12 tons) per
year.
The maintenance or shop area will have various metal wastes such as
broken pieces of equipment, scraps from welding or other repairs, used
grinding balls, empty drums, etc. It is planned that these will be sold
to a local scrap metal dealer for recycling. Waste oils will be sold to
refineries for processing. A small portion of the metal scraps and oily
wastes eventually will be found in the other solid waste from the shop
area such as rags, solvents, grease, wood scraps, cardboard, broken bags
from the baghouses, and paper. These are expected to comprise about
34 metric tons (37 tons) per year to be removed by the disposal
contractor.
The raw mill prepares raw materials, including limestone, clay, sand,
and iron ore, for the manufacture of cement. These materials will be
quarry-run materials but may contain foreign pieces of rocks, wood, and
metal, which will be separated from the raw materials. This source is
estimated to contribute 166 metric tons (183 tons) per year of non-
usable solid wastes, which will be hauled to the landfill for disposal.
Foreign materials found in the coal are removed by use of an electro-
magnet and mechanical separators. The solid wastes from the coal mills
are estimated to be 82 metric tons (91 tons) per year.
The plant will have a catchment area for general stormwater runoff and a
settling basin for industrial wastewaters to reduce the solids loadings.
The suspended solids that settle to the bottom of the basins must be
removed at regular intervals to avoid reducing the detention capacities
of the basins. Based upon influent and effluent estimates, about
68 metric tons (75 tons) of sediment should be removed each year. The
sediment will be surface dried and if possible re-introduced into the
process. However, this material might have to be taken to the
landfill.
A-70
-------
SOLID WASTE (PLAMI' SITE)
In summary, the majority of solid wastes generated from construction and
operation of the cement plant will be taken to the Irvington Landfill
for disposal. It is anticipated that the land clearing wastes may be
disposed on site (chipping or burning) and the dredged materials taken
to an approved disposal area. Excluding the construction wastes, metal
scraps, and waste oils that will be recycled, there will be about
1,043 metric tons (1,150 tons) of wastes disposed each year.
A-71
-------
WATER (PLANT SITE)
WATER UTILIZATION AND DISPOSAL
Water Usage Requirements
The proposed plant has five major demands for water—process cooling,
sanitary facilities, truck and car wash and other floor washes, the
dust suppression sprays, and finish mills/preheaters cooling sprays.
The process cooling system will be non-contact and will service the
various operations such as the raw mills, kilns, finish grinding mills,
etc. A cooling tower will be incorporated into the cooling system, and
two cycles of concentration will be allowed in the cooling system prior
to cooling tower blowdown. The total flow anticipated is approximately
0.8 cubic meters per minute (200 gpm) with about a 0.28 cubic meters per
minute (75 gpni) make-up requirement due to evaporation and cooling
system discharge. Based on a 24-hour per day operation, approximately
409 cubic meters per day (108,000 gpd) will be required for cooling
water make-up.
The projected sanitary water demand for the estimated 135 employees is
20 cubic meters per day (5,000 gpd) to use in toilets, sinks, and
showers. The showers are intended for routine use of the employees.
The projected demand for the truck and car wash and for the floor washes
is 6.6 cubic meters per day (1,750 gpd) and 17.7 cubic meters per day
(4,680 gpd), respectively. This is a total demand of 24 cubic meters
per day (6,430 gpd).
The projected demand for the cooling systems of the finish mills and
preheaters is 436 cubic meters per day (115,200 gpd). The estimated
fugitive dust suppression system will use 190 cubic meters per day
(50,000 gpd).
Therefore, the total water demand is expected to be roughly 1,080 cubic
meters per day (285,000 gpd). This demand will be supplied with potable
water from the Board of Water and Sewer Commissioners of the City of
A-72
-------
WATER (PLANT SITE)
Mobile distribution system in the Theodore Industrial Park. Table A.8
presents the results of an analysis of the finished water for this water
supply.
Industrial Wastewater
The four sources of industrial wastewater will be the raw material
stockpiles, the process cooling water system, the truck and car wash
and floor washes, and the runoff from the aboveground fuel oil storage
tank. The discharges from these sources will be combined in the settling
basins prior to final discharge to the ship channel (see Figure A.24).
The outside raw material storage areas (limestone and clay) will be
diked to capture the runoff from the uncovered piles. Table A.9 gives
the specific sizes of each storage area and their effective areas. The
average yearly rainfall for the Mobile area is 1,700 millimeters
(67 inches), which would produce an average daily flow from the piles of
166 cubic meters (43,800 gallons). A 10-year, 24-hour rainfall, which
is about 200 millimeters (9 inches), in the Mobile area, will produce a
pile runoff water volume of about 8 million liters (2.1 million gal-
lons), not considering any loss from filtration and evaporation.
In order to evaluate the characteristics of the runoff from the raw
material storage piles, simple leachate simulation tests and analyses
were performed. The results for the separate leachates, which are shown
in Table A.10, show a variation of pH of 7.2 to 9.0 for the limestone
leachate and 5.1 to 6.3 for the clay leachate.
While the pH of the clay leachate is below the EPA-stipulated range of
6.0 to 9.0, the runoff volume from the clay stockpile constitutes only
about 2 percent of the total stockpile runoff.
The results in Table A. 10 also show that both the limestone and clay
leachate have a high suspended solids content. However, settling tests
performed on the limestone leachate indicated that a suspended solids
A-73
-------
WATER (PLANT SITE)
Table A.8. Typical Analysis of Water Supply to Mobile, Alabama (1969)
Constituents
Concentrations*
Alkyl Benzene Sulfonate
Alkalinity (Total M.O.)
AntirrK>ny
Arsenic
Barium
Beryllium
Bismuth
Boron
Cadmium
Calcium
Carbonate
Chloride
Chromium
Cobalt
Conductivity, Specific
Copper
Cyanide
Extractable by Chloroform
Extractable by Alcohol
Fluoride
Hardness
Iron
Lead
Magnesium
Manganese
Molybdenum
Nickel
Nitrate
PH
Potassium
Radium
Radioactivity, Alpha
Radioactivity, Beta
Selenium
Silica
Silver
Sodium
Solids, Total
Sulfate
Tin
Uranium
Vanadium
Zinc
.03
14-18
004
005
009
00002
002
.06
<.003
10-12
6-8
7-10
<.0004
<.002
80
.062
<.005
.054
.108
.7-1.1
25-35
.046
<.03
.3-. 5
.002
<.0009
<.003
.2
8.5-9.0
.4
<.l pc/L
<.5 CPM
6.3 mmc/L
<.003
3.1
.002
1.8-2.8
43-62
7.8
.001
l+.l ug/1
T.0009
<.03
*A11 concentrations in milligrams per liter except as noted.
Source: U.S. Geological Survey, 1969.
A-74
-------
,,,,KUI ^V
%Cc!Sl:, \
/ ' I *-S,ltei >
^
Figure A.24
SOURCES OF INDUSTRIAL WASTEWATER
I
REGION IV
U.S. ENVIRONMENTAL PROTECTION
AGENCY ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
SOURCE: Environmental Science and Engineering, Inc., 1977.
PROPOSEDi
MANUFACTURING
PLANT THEODORE INDUSTRIAL PARK
MOBILE, ALABAMA
-------
I
^J
cn
Table A.9. Storage Pile Characteristics
Length
Material meters
Limestone (active) 230
Limestone (reserve) 248*
Clay 39
( feet)
(760)
(813)*
(129)
Width
meters
52
98
20*
(feet)
(170)
(320)
(67)*
Height
meters
20
20
11
(feet)
(65)
(65)
(36)
Actual
sq. meters
12,000
24,200
800
Area
(sq. feet)
(129,200)
(260,200)
(8,640)
*Effective dimension since area is not rectangular.
Source: Ideal Basic Industries, 1977.
•>
-------
Table A.10. Preliminary Leachate Study Results
First Source
Limestone
Second Source
Limestone
Limestone*
Clay*
Sample
No.
8132
8135
8138
8141*
8143
8144
8145
8146*
8147
8148
8149
8150
8151
pH
8.0
8.2
8.3
—
9.0
7.5
7.2
--
._
—
—
5.1
6.3
SS
(mg/l )
1,590.0
964.0
556.0
—
<5.0
<5.0
<5.0
—
152.0
252.0
54.0
77.0
3,180.0
OS
(mg/l)
60.0
166.0
237.0
—
94.0
54.0
52.0
—
—
._
—
28.0
2,220.0
S04
(mg/l)
25.0
19.0
9.9
—
22.0
14.0
14.0
—
—
_.
<5.0
1,600.0
BOD
(mg/l )
3.6
2.7
3.2
—
3.6
1.5
1.9
_.
__
_.
1.8
1.7
COD
22.0
17.0
17.0
—
19.0
15.0
11.0
__
__
_.
__
7.9
8.4
Cd
(ug/D
._
__
<0.5
..
_.
..
<0.5
__
__
<0.5
<0.5
Cu
(ug/D
..
_.
9.6
._
..
—
5.9
__
„_
__
5.9
13.0
Cr
(ug/D
__
<1.0
__
__
..
1.9
__
_«
__
3.3
3.3
Pb
(ug/D
._
<3.0
__
__
..
<3.0
__
__
__
<3.0
72.0
Ag
(ug/l)
__
6.9
__
__
9.6
__
__
__
5.1
18.0
Ni
(ug/i)
__
__
11.0
__
__
„
3.5
__
__
-.
6.5
5.0
*[fflupnt after settling
Source1 Environmental Science and Engineering, Inc., 1977.
m
Crt
-------
WATER (PLANT SITE)
reduction of 85 percent Is achievable. Settling tests were not per-
formed on the clay leachate since the clay stockpile runoff contribution
is minor.
The results of the metals analyses indicate generally low metal concen-
trations, with the exception of a lead concentration of 72 ug/1 that was
found in the clay leachate. However, this concentration will be reduced
to less than 1.5 ug/1 in the combined runoff.
A toxicity test, in which basic fish bioassays were performed, was con-
ducted to determine the nature of the raw material stockpile runoff.
The toxicity test solution was a mixture of the clay and limestone
leachates with water. The areas of the clay and limestone stockpiles,
as determined from preliminary engineering construction designs, were
653 square meters (7,030 square feet) and 16,300 square meters (175,000
square feet), respectively. These estimates of the areas (which are
somewhat more conservative than the areas shown in Table A.9) were used
to determine the proportions for mixing the leachates to create the test
solution.
The results of analyses of the test solution presented in Table A. 11
show only one constituent—iron—with a significantly high concentra-
tion. This concentration of iron, which was expected because of the
nature of the stockpiles, will be reduced through dilution and settling
in the settling basin.
In the toxicity test, no fish died as a result of exposure to the test
solution for the 96-hour test period. Furthermore, the test solution
represented the worst possible condition that might exist using
limestone and clay leachates, since in actuality the runoff from the
stockpiles will be diluted with other wastewaters of generally low
strength, such as cooling tower blowdown.
EPA may permit the effluent discharge into the ship channel with stip-
ulations of TSS and pH as defined in the effluent guidelines. These
A-78
-------
Table A.11. Results of Toxicity Test Solution Analyses
Conductance pH BOD COD Cd Cu Fe Pb Mn Hg Ni
(umhos/cm) (Sta. unit) (mg/1) (mg/1) (ug/1) (ug/1) (ug/1) (ug/1) (ug/1) (ug/1) (ug/1)
355 7.6 4.4 71.5 0.36 <1.0 2,729 <0.8 <55 <0.080 6.9
Source: Environmental Science and Engineering, Inc., 1977.
m
TO
GO
-------
WATER (PLANT SITE)
stipulations are 50 mg/1 of TSS and a pH within the range of 6.0 to 9.0
(see the Draft NPDES Permit in the Permit and Approval section of the
Summary Document).
The cooling system is a non-contact type with a daily make-up rate of
409 cubic meters (108,000 gallons). Approximately 67 percent of the
make-up is required because of evaporation loss, and the remaining
33 percent is used to maintain desired coolant quality in the cooling
tower. The cooling tower will blow down approximately 140 cubic meters
per day (36,000 gpd) to the settling basin to undergo cooling and treat-
ment for reduction of solids and temperature prior to being discharged
to the ship channel.
Based on the analytical results of the potable water of the City of
Mobile, a concentration of as much as three times the original levels
could occur in the cooling system due to evaporation without degrading
the water quality to unacceptable levels. Therefore, the cooling tower
blowdown will serve to dilute other wastewaters discharging to the
basin.
Based on common practices, it is anticipated that the non-contact cool-
ing water system will require use of an algicide and scale inhibitor.
The specific types to be used are still under investigation; however,
Ideal Basic Industries has agreed to obtain EPA's approval prior to use
of any additive.
The truck and car wash will contribute approximately 6.6 cubic meters
per day (1,750 gpd) of wastewater to the basin. An additional
17.7 cubic meters per day (4,680 gpd) of floor wash wastewater will be
routed to the basin.
The primary pollutant of the wastewater generated by the truck and car
wash and the floor washes is expected to be suspended solids. This
should not interfere with the treatment efficiency of the basin because
of the small volume relative to the cooling tower blowdown. In
A-80
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WATER (PLANT SITE)
addition, this wastewater, like the stockpile runoff, will be non-toxic
since the solids will consist of the same materials.
The above-ground fuel oil tank will have a containment berm surrounding
it in case of a spill or tank failure. During typical rainfall events,
this berm will catch runoff from the roof of the tank and direct rain-
fall. This water must be drained to maintain containment capacities;
the water will be routed to the settling basins for mixing with other
wastewater. The estimated average daily flow from the berm is about
0.7 cubic meters (190 gallons) after deducting for evaporation. The
runoff volume from a 10-year, 24-hour storm would be about 35 cubic
meters (9,150 gallons).
Table A.12 summarizes the wastewater flows discharged to the settling
basin prior to discharge to the ship channel. The proposed settling
basin, with an average depth of 2 meters (8 feet), has a capacity of
about 16 million liters (4.2 million gallons). This capacity is
sufficient to contain the wastewater flow, including the stockpile
stormwater runoff volume for the 10-year, 24-hour storm, and thus to
meet the EPA storage capacity requirements.
The basin will discharge continuously into the ship channel. The aver-
age discharge will be 341 cubic meters per day (90,100 gpd). This
accounts for direct rainfall on the basin and for evaporation losses
from the basin.
Due to the dilution of the higher strength wastewaters by the cooling
system discharge and the settling occurring in the basin, the discharge
to the ship channel will meet the requirements of 50 mg/1 or less of TSS
and of a pH within the range of 6.0 to 9.0. Because of the properly
designed settling basin, no water quality problems should occur.
The settling basin will be divided into two sections; one will remain
on-line while the other is cleaned of settled solids. The basin will
A-81
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WATER (PLANT SITE)
Table A.12. Wastewater Discharge to Settling Basin
Source
Runoff from limestone
and clay stockpiles
Cooling system discharge
Trucks and car wash,
floor washes
Fuel tank berm
Total Influent
Direct Rainfall on Pond
Evaporation from Pond
Difference
Total Discharge
Discharge
Cubic Meters/Day
165.8
(8,029.9)
136.3
24.3
0.7
(34.6)*
327.1
(8,225.1)t
43.1
(2,087i4)*
29.2
13.9
341.0
(10,312.5)t
Gallons/Day
43,800
(2,121,500)*
36,000
6,430
190
(9,150)*
86,420
(2,173,080)t
11,400
(551,485)*
7,720
3,680
90,100
(2,724,565)t
* Runoff volume for 10-year, 24-hour storm of 9 inches
t Total discharge including runoff volume for 10-year, 24-hour storm of
9 inches
Source: Environmental Science and Engineering, Inc., 1977.
A-82
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WATER (PLANT SITE)
have to be cleaned approximately once every four months to remove
roughly 50 cubic meters (60 cubic yards) of sediment. As mentioned In
the Solid Waste section, the sediment, if it cannot be recycled into the
process, will be hauled to the Irvington Landfill for disposal.
General Stormwater Runoff
The general Stormwater runoff from the facility site will drain north by
natural flow patterns and drainage ditches. This flow will then enter a
2-hectare (5-acre) catchment area which is enclosed by a 0.9- to
1.5-meter (3- to 5-foot) high earth berm. Water will be discharged to
the freshwater marsh; the catchment area is designed to be drained to
maintain its storage capacity.
The discharge from the bermed area will be approximately 910 cubic
meters per day (240,300 gpd) based on the average annual rainfall of
1,700 millimeters (67 inches), a plant site runoff coefficient of 0.887,
and a plant site area of 22 hectares (54 acres).
A 10-year, 1-hour rainfall at the plant site is about 76 millimeters
(3 inches) (U.S. Soil Conservation Service, 1973). The runoff volume
for this storm will be approximately 15 million liters (3.9 million
gallons). The bermed grassy area, with a storage capacity of 12 million
liters (3.3 million gallons), will retain the runoff for about the first
50 minutes of the storm.
Two basins will be built in series in the catchment area to increase the
efficiency of sediment control. The discharge from the bermed area will
undergo further natural treatment in the marsh system prior to entering
the ship channel.
A-83
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WATER (PLANT SITE)
Summary of Wastewater Flows
Figure A.25 Is a schematic of wastewater flow at the proposed Ideal
Basic Industries cement plant.
The two wastewater discharges to surface waters from the proposed plant
will be from the industrial wastewater settling basin and from the
general stormwater catchment area. These flows will be approximately
341 cubic meters per day (90,100 gpd) and 910 cubic meters per day
(240,300 gpd), respectively.
Sewage System
During construction, the sanitary system for the workers will be port-
able toilets serviced by a local contractor. Disposal of wastes will be
approved in advance by the Mobile County Board of Health.
The projected sanitary wasteloads from the approximately 135 employees
will be 20 cubic meters per day (5,000 gpd).
The Board of Water and Sewer Commissioners of the City of Mobile has
just completed a lift station at the intersection of the North Fork Deer
River and Dauphin Island Parkway. This lift station will take the
sewage to the new McDuffie Island treatment plant.
A-84
-------
MUNICIPAL WATER SUPPLY
MeDUFFIE ISLAND
WASTEWATER
TREATMENT PLANT
EVAPORATION
6233CMD
IIC3200GPDI
10»CMD
lira 000 GPOI
FRESHWATER MARSH
910 CMO
I2W300GPDI
Figure A.25
SCHEMATIC OF WASTEWATER FLOW
(ENGLISH UNITS IN PARENTHESES)
SOURCE: Environmental Science and Engineering, Inc., 1978
PROPOSED CEMENT MANUFACTURING
PLANT THEODORE INDUSTRIAL PARK
MOBILE, ALABAMA
-------
ENVIRONMENTAL SAFEGUARDS (PLANT SITE)
ENVIRONMENTAL SAFEGUARDS
In the proposed design for the cement plant, certain environmental
impacts during construction and operation were anticipated. Therefore,
several mitigating actions were incorporated in the design plans. These
were generally presented in the preceding sections, but are summarized
below.
Stormwater Runoff Control
To reduce the potential for deterioration of existing water quality in
the ship channel and the North Fork Deer River, a stormwater runoff
catchment area with two basins will be built as soon as possible for use
during the construction period. The existing drainage and surface
grading will be utilized to bring the runoff into the grassy bermed area
[about 2 hectares (15 acres)] just between the freshwater marsh and the
actual facility site. During operations, this catchment area also will
serve as the best management plan for controlling the cement plant's
stormwater runoff prior to discharge into the freshwater marsh of the
North Fork Deer River.
Another erosion control will be the use of temporary berms to facilitate
ponding and to slow the movement of runoff. Berms of hay or dirt will
be constructed whenever practical to reduce the solids loading to the
basins. This technique also will be used during the construction of the
roadway, bridge, and railroad trestle since the runoff from this area
(west-northwest) will generally go directly into the freshwater marsh
and the North Fork Deer River.
Industrial Wastewater Control
The wastewater settling basins will also be built as soon as possible to
assist in controlling runoff during construction. However, since the
existing and final grade is to the north, the main priority will be
completing the general catchment area.
A-86
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ENVIRONMENTAL SAFEGUARDS (PLANT SITE)
During plant operations, the wastewater settling basin will provide
adequate treatment to meet the effluent requirements of U.S. EPA and
the Alabama Water Improvement Commission.
Process Air Emissions
The 62 sources of particulate matter emissions will be controlled by the
best available technology—-baghouses of 99 percent collection effi-
ciency. Sulfur dioxide emissions will be limited by the use of low
sulfur coal (1.5 percent maximum) and reduced by the chemical reaction
with the alkaline materials in the manufacturing process.
Fugitive Dust Controls
In the accessible work areas and along the access roadway, the main con-
struction contractor will provide and routinely use water tank trucks
with sprays. These will be utilized whenever practical to reduce the
dust emissions.
During operations, the fugitive dust will be controlled by water sprays
on open stockpiles and the materials handling system. In addition, coal
and all raw materials except limestone and wet clay, will be stored in
covered structures with dust control facilities.
Noise Controls
The heavy construction equipment, such as pile drivers and compressors,
will use available noise suppression equipment and will normally be
scheduled to operate during daylight hours in order to lessen the noise
impacts on local residents. The plant's design is being analyzed to
suggest techniques to reduce noise from various process components. The
greenbelt and other non-developed areas of the property, as well as the
storage piles, will act to reduce noise emissions to the surrounding
area.
A-87
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ENVIRONMENTAL SAFEGUARDS (PLANT SITE)
Burning Controls
Disposal of the vegetative wastes from land clearing will involve chip-
ping, burning, and landfill ing. The contractor will apply to the Mobile
County Board of Health for a burning permit. Preliminary indications
from the county air pollution staff are that burning could be acceptable
if conducted according to specific restrictions that would prevent
occurrence of a localized air pollution problem. Typically the burning
must be performed under the following conditions:
1. Not causing a localized smoke problem;
2. Burning only during favorable air dispersion conditions; and
3. Coordination of activities with the local fire marshal.
The contractor will use an air-blower type pit burner. As explained in
the Solid Waste section, this type of burning has better combustion
efficiencies and less smoke and therefore is preferable from an air
pollution standpoint. The burning will be continuously supervised and
performed quickly to lessen the possibility of nuisances.
Fuel Oil Spills
All above-ground fuel storage tanks will be encircled by earthen berms
designed to hold 100 percent of their storage capacity. If a spill does
occur, it will probably be very small, and removal of contaminated soil
will not be necessary. However, if a large spill occurs, the Mobile
County Board of Health will be notified for specific permission to take
disposal actions.
Solid Wastes
Other than the land clearing wastes already mentioned, the rest of the
construction debris and most of the operational wastes will be taken to
the Irvington Landfill for burial. This site is described in Appen-
dix B, Baseline, as the closest approved site that will accept
construction and operation wastes.
A-88
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ENVIRONMENTAL SAFEGUARDS (PLANT SITE)
Preservation of Natural Communities
The existing ecological communities will not be disturbed except within
the required right-of-way for the access road and railroad spur and in
the general facility area. It is intended that there will be minimum
disturbance in the North Fork Deer River and its wetlands and the area
north of the river will not be physically disturbed or developed.
Archaeol ogical/Hi storical Measures
The area has been surveyed and obvious archaeological or historical
sites were not found. In case a possible site is uncovered, the Alabama
Historical Commission will be notified immediately. Work will be
stopped in that specific area until the commission gives its approval to
resume operations.
Local Community Aspects
Based on the history of previous construction projects, the majority of
construction workers will be from the local area, and substantial money
($10,000,000) should be spent in local purchases of material.
The plant will be operated by employees from the present plant in
Mobile and thus will not create stress on available housing and other
public services and facilities.
A-89
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PERMITS/APPROVALS (PLANT SITE)
PERMITS AND APPROVALS REQUIRED
The construction and operation of the cement plant and of the limestone
quarry must meet the compliance requirements of various environmental
agencies. The environmental permitting and approval requirements for
the construction and operation of the cement plant are presented in
Table A.13. The emission or effluent requirements of these agencies are
presented within the applicable sections of this appendix (Air Quality,
Noise, Water Resources, etc).
A-90
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Table A.13. Environmental Permits and Approval Requirements
Parameter
Agency
Requirements
Air Emissions
i
VD
Mobile County Board
of Health
Alabama Air Pollution
Control Commission
U.S. Environmental
Protection Agency
Permit to construct and permit to operate;
technical and administrative portions of
the Prevention of Significant Deteriora-
tion (PSD) Program. Permit for open
burning.
Permit to construct and permit to operate;
technical and administrative portions of
the PSD Program.
Final approval of PSD permit.
Wastewater Discharge
Alabama Water Improvement
Commission
U.S. Environmental
Protection Agency
U.S. Army Corps of Engineers
Issuance of letter of approval before
construction, and waste discharge permit
after construction completed.
Certification of all COE permits.
National Pollution Discharge Elimination
System (NPDES) permit.
Permit required for construction of dis-
charge outlet in Theodore Ship Channel.
m
50
CO
I
3>
CO
CO
-------
Table A.13. Environmental Permits and Approval Requirements (Continued, page 2 of 3)
Parameter
Agency
Requirements
Stormwater Runoff
Control
U.S. Environmental
Protection Agency
NPDES permit required for discharge to
wetlands.
Alabama Water Improvement
Commission
No permit required. Must use "Best
Management Practices."
Solid Waste
Mobile County Board of
Health
Alabama Health Department
U.S. Environmental
Protection Agency
No permit required but must approve of
types of waste to be disposed in
landfill.
No permit required; but approval for
specific types of waste through Mobile
County Board of Health.
No permit required; requirements under
Resource Conservation and Recovery Act
of 1976; works through state agency.
-o
m
73
CO
I
>
CO
CO
-------
Table A.13. Environmental Permits and Approval Requirements (Continued, page 3 of 3)
Parameter
Agency
Requirements
Docking Facility
U.S. Army Corps of Engineers
Alabama State Docks
Alabama Water Improvement
Commission
Dredge and fill permit; permit for
construction.
Permit for construction and approval for
spoil disposal.
Certification of dredging application to
Corps.
Roadway and Railroad
Trestle Construction
in Wetlands
U.S. Army Corps of Engineers Fill permit for roadway across North Fork
Deer River and marsh.
U.S. Coast Guard
Alabama Water Improvement
Commission
Permission to bridge North Fork Deer
River.*
Certification of applications to Corps
* If the U.S. Coast Guard is determined to have jurisdiction.
Source: Environmental Science and Engineering, Inc., 1978.
co
-o
73
O
CO
CO
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SITE LOCATION/DEVELOPMENT (QUARRY SITE)
QUARRY SITE
LOCATION AND DEVELOPMENT
EXISTING CONDITIONS
The proposed quarry site is located approximately 129 kilometers
{80 miles) northeast of Mobile on the eastern banks of Alabama River in
Monroe County (see Figure A.26). This 1,633-hectare (4,035-acre) tract
of land will provide the limestone rock for the proposed cement plant
operations. The property is approximately 5 kilometers (3 miles)
southwest of the Stockton Road (Monroe County Road No. D-U.S. High-
way 84 intersection (Perdue Hill Community) and about 23 kilometers
(14 miles) down the Alabama River from the Claiborne Lock and Dam (see
Figure A.27). The area generally is hilly with relief ranging from a
base level of less than 3 meters (10 feet) above msl at the Alabama
River to an altitude of nearly 60 meters (200 feet) along Marshal Is
Bluff.
Bluffs and outcrops occur along the western boundary of the property
adjacent to the Alabama River. Relief moderates considerably to the
east, as well as north and south of the site. Underlying the sand and
gravel on the surface is a layer of limestone, which in many areas
protrudes through the surface layer.
There are four large creeks on the proposed quarry site which flow into
the Alabama River. They are shallow creeks which have sand and gravel
bottoms and flow in a southwest direction. In descending order from
north to south they are: Me Girts Creek, Thompson Mill Creek (also known
as Marshalls Creek), Hoi linger Creek, and Randons Creek.
The property is composed of two main land tracts—land owned by Ideal
and land leased to Ideal for mining (see Figure A.28). The northern
A-Q4
-------
CLAY AND SAND QUARRY
r
Figure A.26
PROPOSED CEMENT PLANT AND QUARRY SITES
(EXISTING CLAY AND SAND QUARRY ALSO SHOWN)
0 40
SCALE IN KILOMETERS
REGION IV
U.S. ENVIRONMENTAL PROTECTION
AGENCY ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
PROPOSED GAILLARD QUARRY
MONROE i
, ALABAMA
SOURCE: Environmental Science and Engineering, Inc., 1977.
A-95
-------
Figure A.27
QUARRY SITE VICINITY
0 5 10
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
-------
;
1
I
1
1
IDEAL BASIC
INDUSTRIES
PROPERTY
/ * f-l
'//' 1
1
f I
McWILLIAMS
PROPERTY
FTL
I
Figure A.28
PROPERTY LINE, QUARRY SITE
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
A-97
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SITE LOCATION/DEVELOPMENT (QUARRY SITE)
739 hectares (1,826 acres), called the Gail lard tract, was obtained by
Ideal in separate purchases in 1953 and 1959. The remaining
894 hectares (2,209 acres) have been leased from Mr. Howard McWilliams
for mining rights. It is anticipated that approximately 80 percent of
the total property [1,633 hectares (4,035 acres)] may be quarried by
using present mining techniques over the quarry life of 40 to 50 years.
The Gail lard tract will be the main area to be quarried during the first
15 years of operation. A timber management plan for this land was ini-
tiated in 1969, and controlled hunting was allowed. A grazing lease,
negotiated with Mr. McWilliams in 1976, allowed for timbering and estab-
lishing pastures throughout most of the property south of Thompson Mill
Creek.
Figure A.29, an aerial view of the property, shows the conditions in
June, 1977, after partial timbering and land clearing operations. Cur-
rently the primary use of the land is for pasture, and the reclamation
practices have been planned to return the land to this use. For a more
detailed description of present conditions (1977), refer to Appendix B,
Baseline.
SITE DEVELOPMENT
During the construction period, the main facility area at the quarry
site will be developed. An access road will be constructed from
Stockton Road (Monroe County Road No. 1) to the office site. Other
roads will be developed as needed for access to active quarry areas.
Docking facilities will be constructed along the east bank of the
Alabama River to accommodate four barges in a two-by-two pattern during
limestone loading operations. Construction of these facilities will
require a projection into the river of approximately 28 meters (90 feet)
with a 5-meter (15-foot) minimum depth throughout its 194-meter
(636-foot) length.
A-98
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PROPOSED GAILLARD QUARRY
MONROE COUNTY, ALABAMA
Figure A.29
AERIAL VIEW OF QUARRY SITE
SCALE IN KILOMETERS
SOURCE: Environmental Science and Engineering, Inc., 1977.
A-99
-------
SITE LOCATION/DEVELOPMENT (QUARRY SITE)
Not all of the land at the quarry site can be worked economically
because of deep overburden areas and steep slopes. Throughout the
50-year life of the quarry operation, 80 percent of the site will be
actively quarried and reclaimed to pastureland.
In order to provide adequate pollution abatement controls for stormwater
runoff, all active quarry areas, limestone stockpiles, and overburden
storage areas will be drained to clarification basins. These basins
will be developed from existing low areas, and water will be retained by
earth dams. Wherever practical, overburden piles will be seeded to
prevent excessive erosion and sediment problems.
The major improvements that will be made during the initial construction
involve the following facilities:
1. Operation Office and Maintenance Building. This structure will
house the operations office, a maintenance garage for service
and repairs on quarry equipment, restrooms, a wash and change
room, and an employee's lunchroom.
2. Mooring Facility. A free-standing mooring structure approxi-
mately 194 meters (636 feet) long will be built in the Alabama
River to accommodate a tow of four barges each.
3. Loading Conveyor. A loading conveyor will be constructed to
transport the limestone from the stockpile to the barges. This
conveyor will be able to adjust its length and telescoping boot
to allow loading of a barge regardless of the river stage
fluctuation.
4. Crushers, Conveyors, and Stockpile. Each work face will be
serviced by crushers for breaking oversized rock and a conveyor
system for moving the rock to the storage area. The central
limestone stockpile will be equipped with bottom feed hoppers
to load out material to the barge loading conveyor.
A-100
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SITE LOCATION/DEVELOPMENT (QUARRY SITE)
5. Clarification Basins. South of the loading and storage area,
two large clarification basins (Nos. 1 and 2) will be con-
structed by damming the outflow of natural depressions and will
provide effective storage capacities for stormwater runoff of
approximately 181,000 cubic meters (147 acre-feet) and
56,000 cubic meters (45 acre-feet), respectively. These basins
will provide a sediment trap for all runoff from the disturbed
quarry and limestone storage area. Another large basin [No. 5,
with 176,000 cubic meters (143 acre-feet) storage capacity]
will be created in Milkhouse Branch leading to Thompson Mill
Creek. Since this area is devoid of limestone, the mining
operation will work around it; separate portions will be
clear-cut to provide for water storage capacity and overburden
deposit areas. Two additional basins (Nos. 3 and 4) may be
constructed at an indefinite time when the land north of the
plant area is quarried. The locations of these clarification
basins are illustrated in Figure A.30.
6. Roads. An all-weather access road will be constructed to the
quarry office site from Stockton Road (Monroe County Road
No. 1) located about 5 kilometers (3 miles) east. A bridge or
culverts are planned over Coleman Branch and other drainage-
ways.
7. Power. Electrical power will be supplied by either Alabama
Electric Cooperative or Alabama Power Company. It is
anticipated that power lines will be brought in along Monroe
County Road No. 1 and then along the quarry access road. The
utility company will provide 4.18 kilovolt service, and Ideal
Basic Industries will provide the in-quarry lines and equipment
to meet its needs (3 megawatts). The limestone breakers, belt
conveyors, and traveling stackers will be operated by elec-
tricity. Auxiliary facilities, the office and maintenance
buildings, will also be supplied with electrical lighting and
power.
A-101
-------
CLARIFICATIOI
BASIN 5
CLARIFICATION \*
BASIN 4
CLARIFICATION f/
BASIN 3
QUARRY PLANT
AND DOCK AREA
CLARIFICATION / /
BASIN 2 —ft
CLARIFICATION
BASIN 1
Figure A.30
SITE DEVELOPMENT
(FIRST FIFTEEN YEARS)
0 0.5 1
SCALE IN KILOMETERS
SOURCE: Ideal Basic Industries, 1977.
AREAS TO BE MINED
REGION IV
U.S. ENVIRONMENTAL PROTECTION
AGENCY ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
PROPOSED GAILLARD QUARRY
MONROE COUNTY, ALABAMA
A-102
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SITE LOCATION/DEVELOPMENT (QUARRY SITE)
8. Water and Sanitation. An on-site well for potable water,
approximately 40 liters per minute (10 gpm), will be drilled,
probably in the vicinity of the office building. A septic tank
with a soil absorption field for sewage disposal will be
constructed. Both facilities will be built to meet the
requirements of the Monroe County Health Department.
9. Fuel Depot. A 38,000-liter (10,000-gallon) fuel oil tank and a
23,000 liter (6,000 gallon) gasoline tank will be installed to
service on-site vehicles. Both tanks will be underground.
A-103
-------
CONSTRUCTION (QUARRY SITE)
CONSTRUCTION
The construction period is scheduled to start during the third quarter
of 1978. Therefore, the project should begin in 1978 and finish in
early 1980, for a total of 18 months. The estimated cost for the lime-
stone quarry facility is $12 million (in 1977 dollars). Construction of
the facility will employ an average of 133 workers, with a peak labor
force of about 250 persons.
The construction plan will involve the same major phases as the cement
plant: land clearing, grading, erection of structures and equipment,
construction of docking facility, and equipment needs.
Approximately 40 hectares (100 acres) of the 1,633-hectare (4,035-acre)
site will be cleared for the access road, main building, and stockpile
area. The existing trees and undergrowth will be burned on-site and/or
chipped for use as mulch to the extent practical. This phase is ex-
pected to take 3 months to complete. As soon as road construction will
allow access of heavy earthmoving equipment, work will begin on the
construction of the first two clarification basins. The work areas will
be cleared to facilitate the placement of suitable embankment for the
dam core.
When construction of the first clarification basin dam has progressed to
the point where it can be used as a temporary sediment basin, clearing
and earthwork will begin on the loading and storage site. Development
of the loading and storage site will require grading a plateau at
approximately 21 meters (70 feet) above msl. Design work by Brown &
Root, Inc., may reduce the earthwork requirements for the initial
excavation, but preliminary estimates indicate that approximately
570,000 cubic meters (750,000 cubic yards) of material will be moved.
At least 190,000 cubic meters (250,000 cubic yards) of this material,
which is expected to be overburden, will be permanently moved to a
cleared area in the Milkhouse drainage basin. Additional overburden
material will be used as fill in the construction of the clarification
A-104
-------
CONSTRUCTION (QUARRY SITE)
basin dams wherever suitable. The remaining portion of the initial
excavation should be usable limestone which will be placed near Clarifi-
cation Basin No. 2 or in other nearby locations so that it can be easily
recovered for the initial shipments of limestone to the Mobile plant.
After the grading has been completed at the loading and storage site,
the docking structures will be constructed at the waterfront.
Figure A.31 shows the preliminary schematic layout for the loading and
storage area at the quarry. Mooring dolphins will be placed in the
river so that barges may be secured for loading. These structures will
also provide support for the shuttle conveyor which will extend over the
bank. A typical section of the waterfront development is shown in
Figure A.32. Shoreline protection or stabilization improvements are not
planned at the loading area since the existing river banks are very
stable.
Ideal Basic Industries will begin operation of the quarry when the
loading and storage facilities have been constructed and all equipment
is operational. Three clarification basins will be complete and will
function as the primary sedimentation control.
The overall schedule for construction is shown in Figure A.33, and the
equipment required is listed in Table A.14.
A-105
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|
UNDERGROUND
FUEL TANKS
BARGES^'
Figure A.31
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 GAILLARO QUARRY
MONROE COUNTY, ALABAMA
A-106
-------
ORIGINAL GROUND SURFACE
OVERBURDEN
(TO BE REMOVED DURING
INITIAL PLANT GRADING)
INITIAL PLANT GRADE
o
•vj
ALABAMA
RIVER
LIMESTONE
(TO BE REMOVED AFTER
QUARRY OPERATIONS BEGIN)
SECTION
DRAWING NOT TO SCALE
Figure A.32
TYPICAL SECTION OF WATERFRONT DEVELOPMENT
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
-------
o
00
LAND CLEARING
AND GRADING
ACCESS ROADWAYS
PILE DRIVING
DREDGING AND
DOCK CONSTRUCTION
ERECTION
OF FACILITIES
AND EQUIPMENT
SETTLING BASINS
I
9
12
15
I
18
MONTHS
Figure A.33
SCHEDULE OF MAIN CONSTRUCTION TASKS
REGION IV
U.S. ENVIRONMENTAL PROTECTION
AGENCY ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
SOURCE: Brown & Root, Inc.. 1977.
PROPOSED GAILLARD QUARRY
MONROE COUNTY, ALABAMA
-------
CONSTRUCTION (QUARRY SITE)
Table A.14. Equipment Requirements
Equipment
Earth Moving:
Push Dozers
Scrapers
Graders
Loaders
Bulldozers
Carry-Alls
Rollers, Compactors
Lifting:
Light Cranes
Heavy Cranes
Side Booms
Cherry Pickers
Forklifts
Miscellaneous Portable:
D & G Welders
Air Compressors
Portable Generators
Paving & Concrete:
Backhoes
Portable Mixers
Ready-Mix Haulers
Vibrators
Rollers
Asphalt Distributors
Concrete Finishers
Pile Drivers:
Transporters:
Light Trucks
Heavy Trucks
Flat beds, Low Boys
Dump Trucks
Project Duration (In
3
4
4
4
3
4
3
2
1
-
-
1
1
2
2
1
3
_
-
-
_
-
-
_
3
2
1
10
3
2
2
2
2
2
2
2
1
1
2
2
2
5
5
2
3
2
5
3
_
-
2
1
5
2
1
10
3
1
1
1
2
2
1
1
2
1
2
3
2
10
5
2
5
2
10
5
1
1
5
1
5
2
1
5
3
1
1
1
2
2
1
1
2
1
2
3
3
10
5
2
5
2
10
5
1
1
5
1
5
2
1
1
Months)
3
-
_
2
2
-
-
2
1
2
3
2
10
3
1
5
2
5
3
1
1
3
1
5
1
1
1
3
-
_
1
1
-
-
1
-
_
1
1
5
1
-
2
_
1
1
1
1
1
_
5
1
1
••
Source: Brown & Root, Inc., 1977.
A-109
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OPERATIONS (QUARRY SITE)
OPERATIONS
QUARRYING SEQUENCE
The present plan Is to work away from the limestone storage area. The
areas most accessible are expected to be mined within the first
15 years. The development sequence has not been planned beyond this
time due to the many possible variables to be considered. The planned
development sequence and reserve estimates are discussed In the
following paragraphs.
After the limestone excavated and stored during construction Is con-
sumed, production will shift to the areas around Clarification Basin
No. 2 and then to the area between Basin No. 1 and No. 2. This area is
shown in Figure A.34 as Area I.
There will be several active quarry areas with at least two active faces
at any given time so that an area is in reserve for operations if exca-
vation is not possible at the primary quarry face or area.
The portion of Area I between Basins No. 1 and No. 2 has limestone
deposits, 0 to 15 meters (50 feet) thick, with an expected six-month
production of limestone. The remaining portion on the north side of
Basin No. 1 has approximately 115,000 cubic meters (150,000 cubic yards)
of overburden (to be moved to Milkhouse Branch) and enough limestone to
complete the first year's operation.
Attempts will be made to quarry first in areas with little overburden so
that overburden will not have to be moved twice in the quarry operation.
As the quarry progresses and overburden has to be stripped prior to
limestone removal, the overburden can be placed in previously quarried
areas. This "haulback" quarry operation will allow the permanent place-
ment of stripped overburden on areas which have already been quarried.
Topsoil will be stockpiled in a nearby sinkhole where it can be pre-
served until the replaced overburden has been brought up to grade. It
will take up to approximately five years before topsoil is taken from
A-110
-------
CLARIFICATION
BASIN 5
CLARIFICATION
BASIN 4
CLARIFICATION
BASIN 3
QUARRY PLANT
AREA
CLARIFICATION
BASIN 2
CLARIFICATION
BASIN 1
Figure A.34
MINING AREAS
(FIRST FIFTEEN YEARS)
0 0.5
SCALE IN KILOMETERS
PROPOSED GAILLARD QUARRY
MONROE COUNTY, ALABAMA
SOURCE: Environmental Science and Engineering, Inc., 1977.
A-lll
-------
OPERATIONS (QUARRY SITE)
storage and used In final reclamation. The stockpiled topsoil will be
graded and seeded so that it will be stable and resist erosion until
utilized in the reclamation program.
After the first year's operation, the quarry expansion could continue
into Areas II, III, IV, or VI since they are all fairly close to the
initial Area I. In order to provide the necessary flexibility of mining
operations, a sequence is not specified. The seven areas shown in
Figure A.34 are the areas which can be mined most conveniently in the
first 15 years. Production will require about 37 million metric tons
(41 millon tons) of limestone (wet basis) during this period, whereas
the expected quantities contained in the seven areas shown are signifi-
cantly greater. Thus, not all of the areas shown will be mined, by the
fifteenth year, but the areas are presented to illustrate the maximum
extent of the quarry operations that could be developed in 15 years
given all the possible sequences.
The sequence that would require the storage of a minimum amount of over-
burden is the developing of Area II prior to the development of the
other remaining areas. Area II is estimated to contain approximately
16 million metric tons (17 million tons) of limestone (wet basis), with
only approximately 4.2 million cubic meters (5.5 million cubic yards) of
overburden. These reserves are estimated to be adequate for approxi-
mately six years of operation. This sequence of development will
provide adequate space for overburden placement from the other areas as
they will be developed and will eliminate the need for double handling
the material.
As alternatives to a southern expansion into Area II, the quarry could
be developed to the north, east, northeast, or southeast of the storage
facility. The expected boundaries of these areas, known as Areas III,
IV, and VI, are shown in Figure A.34. Preliminary estimates indicate
that there are more than 35 million metric tons (39 million tons) of
limestone (wet basis) within these areas and that they represent at
least 14 years of quarry production. However, these areas do contain
A-112
-------
OPERATIONS (QUARRY SITE)
much more overburden than Area II and will require the additional use of
an overburden storage area in the Milkhouse Branch drainage area if
substantial previously quarried areas are not available. Overburden
will be deposited, contoured, and seeded for long-term or ultimate
storage. As the quarry operations proceed, the "haul-back" reclamation
process will be reinstituted. The stored material could be used for the
grading and sloping of completed areas to establish final drainage
patterns or could permanently remain in storage.
At least two additional clarification basins may be constructed if
necessary to control adequately the drainage from the developed areas
(shown as Basins Nos. 3 and 4 in Figure A.34). These two basins, or
more if required, would be constructed in a manner similar to the two
clarification basins south of the loading and storage facility.
GENERAL OPERATIONS
The Gaillard quarry will be a conventional, open-type operation using
dozers, front-end loaders, and scrapers in combination with crushing and
loading equipment to handle the limestone and overburden material (see
Figure A.35).
As determined by exploratory drilling, usable limestone deposits vary up
to 29 meters (95 feet) thick and average about 9 meters (30 feet)
throughout the property. Sinkholes, caverns, minor faulting, and qual-
ity variations complicate delineation and quarry operation. Additional
exploratory drilling may be performed in advance of further quarry
operation so that mining plans can be finalized for property develop-
ment after the fifteenth year. The thickness of the overburden, which
is more than 34 meters (110 feet) in some areas, may render portions of
these areas uneconomical to quarry. The ratio of overburden to lime-
stone normally should not exceed 1 to 1 except for areas developed for
access or "breakthroughs" to other areas.
A-113
-------
1 ) VEGETATION AND OVERBURDEN REMOVAL
2) QUARRYING
3) CRUSHING
4)STORAGE
LIMESTONE PILE
5) BARGE LOADING
Figure A.35
STEPS OF PROPOSED QUARRY PROCESS
6) RECLAMATION
.>>"/.
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
-------
OPERATIONS (QUARRY SITE)
A southwesterly slope (0.6 percent to 0.8 percent) of the deposits will
position the quarry floor more than 30 meters (100 feet) above msl on
the northeast portions of the property, and approximately 12 meters
(40 feet) above msl at the southern boundary between Ideal Basic
Industries and the McWilliams property. Throughout the developed areas,
the quarry floor will be about 3 meters (10 feet) above the bottom of
the lower Ocala limestone layer.
Ideal Basic Industries plans to have several areas available for exca-
vation. Two active slopes will normally be used to meet the required
production levels, with the other slopes on a standby status in case
some operational problem prevents work at the primary site.
Where topsoil and/or overburden are present, they will be removed sep-
arately from the limestone formation to attempt to maintain their own
soil characteristics. This removal will be performed to insure that
production will be maintained at the active quarry areas. Ripping
equipment mounted on a dozer will loosen the limestone. Because of the
need for maximum blending of different limestone deposits, the dozer
will rip downward on a 25- to 30-degree slope, or about a 2 to 1 grade.
Blasting is not anticipated because the limestone is soft enough to be
loosened by ripping. Front-end loaders will then load the material and
transport it to a slowly turning breaker mechanism for crushing hard,
oversize slabs 1.2-meter (4-foot) input to 0.15-meter (0.5-foot) output.
The crushers will be located near the quarry face and will feed the
limestone onto a conveyor system for transport to the central storage
area. Use of several crushers and conveyors is anticipated to
facilitate working simultaneously at least two quarry areas. When the
limestone reaches the storage area, it will be either loaded directly
onto a barge or placed on the stockpile by a traveling stacker belt.
The long-term operation of the quarry, the high rate of production, and
the variable, discontinuous physical features of the limestone may
require that up to 120 hectares (300 acres) of land surface be disturbed
at any given time. After the initial opening of sufficient active
A-115
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OPERATIONS (QUARRY SITE)
quarry area, the amount of disturbed area can be kept relatively con-
stant and the efficiency of operation maintained by depositing stripped
overburden directly on reclaimed areas. This technique will reduce to a
minimum the need to store, maintain, or rehandle overburden. It is
anticipated that the quarry will operate for approximately five years
before any significant area is completely reclaimed. This length of
time will be required because of the necessity to maintain at least two
operating quarry areas, several active stripping disposal areas, and a
network of heavy equipment roads and belt conveyor routes, and because
the initial production will come from areas with no overburden.
The planned equipment for the quarry will include approximately:
2-4 Large dozers with ripper attachments (D-9 or D-10 Class)
4-6 Front-end loaders (10-12 yard capacity)
2-3 36-yard self-loading scrapers
1 Road grader
2 Pickup trucks
1 Tractor and seeder
1 Water spray truck.
All equipment will be operated according to Mining Enforcement and
Safety Administration (MESA) and Occupational Safety and Health Admin-
istration (OSHA) regulations.
It is estimated that a total of 19 people will be employed at the quarry
site. General job descriptions and numbers of personnel are as follows:
1 Supervisor
11 Equipment operators
3 Maintenance personnel
4 Laborers.
Generally the quantity of overburden material increases as the surface
elevations rise from the ravines up to the ridges. The initial quarry
operations will follow these slopes around the clarification basins.
The second phase of excavation will require significant overburden
A-116
-------
OPERATIONS (QUARRY SITE)
removal. When there are areas to reclaim, overburden will not be hauled
to Milkhouse Branch but will be placed on previously quarried areas.
The topsoil will be stripped and stored in a separate area so that it
can be used in the final phase of reclamation. The topsoil removed
during the first three to five years of operation will be stockpiled in
an area where overburden depths prohibit quarrying. After the topsoil
is removed, the overburden will be stripped off the limestone layers.
As the first stage of reclamation, this overburden will be hauled by pan
scrapers and deposited on previously quarried areas. The deposited
material will be compacted to approximately the same density as in its
natural state. Placement of the overburden in thin layers will enable
the travel of the equipment across the area to provide stable, well-
compacted strata. The overburden material will be placed on several
different areas at any given time so that previously quarried areas will
gradually be brought up to the final grades required for reclamation.
Final grades will be limited to a 3 to 1 slope and will be blended to
meet existing slopes.
As shown schematically in Figure A.3b, a drainage and transportation
route from the active quarry area will be maintained through the
reclamation zone. This alignment will provide the route for the
conveyor system linking the active quarry face with the loading and
storage facility at the river. The temporary access roads will parallel
the conveyor route to allow access to the work site, and to allow
inspection and maintenance of the conveyor system. The major drainage
system from the quarry and reclamation areas will be located within this
alignment corridor. All of the drainage from these areas will be
directed into the nearest natural drainway flowing into the clarifica-
tion basins. Figure A.37 shows cross sections of a typical active quarry
area.
The quarry development will extend into drainage areas adjacent to the
natural drainage areas of Clarification Basins No. 1 and No. 2. In some
locations, the development will extend upslope and across the drainage
A-117
-------
oc
OVERBURDEN
REPLACEMENT
DRAINAGE DITCH
CLARIFICATION
BASIN
CONVEYOR
TO STORAGE
, OVERBURDEN STRIPPED
A- TOPSOIL REMOVAL
Figure A.36
PLAN OF TYPICAL QUARRY CUT
NOTE: SEE FIGURE A.37 FOR CROSS SECTIONS OF A-A' AND B-B'
ACTIVE QUARRY FACE
DRAWINGS NOT TO SCALE
DRAINAGE DITCH
TEMPORARY ACCESS ROAD
CONVEYOR
REGION IV
U.S. ENVIRONMENTAL PROTECTION
AGENCY ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
SOURCE: Environmental Science and Engineering, Inc., 1977.
PROPOSED QAILLARO QUARRY
MONROE COUNTY, ALABAMA
-------
A-A'
YAZOO CLAY
LOWER OCALA LIMESTONE
^^^^^
DRAINAGE DITCH
CONVEYOR
TEMPORARY ACCESS ROAD
PAN SCRAPER
B-B'
DRAWINGS NOT TO SCALE
PAN SCRAPER
I • I I I I I
LOWER OCALA LIMESTONE
YAZOO CLAY
Figure A.37
CROSS SECTIONS OF A TYPICAL QUARRYING AREA
NOTE: SEE FIGURE A.36 FOR LOCATION OF A-A' AND B-B'
SOURCE: Environmental Science and Engineering, Inc., 1977.
TOPSOIL
OVERBURDEN
LIMESTONE
RECLAIMED LAND AND LAND
IN THE PROCESS OF RECLAMATION
REGION IV
U.S. ENVIRONMENTAL PROTECTION
AGENCY ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
PROPOSED GAILLARD QUARRY
MONROE COUNTY, ALABAMA
-------
OPERATIONS (QUARRY SITE)
divides into drainage areas without a clarification basin. The strip-
ping of overburden and quarrying of limestone will reverse the natural
drainage pattern so that runoff is directed into the previously
disturbed areas. This arrangement will enable all runoff from disturbed
areas to be routed through the clarification basins for sediment
removal.
The clarification basins will be designed to provide proper retention
time to reduce sediment concentrations to the allowable discharge
levels. In many areas drainage from the quarry face will require little
if any man-made modifications. However, where the quarry is developed
south of Basins No. 1 and No. 2, the natural slope of the quarry floor
will tend to drain water south rather than north back toward the basins.
There will be areas where ditching or pumping will be required to carry
the flow back to the north against the natural slope gradient of the
lower Ocala limestone formation.
Within the areas to be mined during the first 15 years, the existing
drainage patterns are north to Thompson Mill Creek [173 hectares
(427 acres)], south to Hollinger Creek [114 hectares (281 acres)], and
west via several tributaries [69 hectares (171 acres)] to the Alabama
River (see Figure A.38). Once the areas are mined, reclaimed, and
revegetated, the drainage patterns will follow the corridors remaining
from the conveyor systems into each area. The northern areas (I, II,
IV, VII) will drain southwestward to the two permanent clarification
basins, and the southern areas (II, V, VI) will be reclaimed to estab-
lish several drainage patterns into Hollinger Creek. This drainage
pattern is shown schematically in Figure A.39.
Since the slope of quarry floor dominates the drainage patterns, re-
establishing natural drainage into Thompson Mill Creek and the Alabama
River would be difficult. In order to reverse the slope of the
drainage/conveyor corridors, additional layers of overburden would have
to be placed after an area has been mined. However, since the surface
elevation will be lowered approximately 8 to 15 meters (25 to 50 feet)
A-120
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QUARRY PLANT
AREA
0 0.5 1
SCALE IN KILOMETERS
Figure A.38
EXISTING DRAINAGE PATTERNS IN QUARRY AREAS
SOURCE: Environmental Science and Engineering; Inc., 1977.
REGION IV
US ENVIRONMENTAL PROTECTION
AGENCY ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
PROPOSED GAILLARD QUARRY
MONROE COUNTY, ALABAMA
A-121
-------
QUARRY PLANT
AREA
Figure A.39
FINAL DRAINAGE PATTERN OF RECLAIMED AREAS
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
A-122
-------
OPERATIONS (QUARRY SITE)
throughout the reclaimed areas, reversing the drainage would require
massive amounts of soil to bring the surface back up to baseline eleva-
tions. While this would not be practical in most cases, each mined area
will be assessed for the possibility of re-establishing drainage or a
portion of the drainage back into the baseline watershed.
The final surface elevations will form a gently rolling terrain suitable
for cattle grazing. Slopes will be blended with nonquarried areas to
minimize an erosion problem. The revegetation of a reclaimed area will
be done as soon as practical with consideration to the soil fertiliza-
tion requirements, growing season of desired types of grasses, and
seasonal weather conditions.
A-123
-------
RESOURCES REQUIRED (QUARRY SITE)
ENVIRONMENTAL CONSIDERATIONS
RESOURCES REQUIRED
The operation of the Gail lard quarry will require the resources shown in
Figure A.40, "Daily Resources Cycle."
Approximately 14 hectares (35 acres) of pastureland will be quarried
each year to produce approximately 2.4 million metric tons (2.7 million
tons) of limestone (wet basis). Simultaneously, with the removal of
limestone, the depleted area of the quarry will be reclaimed to pasture-
land, as described in the operations section of this appendix.
Labor
The quarry facility will have 19 workers and will generate about
$400,000 per year in salaries.
Electricity
The operation of the conveying and crushing equipment and other
equipment will use 3.0 megawatts of electricity. The plant will have
4.18 kilovolt service supplied from the Alabama Electric Cooperative or
the Alabama Power Company. Transmission lines and a transformer
substation on-site will be required. An aboveground transmission system
located within the access roadway corridor is planned.
Water Supply
In order to supply the potable water for sanitary facilities, a deep
well will be drilled to deliver 1.8 cubic meters (475 gallons) per day.
Water Transportation
The quarried limestone will be transported to the Theodore cement plant
at the rate of 7,788 metric tons (8,585 tons) per day. Sixteen barges
A-124
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19 EMPLOYEES
1.8 CM (475 G) WATER
3 MEGAWATTS
AIR
0.04 HECTARES (0.1 ACRES)
PASTURELAND
0.04 HECTARES (0.1 ACRES)
RECLAIMED
LIMESTONE
QUARRY
T PARTICULATES - NO ESTIMATE
.37.(0.41) T SOLID WASTES
1.8 CM (475 G) SEWAGE
7203 CM (194.500G) WASTEWATER
ALABAMA RIVER
7788 (8585) T LIMESTONE
CM - CUBIC METERS
G - GALLONS
T - METRIC TONS (ENGLISH TONS)
Figure A.40
DAILY RESOURCES CYCLE (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 COUNTY, ALABAMA
A-125
-------
RESOURCES REQUIRED (QUARRY SITE)
and three tow boats will be utilized with a dally schedule of four
barges being loaded, four barges en route to Theodore, four barges being
unloaded at Theodore, and four barges returning to the quarry site.
Every 20.5 hours a new set of four barges will leave the quarry
facilities.
The facility outputs shown in Figure A.40 are environmental discharges
and conversion products of the resources used as production input.
These daily outputs, which are typically based on annual outputs divided
by 365 days per year, are described in the following sections.
A-126
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AIR (QUARRY SITE)
AIR POLLUTANT EMISSIONS
Construction and Operation
The construction and operation activities are generally similar in
emission characteristics, in that they both could generate fugitive
dust. During construction, land clearing and grading could produce small
quantities of fugitive dust, especially during dry periods. During
operations the activities within the quarry area could cause similar
emissions.
The natural moisture content of the limestone is high (22 percent) and
will tend to reduce the potential for dust emissions from these heavy
equipment activities. In addition, it is planned to use a water tank
truck to wet active areas and haul roads to the extent needed (during
dry periods). Because of slopes and terrain, this method of wetting is
not practical for all of the areas being worked.
Other potential dust emissions are related to the operation of rock
breakers, conveyors, stockpiles, and barge loaders. Water sprays will
be used as needed in these areas to reduce fugitive dust generation.
Again, the inherent moisture content of the limestone should lessen
these potential emissions. The barge-loading conveyor will use a
telescoping boot to minimize dust.
The emission rates of fugitive dust have not been quantified due to a
lack of data for similar operations. However, because of the measures
previously mentioned, dust emissions are not projected to affect ambient
air quality significantly beyond the boundaries of the property, and
on-site air quality should be well below the AAQS standards (see Air
Quality section of Appendix C, Impacts).
A-127
-------
NOISE (QUARRY SITE)
NOISE
Construction
Noise will be generated from construction activities of land clearing
and grading, pile driving, construction of buildings, and erection of
equipment (refer to Table A.14 for a listing of equipment to be used).
Figure A.41 shows the estimated noise levels that could be generated
from these activities. Nearby residences will not be impacted by the
noise; the equipment used will have noise suppression devices that will
reduce noise levels for workers on-site.
Operations
The expected noise levels from the operation of the quarry's facilities
are expected to be related to the heavy equipment used in the active
quarrying areas. Due to the planned mobility of these operations, noise
levels are difficult to show graphically as was done for the construc-
tion activities.
It has been estimated that quarrying activities could generate sound
levels equal to or greater than 55 dBA within a 1-kilometer (0.6-mile)
radius.
Noise levels are shown in Figure A.42; these levels are not expected to
impact nearby residences. On-site impacts will be lessened by use of
equipment that meets the Occupational Safety and Health Administration's
requirements.
A-128
-------
i ) RANDONS CR EEK
EAST OF QUARRY SITE
NORTH OF QUARRY SITE
Figure A.41
EQUAL SOUND LEVEL (L^) 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
A-129
-------
rtr
Figure A.42
ESTIMATED BOUNDARY OF SOUND LEVEL, Ldn of
55 DECIBELS, SURROUNDING THE QUARRY SITE
DURING OPERATION ^^^Si^^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
A-130
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SOLID WASTE (QUARRY SITE)
SOLID WASTES
Construction
The construction of the quarry facilities will generate wastes from
land clearing, dredging, grading, and construction.
The ground clearing wastes will include any trees and brush remaining
from current timber operations and conversion to pasturelands.
The two viable methods of disposal are chipping for mulch and burning.
(Hauling to the Monroe County Landfill is not considered practical due
to quarry access problems at the time of the construction schedule and
due to the potential quantities and hauling distance.)
Chipping of the smaller-sized trees and brush will be performed on-site,
and the product used for mulch to assist with erosion protection and
revegetation of fringe areas.
The burning technique will be the same as that used at the plant site—
an air blower type pit burner. While not expected to be needed due to
the remoteness of the site, this method will produce less smoke than
regular open burning. The contractor will apply to the Alabama Air
Pollution Control Commission for the appropriate permit. Burning will
be continuously supervised and controlled for fire prevention. Burning
will be conducted only under favorable meteorological conditions to
insure adequate dispersion of the smoke generated.
Dredging is not expected to be required for constructing the docking
facility. The overburden removed for site grading will be stored for
reclamation purposes later in the project. Any overburden remaining
will be stockpiled in the areas designated for non-quarrying, whereas
the limestone will be stockpiled for use in the startup of crushing
operations.
A-131
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SOLID WASTE (QUARRY SITE)
The construction debris from the erection of the structures and
buildings—lumber, concrete, paper wastes, and metal scraps—will be
transported to the Monroe County Landfill for burial.
Operations
The solid wastes generated from the quarry operations will be approxi-
mately 137 metric tons (151 tons) per year. These wastes do not include
trees and overburden removed since, for the most part, the vegetative
cover of the lands will have been removed, and the soil overburden
stored for reclamation use. Prior to quarrying, the area essentially
will be changed to pastureland by a local rancher (Mr. McWilliams).
The quarry will have an office with two employees who will generate var-
ious paper and cardboard wastes of about 4.5 kilograms (10 pounds) per
day. In addition, 19 employees will generate roughly 2.3 kilograms
(5 pounds) of lunchroom wastes each day. Therefore, a total wasteload
of 6.8 kilograms (15 pounds) per day is expected.
The quarry will have a shop for the maintenance of bulldozers, scrapers,
trucks, breakers, and conveyors. The daily waste load from this area is
projected to be 4.5 kilograms (10 pounds) of oily rags, grease and oil,
oil containers, cardboard and wood, and metal scraps. Waste oils and
large metal scraps will be recycled through appropriate vendors.
Present quarry plans show the use of three settling basins over the
first 15 years of operation. The solids that settle in these basins
must be removed as needed to maintain depths and capacities. These
solids will amount to about 360 kilograms (800 pounds) per day and will
be used in the reclamation of quarried lands.
Table A.15 summarizes the expected solid wastes that will be taken to
the Monroe County Landfill and that will be used in reclamation.
A-132
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Table A.15. Solid Waste Disposal
CO
CO
Area
Office
Maintenance
Settling
Basin
TOTAL
Metric
Type Tons/Year*
Papers, lunch- 2.5
room trash
Oily rags, oil, 1.7
grease, metal
scraps, cardboard,
wood
Sediment 132.4
136.6
Quantity
Kilograms/ Disposal
(Tons/Year)* Day (Pounds/Day) Method
(2.7) 6.8 (15) Off-site landfill
(1.8) 4.5 (10) Off-site landfill
(146.0) 362.8 (800) Reclamation
(150.5) 374.1 (825)
*365 days/year.
Source: Powledge, 1977.
CO
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o
5
CO
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o
£
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CO
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WATER (QUARRY SITE)
WATER UTILIZATION AND DISPOSAL
Water Requirement
The potable water requirements for the 19 employees at the facility will
be supplied by an on-site well [1.8 cubic meters per day (475 gpd)].
The well is expected to be about 76 meters (250 feet) deep, which will
be below the Yazoo clay layer. Because of the low quantities to be
withdrawn, problems caused by aquifer drawdown are not expected.
The fugitive dust suppression equipment (tank truck and various water
sprays) will be supplied with water from the clarification basins.
Wastewater
Construction and Operation
At the beginning of the construction phase, Clarification Basins No. 1
and No. 2 will be built to control sediment inputs to the Alabama River.
During quarry operations these basins will collect and reduce the solids
content of stormwater runoff from the quarry areas, stockpiles, and
unvegetated areas being reclaimed.
Control of surface runoff is required by the U.S. EPA and the Alabama
Water Improvement Commission (AWIC). The agencies' requirements, which
vary regarding specific controls, are the following:
1. U.S. EPA (40 CFR 436-Subpart B-Crushed Stone) requires that
mine dewatering must meet the proposed New Source Performance
Standards for total suspended solids (TSS) of 30 mg/1 (1 day
maximum) and pH of 6.0 to 9.0 or have a capacity to store the
runoff from a 10-year, 24-hour storm.
2. AWIC (Proposed Revisions to Surface Mining Regulations)
requires that drainage from all storage, mining, and reclaimed
areas must meet limitations of TSS of 90 mg/1 (1 day maximum)
and 30 mg/1 (30 day average), and a pH of 6.0 to 9.0. During
overflow from a ten-year storm, the TSS must be £ 1000 mg/1.
A-134
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WATER (QUARRY SITE)
Clarification basins should be designed for a capacity of
762 cubic meters per hectare (0.25 acre-feet per acre) of
disturbed area.
The overall drainage control will allow for less than 30 mg/1 TSS in the
clarification basin effluent and for a storage capacity (above average
water level) for a 10-year, 24-hour storm. Based on a settleability
test performed on the natural soils and limestone found at the site, the
TSS standard should be met by a detention time of at least 24 hours.
Table A.16 presents the storage capacities of the five clarification
basins and the areas of land to be quarried. Based on these figures,
Basins No. 1 and No. 2 have a combined storage capacity of 237,000 cubic
meters (192 acre-feet). This capacity is equivalent to the runoff from
approximately 263 hectares (650 acres) during a 10-year, 24-hour storm.
The present plan allows for approximately 120 hectares (300 acres) of
mining activity at any one time and for about 14 hectares (35 acres) to
be exhausted and reclaimed per year. Therefore, allowing for areas that
are reclaimed and vegetated, and no longer drain to the basins, there is
sufficient capacity for at least the first 15 years of operation. It is
planned that, whenever possible, an area that has been reclaimed and has
well-established vegetation will be drained to bypass the clarification
basins to allow for additional drainage capacity.
Based on an average annual rainfall of 1,397 millimeters (55 inches),
the average daily flow to these two basins from 263 hectares (650 acres)
is 4,760 cubic meters (3.9 acre-feet) per day and the effective average
detention time should be about 50 days.
The overburden storage area, Milkhouse Branch, is calculated to have a
runoff of about 122,000 cubic meters (98.7 acre-feet) in the design
storm, whereas its proposed basin will have a storage capacity of
176,000 cubic meters (143 acre-feet). Thus, the basin appears more than
adequate to store the worst case runoff. Actually, as mining areas III,
A-135
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WATER (QUARRY SITE)
Table A.16. Proposed Storage Capacities of Storage Basins
and Area of Quarry Areas
Clarification
Basin
No. 1
No. 2
No. 3
No. 4
No. 5
Quarry
Areas
I
II
III
IV
V
VI
VII
TOTAL
Milkhouse Branch
Cubic
181,
56,
11,
53,
176,
Storage Capacity
Meters (Acre-Ft)
000 (147)
000 ( 45)
000 ( 9)
000 ( 43)
000 (143)
Area
Hectares (Acres)
27
40
72
55
27
37
30
288
142
( 67)
(100)
(179)
(136)
( 67)
( 92)
1.731
(714)
(351)
Source: Environmental Science and Engineering, Inc., 1977.
A-136
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WATER (QUARRY SITE)
IV, V, VI, and VII are developed, the potential runoff will decrease
substantially since these mining areas will drain more than half of
Mllkhouse Branch's natural drainage area Into the other clarification
basins. The average dally flow for the Mllkhouse Branch drainage of
142 hectares (351 acres) should be about 2,440 cubic meters
(2 acre-feet) per day, with an effective detention time of 72 days.
The basins will have an intermittent discharge to provide these storm
capacities. In addition, sediment must be removed periodically to
maintain capacities.
Erosion control practices of contour terracing and berming the developed
areas and their slopes will lessen the potential sediment loading of the
runoff. The problem of erosion and stormwater runoff is basically one
of controlling water velocities. The use of contour terracing in the
placement of overburden and at blend points will slow down the runoff.
Slopes will be limited to a maximum of 3 to 1, which in addition to the
contour terracing, should lessen the erosion potential from unvegetated
soils. The edge of each terrace will rise slightly or be bermed to
allow ponding of water and will be sloped for drainage perpendicular to
the face.
Additional erosion protection will be obtained by seeding the long-term
overburden storage piles and reclaimed areas. Grassy vegetation will be
effective for retaining soils and will be compatible with the intended
use of the reclaimed areas for pasture.
Limestone quarrying and reclamation will produce at least an 8-meter
(25-foot) drop in average land elevations. This terrain change will
alter somewhat the natural watersheds in the area. Approximately
13 percent of the Hoilinger drainage area and 10 percent of the Thompson
Mill drainage area will be modified by the projected mining activities.
Therefore, whenever practical, the reclaimed drainage patterns will
re-establish or simulate natural drainage to maintain base flows in the
creeks. It is expected that the Hoi linger Creek watershed can retain at
A-137
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WATER (QUARRY SITE)
least an equivalent area. However, the Thompson Mill Creek watershed
area will decrease because the quarry floor slopes away from the creek.
Sanitary Wastes
During construction the only sanitary facilities available will be
portable toilets. A septic tank and soil absorption system will be
constructed to serve as permanent sanitary facilities. The wasteload
during operations is expected to be about 1.8 cubic meters per day
(475 gpd).
A-138
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ENVIRONMENTAL SAFEGUARDS (QUARRY SITE)
ENVIRONMENTAL SAFEGUARDS
The design of the proposed quarry has been modified to mitigate poten-
tial environmental impacts. These actions have been described in the
preceding sections and are summarized below.
Stormwater Runoff Control
During construction the two main clarification basins will be built
quickly in order to treat the runoff from the disturbed area and to
mitigate the sediment loadings to the Alabama River.
These same basins (Nos. 1 and 2) will have the capacity to maintain the
runoff from a 10-year, 24-hour storm from the quarry areas. Also, Basin
No. 5 will meet the same requirements for runoff from the overburden
storage area in Milkhouse Branch. All the basins should have levels of
suspended solids in the discharge well below the 30 mg/1 level required
by EPA.
Erosion Controls
Erosion will be reduced by use of contour terracing, berms, and ditches
in appropriate areas. Also, reclaimed areas and long-term overburden
storage will be vegetated for better soil retention.
Fugitive Dust Controls
Roadways and quarrying areas will be wetted as needed by a water tank
truck to control dust emission. Other process areas will use water
sprays to suppress dust emissions.
Noise Controls
Construction and operation equipment will meet or exceed the applicable
MESA requirements. Noise levels from quarrying activities will be
A-139
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ENVIRONMENTAL SAFEGUARDS (QUARRY SITE)
attenuated by vegetation and terrain effects and by the distance of
residences from the quarry area.
Burning Controls
Burning of vegetation wastes (trees and brush) will be conducted only
during periods of favorable dispersion conditions and will be
continuously supervised. In addition, the air-blower type pit burner
will reduce potential smoke emissions more than normal "open burning"
techniques.
Solid Wastes
The wastes from construction (except for vegetation wastes, which will
be chlpoed or burned) and from operations will be taken to the Monroe
County Landfill for proper disposal.
Preservation of Natural Communities
The existing ecological communities in woodland areas not converted to
pasture generally will not be disturbed by the quarry activities.
Reclamation activities will create blend areas between reclaimed and
existing lands.
Archaeological/Historical Measures
Ideal Basic Industries authorized a salvage operation on a site (No. 6)
that was identified as having potential archaeological /historical sig-
nificance, and the salvage operation was conducted in October, 1977.
The archaeologist's final report was submitted in March, 1978, and the
approval of the Alabama Historical Commission is pending.
If another archaeological or historical site is uncovered during
construction or operations, the Alabama Historical Commission will be
notified immediately. Work will stop in that specific area until the
Commission gives its approval to resume operations.
A-140
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PERMITS/APPROVALS (QUARRY SITE)
PERMITS AND APPROVALS REQUIRED
The environmental permits and approval requirements for the construction
and operation of the quarry facility are presented in Table A.17.
The various emission or effluent requirements of these agencies are
presented within the applicable sections of this appendix (Air and
Water).
A-141
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Table A.17. Environmental Permits and Approval Requirements
Parameter
Agency
Requirements
Air Emissions
Alabama Air Pollution
Control Commission
Permit for construction and permit for
operation of crusher and conveyor systems.
Permit for open burning.
Solid Waste
Wastewater Discharges
Monroe County Health
Department
Alabama Health Department
U.S. Environmental
Protection Agency
Alabama Water Improvement
Commission
U.S. Environmental
Protection Agency
U.S. Army Corps of Engineers
No permit required but must approve of
type of waste to be disposed in landfill.
No permit required but approval of land-
fill for specific wastes; works through
Monroe County Health Department.
No permit required; requirements under
Resource Conservation and Recovery Act of
1976; works through state agency.
Surface mining permit required before
operation. Certify Corps permit
applications.
NPDES permit required.
Permits required for construction of
discharge structures. Fill permit may be
required for construction of dams by
filling operations.
-o
m
30
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30
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30
-<
CO
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Table A.17. Environmental Permits and Approval Requirements (Continued, page 2 of 2)
Parameter
Agency
Requirements
co
Sanitary Waste
Potable Water Supply
Docking Facility
Access Roadway and
Bridge
Monroe County Health
Department
Alabama Health Department
Monroe County Health
Department
Water Well Standards Board
U.S. Army Corps of Engineers
Alabama Water Improvement
Commission
U.S. Coast Guard
Occupancy permit for planned sanitation
facilities; construction permit for septic
tank and soil absorption system.
Certification of potable water supply;
works through Monroe County Health
Department.
Certification of potable water supply.
Requires Engineering Report of water
system.
Permit for construction of docking
facility.
Certification of applications to Corps.
Permission to bridge Coleman's Branch and
other navigable streams may be required.*
TO
3
to
73
O
* If the U.S. Coast Guard is determined to have jurisdiction.
Source: Environmental Science and Engineering, Inc., 1977.
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