DRAFT
ENVIRONMENTAL IMPACT STATEMENT
IDEAL BASIC INDUSTRIES
CEMENT PLANT
THEODORE INDUSTRIAL PARK, ALABAMA
LIMESTONE QUARRY
MONROE COUNTY, ALABAMA
APPENDICES
VOLUME IV
APPENDIX C IMPACTS
APPENDIX D MITIGATING MEASURES
APPENDIX E ALTERNATIVES
UNITED STATES ENVIRONMENTAL PROTECTION AGENCY, REGION IV
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TABLE OF CONTENTS
APPENDIX C. IMPACTS
INTRODUCTION C-l
PLANT SITE
AIR QUALITY C-3
CONSTRUCTION IMPACTS C-3
Fugitive Dust C-3
Burning of Vegetative Wastes C-4
Vehicular Exhausts C-4
OPERATIONAL IMPACTS C-5
Emissions C-5
Prevention of Significant Deterioration Analysis C-6
Maximum Concentrations C-20
Maximum Degradation C-21
Maximum Impact of Ideal C-22
Nitrogen Oxides C-24
NOISE C-27
CONSTRUCTION IMPACTS C-27
Ship Channel Construction: Noise Analysis C-27
Cement Plant Construction: Noise Analysis C-28
Predicted Noise Levels at Baseline Monitoring Stations C-30
OPERATION IMPACTS C-37
Equipment Noise C-37
Noise Analysis of a Typical Plant C-37
Impacts of the Ideal Basic Industries Facility C-43
Automobile and Truck Traffic C-43
Predicted Noise Levels at Baseline Monitoring Stations Upon C-45
Completion of the Proposed Project
Predicted Noise Levels at Baseline Monitoring Stations C-45
In 1992
SOLID WASTE C-49
CONSTRUCTION IMPACTS C-49
OPERATIONAL IMPACTS C-50
WATER RESOURCES AND GEOTECHNICAL C-52
IV-i
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CONSTRUCTION IMPACTS C-52
Stormwater Runoff and Erosion C-52
Rail Trestle and Access Road C-52
Ground Water C-52
Docking Facilities C-53
Oil Spills C-53
OPERATION IMPACTS C-54
Material Spills C-54
Wastewater and Storage Pile Runoff C-54
General Stormwater Discharge C-55
Ground Water C-55
Sanitary Wastes C-56
Navigation Aspects C-56
ARCHAEOLOGY C-57
ECOLOGY C-58
CONSTRUCTION IMPACTS C-58
Land Clearing and Grading C-58
Land Access Corridor C-59
Dredging C-60
Noise C-60
Stormwater Discharges C-60
Oil Spills C-61
OPERATION IMPACTS C-61
Air Emissions C-61
Noise C-62
Highway Traffic C-62
Waterway Traffic C-62
Wastewater Discharge C-63
Oil Spills C-64
General Human Activities C-64
SOCIOECONOMICS C-65
CONSTRUCTION IMPACTS C-65
Introduction C-65
Economic Activity C-65
Highway Transportation C-66
Land Value and Land Use C-68
OPERATIONS IMPACTS C-70
Introduction C-70
IV-ii
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Regional Economic Impact C-70
Transportation C-74
Land value and Residential Amenity C-77
Local GovernmentC-79
QUARRY SITE
AIR QUALITY C-80
CONSTRUCTION IMPACTS C-80
OPERATIONAL IMPACTS C-81
NOISE C-82
CONSTRUCTION IMPACTS C-82
Equipment Noise C-82
Traffic Noise C-82
Construction Noise Analysis C-82
Construction Noise Impacts" C-84
Predicted Noise Levels at Baseline Monitoring Stations C-84
OPERATION PHASE C-86
Equipment Noise C-86
Traffic Noise C-86
Operational Noise Analysis C-89
SOLID WASTE C-91
CONSTRUCTION IMPACTS C-91
OPERATION IMPACTS C-92
WATER RESOURCES AND GEOTECHNICAL C-93
CONSTRUCTION IMPACTS C-93
Clearing and Grading C-93
Docking Facilities C-94
OPERATION IMPACTS C-94
Stormwater Runoff C-94
Sanitary Waste C-94
"Material Spills C-95
Navigation C-95
TopograpRy and Drainage C-95
Ground Water C-96
ARCHAEOLOGY C-98
IV-iii
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ECOLOGY C-100
CONSTRUCTION/OPERATION IMPACTS C-100
Introduction C-100
Impact Identification C-101
Land Clearing C-101
Erosion and Stormwater Runoff C-104
Fugitive DustC-105
Noise Disturbance C-106
Reclamation C-106
Land Transportation C-106
Water Transportation C-106
Clarification Basins C-107
Drainage Patterns C-107
Material Spills C-107
SOCIOECONOMICS C-109
CONSTRUCTION PHASE C-109
OPERATIONS IMPACTS C-lll
IV-iv
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APPENDIX C. IMPACTS
LIST OF TABLES
AIR QUALITY
C.I Summary of PSD Evaluation Results for Proposed C-9
Ideal Basic Industries Cement Manufacturing
Plant
NOISE
C.2 Types, Numbers, and Noise Characteristics of Heavy C-29
Pieces of Equipment Required During Busiest Phase
of Construction
C.3 Noise Levels (dBA) at the Baseline Monitoring C-33
Stations and Predicted Levels for Three "Worst*-
Case" Situations
C.4 Dwelling Counts Within the Zone of Influence C-36
of the Noise Levels from Construction and
Operation of the Proposed Plant
C.5 Sources of Noise During Plant Operation C-38
C.6 Average Values of Sound Levels Measured in C-39
Operating Cement Plants at Distances of 4.5 Meters
(15 Feet)
C.7 Ldn and Leq(24) Noise Levels (dBA) Predicted in C-46
the Vicinity of the Plant Site During Operation of
Proposed Facility (1981)
C.8 Ldn and Leq(24) Noise Levels (dBA) in the Vicinity C-47
of the Proposed Site Predicted for 1992 (Exclusive
of Any New Industries)
SOCIOECONOMICS
C.9 Summary of Traffic Impacts C-67
C.10 . Gross and Net Employment Attributable to Ideal C-73
Basic Industries Under Worst-Case Conditions;
Mobile SMSA
C.ll Alabama River Traffic Through Claiborne Lock and C-76
Dam, 1976
IV-v
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LIST OF TABLES
(continued)
QUARRY
NOISE
C.12 Types, Numbers, and Noise Characteristics of Heavy C-83
Pieces of Equipment Required During Busiest Phase
of Construction at Quarry Site
C.13 Types, Numbers, and Noise Characteristics of Heavy C-87
Pieces of Equipment Required During Operation of
the Quarry Site
C.14 Noise Levels Associated with a Tug and Associated C-88
Barges (dBA)
SOCIOECONOMICS
C.15 Summary of Quarry Impacts on Monroe County Popula- C-112
tion and Employment
IV-vi
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APPENDIX C. IMPACTS
LIST OF FIGURES
AIR QUALITY
C.I Isopleths of Predicted Annual Average Ground-Level C-10
Sulfur Dioxide Concentrations (ug/m3) Without
the Proposed Cement Plant, Theodore, Alabama, 1980
C.2 Isopleths of Predicted Annual Average Ground-Level C-ll
Sulfur Dioxide Concentrations (ug/m3), with
the Proposed Cement Plant in Operation, Theodore,
Alabama, 1980
C.3 Isopleths of the Incremental Contributions to C-12
Predicted Annual Average Ground-Level Sulfur Dioxide
Concentrations (ug/m3), Proposed Cement Plant Only,
Theodore, Alabama, 1980
C.4 Isopleths of Predicted Annual Average Ground-Level C-13
Suspended Particulate Matter Concentrations (ug/m3),
Without the Proposed Cement Plant in Operation,
Theodore, Alabama, 1980
C.5 Isopleths of Predicted Annual Average Ground-Level C-14
Suspended Particulate Matter Concentrations (ug/m3),
with the Proposed Cement Plant in Operation,
Theodore, Alabama, 1980
C.6 Isopleths of the Incremental Contributions to C-15
Predicted Annual Average Ground-Level Suspended
Particulate Matter Concentrations (ug/m3),
Proposed Cement Plant Only, Theodore, Alabama,
1980
C.7 Predicted Highest, Second Highest 24-Hour Sulfur C-16
Dioxide Concentrations (ug/m3), at the Critical
Locations, All Sources at Allowable Emissions Rates,
Theodore, Alabama, 1980
C.8 Predicted Highest, Second Highest 24-Hour Suspended C-17
Particulate Matter Concentrations (ug/m3), at the
Critical Locations, All Sources at Allowable Emis-
sion Rates, Theodore, Alabama, 1980
C.9 Isopleths of Predicted Annual Incremental Highest, C-18
Second Highest 24-Hour Ground-Level Sulfur Dioxide
Concentrations (ug/m3), for the Ideal Basic Industries
Proposed Cement Plant Only, Theodore, Alabama
IV-vii
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LIST OF FIGURES
(continued)
C.10 Isopleths of Predicted Annual Incremental Highest, C-19
Second Highest 24-Hour Ground-Level Suspended
Particulate Matter Concentrations (ug/m3) for
the Ideal Basic Industries' Proposed Cement Plant
Only, Theodore, Alabama
C.ll Isopleths of the Incremental Contributions to C-26
Annual Average Ground-Level Nitrogen Dioxide
Concentrations (ug/m3), Due to Operation of the
Proposed Cement Plant Only, Theodore, Alabama
NOISE
C.12
C.13
C.14
C.15
C.16
C.17
Equal Sound Level (Ldn) Contours Due to Worst-Case C-31
Construction Activities from the Proposed Plant Only
Noise Monitoring Stations (Plant Site)
Equal Sound Level (Ldn) Contours Due to Plant
Operations Only
C-32
Sound Levels (Leq) Recorded at Cement Plant "A" C-40
(dBA)
Sound Levels (Ldn) Calculated at Cement Plaint "A" C-41
(•dBA)
Equal Sound Level (Ldn) Contours at Cement Plant C-42
"A" (dBA)
C-44
NOISE
C.18
C.19
QUARRY SITE
Equal Sound Level (Ldn) Contours Surrounding the
Quarry Site During Construction Activities
Estimated Boundary of Sound Level, Ldn of
55 Decibels, Surrounding the Quarry Site
During Operation
C-85
C-90
ARCHAEOLOGY
C.20 Locations of Archaeological Sites No. 6 and No. 8 C-99
IV-viii
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TABLE OF CONTENTS
APPENDIX D. MITIGATING ACTIONS
INTRODUCTION D-l
PLANT SITE
AIR QUALITY D-2
CONSTRUCTION D-2
Fugitive Dust Emissions D-2
Environmental Safeguards D-2
Mitigating Measures D-3
Burning of Vegetative Wastes D-3
Environmental Safeguards D-3
Mitigating Measures D-4
OPERATIONS D-4
Environmental Safeguards D-4
Process Selection D-5
Particulate Matter Controls D-5
Fugitive Dust Controls D-6
Sulfur Dioxide Controls D-6
Nitrogen Oxide Controls D-7
Mitigating Measures D-7
Stack Design D-7
Fugitive Dust D-8
Lower Sulfur Coal D-8
NOISE D-9
CONSTRUCTION D-9
Environmental Safeguards D-9
OPERATIONS D-9
Environmental Safeguards D-10
Mitigating MeasuresD-10
SOLID WASTE D-ll
CONSTRUCTION AND OPERATION D-ll
Environmental Safeguards D-ll
Mitigating Measure's D-ll
IV-ix
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ARCHAEOLOGY D-12
WATER RESOURCES AND GEOTECHNICAL D-13
CONSTRUCTION D-13
Environmental Safeguards D-13
Mitigating Measures D-14
OPERATIONS D-14
Environmental Safeguards D-14
Mitigating Measures D-15
ECOLOGY D-16
CONSTRUCTION D-16
Environmental Safeguards D-16
Mitigating Measures D-16
OPERATIONS D-17
Environmental Safeguards D-17
Noise DisturbanceD-17
Waterway Traffic D-17
Oil Spills D-18
Mitigating Mpasures D-18
SOCIOECONOMICS D-19
CONSTRUCTION D-19
Safeguards D-19
OPERATIONS D-19
Safeguards D-19
Land Value and Amenity D-19
Labor Force D-20
Mitigating Measures D-20
QUARRY SITE
AIR QUALITY D-21
_PJ
ST
CONSTRUCTION D-21
Environmental Safeguards D-21
Mitigating MeasuresD-21
IV-x
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OPERATIONS D-22
Environmental Safeguards D-22
Mitigating Measures D-22
NOISE D-23
CONSTRUCTION AND OPERATIONS D-23
Environmental Safeguards D-23
Mitigating Measures D-23
SOLID WASTE D-24
CONSTRUCTION AND OPERATIONS D-24
Environmental Safeguards D-24
Mitigating MeasuresD-24
ARCHAEOLOGY D-25
Environmental Safeguards D-25
Mitigating Measures D-25
MATER RESOURCES AND GEOTECHNICAL D-26
CONSTRUCTION AND OPERATION D-26
Environmental Safeguards D-26
Drainage/ErosionD-26
Mitigating Measures D-27
ECOLOGY D-28
CONSTRUCTION AND OPERATIONS D-28
Environmental Safeguards D-28
Mitigating Measures D-28
SOCIOECONOMICS D-30
IV-xi
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TABLE OF CONTENTS
APPENDIX E. ALTERNATIVES
INTRODUCTION E-l
PLANT SITE ALTERNATIVES E-3
NO ACTION ALTERNATIVE E-3
FUTURE LAND USE E-3
AIR QUALITY E-3
NOISE E-5
WATER RESOURCES AND AQUATIC ECOLOGY E-7
TERRESTRIAL ECOLOGY E-8
SOCIOECONOMIC CONDITIONS E-8
SITE LOCATION E-10
INTRODUCTION E-10
MODERNIZED AND EXPANDED FACILITIES AT EXISTING PLANTS E-10
MULTIPLE NEW PLANT LOCATIONS E-l2
CONSOLIDATED PRODUCTIVE CAPACITY AT A SINGLE NEW LOCATION E-l3
Evaluation Criteria E-l3
Site Evaluations E-l5
Second-Level Site Evaluations E-l6
PROCESS/RESOURCES E-27
WET PROCESS VERSUS DRY PROCESS E-27
RAW MATERIALS E-28
EQUIPMENT ARRANGEMENT E-29
FUELS E-29
ABATEMENT MEASURES E-31
AIR EMISSIONS E-31
Proposed Action. Use of Baghouses, Water Sprays, E-31
Process Design
IV-xiii
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Alternative I. Scrubbers E-32
Alternative II. Cyclones E-32
Alternative III. Electrostatic Precipitators E-33
Alternative IV. Venting of Fugitive Dust Sources E-33
Rationale for the Proposed Action E-33
NOISE E-34
Proposed Action. Layout of Plant Site for E-34
Efficient Production
Alternative I. Plant Layout to Minimize E-34
Noise Impact
Rationale for the Proposed Action E-34
SOLID WASTE E-35
Proposed Action. Landfill E-35
Alternative I. Burial On-Site E-35
Alternative II. Burial Off-Site E-35
Rationale for the Proposed Action E-35
Proposed Action. Disposal of Vegetative Hastes E-36
Alternative I. Use as Firewood E-36
Alternative II. Selling Wastes for Use in a E-37
Pulp Mill or Waste Wood Boiler
Alternative III. On-Site Burial E-37
Rationale for Proposed Action E-37
SANITARY WASTES E-38
Proposed Action. Regional Sewage Treatment Plant E-38
Alternative I. On-site Treatment During Operations E-38
Rationale for the Proposed Action E-38
PLANT WASTEWATER E-38
Proposed Action. Settling Basin and Discharge E-38
to the Ship Channel
Alternative I. Settling Basin with Effluent to E-39
the Marshes
Alternative II. Common Outfall in Mobile Bay E-39
Rationale for the Proposed Action E-39
STORMWATER RUNOFF E-41
Proposed Action. General Runoff Catchment Area-- E-41
Discharge to MarsT
Alternative I. General Runoff Basin-- E-41
Discharge to Ship Channel
IV-xiv
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Alternative II. General Runoff Basin— E-41
Discharge to Both the Marsh and Ship Channel
Rationale for the Proposed Action E-42
OIL SPILLS E-43
DREDGING E-43
LAND CLEARING AND GRADING E-43
PLANT ACCESS E-44
Proposed Action. Access to Island Road North E-44
Along Western Plant Boundary
Alternative I. Access from Dauphin Island Parkway E-44
Alternative II. Bridging of the Marsh E-45
Rationale for the Proposed Action E-45
QUARRY SITE ALTERNATIVES E-47
NO-ACTION ALTERNATIVE E-47
FUTURE LAND USE E-47
AIR QUALITY E-47
NOISE E-48
WATER RESOURCES AND AQUATIC ECOLOGY E-48
TERRESTRIAL ECOLOGY E-49
SOCIOECONOMIC CONDITIONS E-50
SITE LOCATION AND DEVELOPMENT E-51
ALTERNATIVE SITES E-51
ALTERNATIVE SOURCES OF CALCIUM CARBONATE E-51
PROCESS ALTERNATIVES E-53
Proposed Action. Movable Crusher E-53
Alternative I. Centrally-Located Crusher E-53
Rationale for Proposed Action E-53
ABATEMENT MEASURES E-54
AIR QUALITY E-54
Proposed Action. Dust Suppression System on E-54
Conveyors and Barge Loading Facilities
IV-xv
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Alternative I. Enclosing and Venting to a E-54
Higher-Efficiency Control System
Rationale for Proposed Action E-55
NOISE E-55
WASTES FROM LAND CLEARING E-55
Proposed Action. Burning and Chipping Land E-55
Clearing Wastes
Alternative I. Landfill E-55
Alternative II. On-site Disposal E-56
Rationale for Proposed Action E-56
SOLID WASTE E-56
Proposed Action. Disposal at an Approved Landfill E-56
Alternative I. On-site Disposal E-56
Rationale for the Proposed Action E-57
PROCESS WASTEWATER/GENERAL STORMWATER RUNOFF— E-57
CONSTRUCTION AND OPERATION
Proposed Action. Clarification Basins E-57
Alternative I. Vegetation Buffers E-57
Alternative II. Quarry Pit Storage E-57
Rationale for Proposed Action E-58
WATER USAGE AND SANITARY WASTES E-58
Proposed Action E-58
ECOLOGICAL SYSTEMS E-59
RECLAMATION ALTERNATIVES E-59
Proposed Action. Reclamation to Pasture!and E-59
Alternative I. Reclamation to Timber!and E-59
Alternative II. Industrial Park E-59
Rationale for Proposed Action E-60
IV-xvi
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LIST OF TABLES
Table E.I Ldn and Leq(24) Noise Levels (dBA) at
Baseline Monitoring Stations in 1977 and
in 1992 (exclusive of any new industries)
Table E.2 Profile of Ideal Plants Serving Southern
Markets in 1974: Expansion Possibilities
Table E.3 First-Level Site Evaluation
Table E.4 Comparative Environmental Evaluation for Location
of the Proposed Plant at Theodore Versus Gail lard
E-6
E-ll
E-17
E-25
LIST OF FIGURES
Figure E.I Projected Land Use in the Vicinity of the Proposed
Ideal Basic Industries Plant Site, 1992
Figure E.2 Wastewater Outfall in Mobile Bay
E-4
E-40
IV-xvii
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APPENDIX C
IMPACTS
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PLANT AND QUARRY SITES
APPENDIX C. IMPACTS
INTRODUCTION
This impacts section identifies, evaluates, and describes both the
beneficial and detrimental environmental impacts associated with the
Ideal Basic Industries proposed project.
The impacts addressed are only those which will be mitigated but not
completely eliminated by the environmental safeguards to be taken as
presented in Project Description. These impacts have been classified
and evaluated according to the following criteria:
1. Primary impacts (direct) are those attributable to the action
of process wastes, demands upon resources, accidents or abnor-
mal conditions of operations, and initial project construction.
Primary impacts are associated with the project site and local
area.
2. Secondary impacts (induced) are those attributable to some
indirect demand or impact of the project upon the environment,
society, or economy which occurs or becomes important at some
different point in time or space or in some other sector of the
environment, society, or economy. Secondary impacts are asso-
ciated with the overall region surrounding the project area.
3. Magnitude factors may be described through normal parameters of
quantification based on some measurable physical property of
the impact.
* High magnitude—impacts involve substantial quantities and
have extensive effects.
* Moderate magnitude—impacts involve moderate quantities
and may have extensive effects.
* Low magnitude—impacts involve small quantities and do not
have extensive effects.
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PLANT AND QUARRY SITES
4. Significance factors require consideration of the relative
importance of the magnitude of an impact in relation to its
effects on the area and the residents surrounding the proposed
facility. Determination of impact significance involves a
judgmental evaluation of the described effects.
* High significance—impacts are of high relative importance
and require special consideration.
* Moderate significance—impacts are relatively important
and may require special consideration.
* Low significance—impacts are not considered relatively
important and do not require special consideration.
5. Duration indicates the persistency of the impact. Long-term
impacts are those which persist for more than several years and
ordinarily will last for the expected life of the project.
Short-term impacts will last for several years or less.
6. Reversibility factors may be described in relation to the
ability of specific disturbed conditions to return to existing
or equivalent conditions, levels, appearances, or usages
without extensive assistance by man.
7. Avoidability characteristics are assessed on the basis of
whether or not the impact could be completely eliminated by
some alternative action. Most impacts are considered
unavoidable, assuming that the proposed project is to be
constructed and operated. Therefore, only the avoidable
impacts are so classified in the text.
This appendix assesses the critical and apparent impacts and also men-
tions impacts of minor importance. Impacts of minor importance are
rated as "negligible" in the text and have been included to show that
they were considered in the impact assessment.
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AIR QUALITY (PLANT SITE)
PLANT SITE
AIR QUALITY
CONSTRUCTION IMPACTS
Various construction activities associated with the proposed Ideal
Basic Industries development, including land clearing, heavy machinery
operation, truck traffic, and road construction, will generate air
pollutants. Because of the nature of these operations, emissions are
extremely difficult to quantify accurately. Thus, this discussion
addresses primarily the qualitative air pollution aspects of these
construction activities.
Fugitive Dust
The most significant air pollutant generated during construction opera-
tions will be particulate matter, in the form of fugitive dust. Heavy
machinery operations, including road construction, vehicular and heavy
machinery traffic along unpaved roads, grading, excavating and land
clearing, will be the primary sources of fugitive dust. The quantities
of dust emitted will be dependent on a number of factors, including
frequency of operations, specific operations conducted, weather, and
soil conditions. Some construction operations, such as land clearing
and grading, will be intermittent and of short duration. In addition,
the majority of dust particles are expected to be large and settle out
close to the source (Kosky and Wanielista, 1975).
Some of the dust, however, will remain suspended in the atmosphere.
Suspended dust emissions from heavy construction operations have been
generally estimated at 2.7 metric tons per hectare (1.2 tons per acre)
per month of activity (U.S. EPA, Office of Air Quality Planning and
Standards, 1975). This impact 4s felt to be of moderate magnitude due
C-3
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AIR QUALITY (PLANT SITE)
to the quantities of dust that will be emitted, but of low significance
In the area/region due to its short-term and reversible nature.
Burning of Vegetative Wastes
The impact of burning the land clearing wastes will depend on the amount
of wastes which are burned rather than chipped or hauled to a landfill
for burial. The "worst case" impact would occur if the other two
methods are found to be impractical or undesirable and all the wastes
are burned. As described in Appendix A, Project Description, burning
will be performed with an air-blower type pit burner so that there will
be better combustion efficiencies and less smoke than in typical "open
burning."
Burning will be conducted as needed during the first three months of
construction. Short-term impacts mainly from the smoke emitted can
result from these operations. The local and state air pollution
agencies require that burning be conducted only during periods of
favorable dispersion conditions which will also minimize potential
impacts. Under these conditions, the resulting impacts on air quality
should be of low significance and low magnitude. In addition, the
impact would be reversible and of short duration. (This impact may be
avoided by chipping or by landfill ing all vegetative waste).
Vehicular Exhausts
Exhaust from heavy machinery and truck traffic will be a minor source of
air pollutants, mainly carbon monoxide, particulate matter, nitrogen
oxides, hydrocarbons, and sulfur oxides. These exhaust emissions will
be of relatively small quantities because of the limited amount of
construction traffic expected, and are expected to have an impact of
negligible significance and magnitude.
In summary, the heavy construction activities are expected to have a
short-term impact in the immediate vicinity of the plant site, with the
primary impact on suspended parti cul ate matter levels. During clearing
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AIR QUALITY (PLANT SITE)
and grading operations, which will require approximately 3 months, the
construction impacts on air quality will be greater than during other
phases of construction due to the burning of vegetative wastes. Sus1-
pended particulate matter levels are anticipated to increase during
construction, both on-site and in the vicinity. These impacts are
expected to be of low significance. Secondary impacts are discussed in
the Ecology and Socioeconomics sections.
OPERATIONAL IMPACTS
Emi ssions
Operational impacts of the cement plant will be caused by air pollutants
emitted from the various manufacturing processes. Expected emissions of
particulate matter, sulfur dioxide, hydrocarbons, nitrogen oxides, and
carbon monoxide were quantified in Appendix A, Project Description.
Emissions of particulate matter and sulfur dioxide have been evaluated
for their air quality impacts by estimating ambient air concentrations
of these pollutants through dispersion modeling and comparing these
concentrations to the ambient air quality standards and to the 1977
estimated baseline air quality. Quantities of fugitive dust emissions
are expected to be negligible because of the high moisture content of
the raw materials, the use of water sprays, and a cover over some of the
stockpiles.
Suitable dispersion models do not exist for reactive pollutants, such as
hydrocarbons and nitrogen oxides, to estimate ambient air concentrations
accurately. However, emissions of hydrocarbons from the proposed plant
are estimated to be small—7, metric tons (8 tons) per year, and their
impact is expected to be of negligible significance and magnitude.
Nitrogen oxides will be emitted in significant quantities from fuel-
burning sources at the plant, an estimated 3,237 metric tons
(3,568 tons) per year. The impact of these emissions was evaluated by
application of a long--term, non--reactive dispersion model and a quali-
tative evaluation of the results. Carbon monoxide, which will be
emitted in small quantities, 25 metric tons (28 tons) per year, is
expected to have an impact of negligible significance on the carbon
monoxide air quality levels in the vicinity of the plant site.
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AIR QUALITY (PLANT SITE)
Prevention of Significant Deterioration Analysis
A comprehensive evaluation of the participate matter and sulfur dioxide
air quality impact of the proposed cement plant was performed as part of
the Prevention of Significant Deterioration (PSD) review required in the
Code of Federal Regulations, Title 40, Part 52, Subpart 52.21. The
review also addresses the application of Best Available Control Techno-
logy (BACT) for the control of emissions from the proposed plant. This
PSD review is necessary prior to issuance of an approval to construct
the cement manufacturing facility. A complete copy of the PSD applica-
tion is available for review from the U.S. EPA Region IV office in
Atlanta, Georgia, and a copy of the agency approval is included in the
Permit and Approval section of the Summary Document.
The proposed cement plant will utilize air pollution controls, including
baghouses and relatively low sulfur content fuel (1.5 percent maximum by
weight) to reduce the potential emissions of particulate matter and
sulfur dioxide, respectively. These controls have"been reviewed and are
considered BACT, pending review of the specific equipment selected and
the final design plans.
PSD regulations require that the impact of the particulate matter and
sulfur dioxide emissions from the proposed facility be determined and
reviewed for compliance with the following standards:
1. Ambient air quality standards (AAQS) must not be exceeded at
any location as a result of the proposed new source. These
standards pertain to the following air quality measures:
Sulfur dioxide
(a) annual arithmetic mean concentration;
(b) second highest 24-hour concentration in an annual
period;
(c) second highest 3-hour concentration in an annual period.
Suspended particulate matter
(a) annual geometric mean concentration; and
(b) second highest 24-hour concentration in an annual
period.
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AIR QUALITY (PLANT SITE)
2. Allowable federal Increments In air pollutant concentrations
must not be exceeded. These Increments represent fixed limits
upon the amounts by which the air quality measures listed above
can change relative to 1974, the baseline year. All sources of
air quality degradation are Included, not just the proposed new
source. As In the case of AAQS, the new source must be shown
not to violate the allowable Increment at any location, under
expected worst-case meteorological conditions. The purpose of
the increments is to prevent significant air quality
deterioration in areas where the 1974 ambient concentrations
were substantially below the applicable standards.
The maximum concentration estimates for 1980 with the proposed plant in
operation were derived by assuming that all sources in Mobile County
were emitting at allowable or permitted rates, except for a few sources
which theoretically could not emit up to the allowable limit due to pro-
cess design or other limitations. However, it is expected that many
sources in Mobile County will emit quantities of particulate matter and
sulfur dioxide below the allowable limit because of the application of
control equipment or use of low sulfur fuels.
In addition, the estimated quantities of emissions from the proposed
plant used for the modeling analysis were based upon a worst-case design
condition of separate clinker cooler exhausts. Since the analysis was
performed, Ideal Basic Industries has rejected this alternative. There-
fore, emission rates have been reduced from 608 metric tons (670 tons)
per year to 504 metric tons (555 tons) per year of particulate matter
and from 6,978 metric tons (7,694 tons) per year to 6,372 metric tons
(7,024 tons) per year of sulfur dioxide. In addition, no^reduction was
assumed for the sulfur dioxide emissions, even though there is strong
evidence to expect up to 75 percent reduction (U.S. EPA, 1975) due to
contact of the exhaust gases with the alkaline-raw materials (see the
Air Quality section of Appendix A, Project Description). Because of
these factors, actual maximum concentrations in 1980 with the proposed
C-7
-------
AIR QUALITY (PLANT SITE)
plant in operation are expected to be lower than those shown in
Table C.I.
Isopleths of annual average ground-level sulfur dioxide concentrations
predicted for 1980 are shown in Figure C.I (without the proposed plant
in operation) and Figure C.2 (with the proposed plant in operation).
These predicted concentrations are based on allowable emissions.
Figure C.3 shows isopleths of the incremental contributions to the
annual average sulfur dioxide concentrations from the proposed cement
plant.
Isopleths of annual average ground-level suspended particulate matter
concentrations for 1980, based on allowable emissions from all sources
in Mobile County, are shown in Figure C.4 (without the proposed plant)
and in Figure C.5 (with the proposed plant in operation). Isopleths of
the incremental contributions to the annual average particulate matter
concentrations due to operation of the proposed plant are shown in Fig-
ure C.6. The impacts of the particulate matter and the sulfur dioxide
concentrations due to the cement plant are very slight in relation to
Ambient Air Quality Standards.
Due to the present level of methodology, isopleths of the short-term
concentrations (24-hour for particulates, 24-hour and 3-hour for sulfur
dioxide) are not available. Instead, a grid of receptor points was
established in the Theodore Industrial Park area and the highest, second
highest concentrations for each receptor were noted. (The "highest,
second highest" relates to the ambient air quality standard of "not to
be exceeded more than once per year." Each receptor's position was
modeled for 5 years of concentrations and the highest of all the years'
second highest concentrations are shown.) This information is depicted
in Figure C.7 (sulfur dioxide) and in Figure C.8 (particulate matter).
The values shown will not occur simultaneously since they represent the
concentration at one receptor for one day out of 5 years. Figures C.9
and C.10 show the highest, second highest 24-hour concentrations of
sulfur dioxide and particulate matter, respectively, expected to exist
at each location in an annual period (from the cement plant only).
C-8
-------
o
I
C.I. Summary of PSD Evaluation Results for the Proposed Ideal Basic Industries Cement Manufacturing
Plant
Ambient Ground-Level Concentration (ug/m3)
Emi ssi on Si tuati on
Annual
An' thmeti c
Mean
Sulfur Dioxide
Second
Highest
24--Hour
Period
Second
Hi ghest
3-Hour
Period
Suspended P articulates
Second
Annual Hi ghest
Geometric 24--Hour
Mean Period
POINTS OF MAXIMUM CONCENTRATION
1980 With Ideal * 20
Percent of Standard 25%
Ideal Impact!Contribution) <1
POINTS OF MAXIMUM DEGRADATION
1974 Baseline 8
1980 With Ideal t 20
Degradation 12
Increment Remaining 8
Percent of Increment Remaining 40%
Ideal Impact(Contribute on)
Percent of Increment
<1
90
25%
28
10
90
80
11
12%
28
31%
315
24%
146
32
315
283
229
45%
146
28%
46
77%
44
44
0
19
100%
<1
149
99%
0
45
68
23
14
38%
21
57%
MAXIMUM IMPACT OF IDEAL **
Ideal Impact
Percent of Increment
Increment Remaining
1.2
6%
15
38
53
42%
199
39%
12%
313
21
* Concentrations from all sources at points of maximum impact from all sources combined.
t Concentrations from all sources at points of maximum degradation since 1974.
** Concentrations from Ideal at points of maximum Ideal effect.
Source: Environmental Science and Engineering, Inc.. 1977.
23
62%
26
Allowable Federal Increment
Federal Primary Standard
Federal Secondary Standard
20
80
NA
91
365
NA
512
NA
1300
19
75
60
37
260
150
-<
"•5
t/i
-------
16
14
ISLAND
14
ROAD
M
16
AIRCOf ^ >
RIVER*-
14
12
12
DEER RIVER POINT
MOBILE BAY
LAURENDINE
ROAD
10
0 05 1
SCALE IN KILOMETERS
[•*LOCATION OF MAXIMUM CONCENTRATION (19«jg/mjj
10
Figure C.1
ISOPLETHS OF PREDICTED ANNUAL AVERAGE
GROUND-LEVEL SULFUR DIOXIDE CONCENTRATIONS
(ug/m3) WITHOUT THE PROPOSED CEMENT PLANT IN
OPERATION, THEODORE, ALABAMA, 1980
SOURCE: Environmental Science and Engineering, Inc., 1977.
JL_!
REGION IV
U.S. ENVIRONMENTAL PROTECTION
AGENCY ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
PROPOSED CEMENT MANUFACTURING
PLANT THEODORE INDUSTRIAL PARK
MOBILE, ALABAMA
C-10
-------
14
16
18
ISLANC
^~
•^^
OEGUSSA
FOf,K\
-jg
AiRCOJ
RIVER*
3LANT
SITE />
DEER RIVER POINT
\
14
12
'12
MOBILE BAY
1OAD
rPOINT OF MAXIMUM PREDICTED CONCENTRATIONS (f) jig/m')
Figure C.2
ISOPLETHS OF PREDICTED ANNUAL AVERAGE
GROUND-LEVEL SULFUR DIOXIDE CONCENTRATIONS
(ug/m3), WITH THE PROPOSED CEMENT PLANT IN
OPERATION, THEODORE, ALABAMA, 1980
SOURCE: Environmental Science and Engineering, Inc., 1977.
C-ll
REGION IV
U.S. ENVIRONMENTAL PROTECTION
AGENCY ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
PROPOSED CEMENT MANUFACTURING
PLANT THEODORE INDUSTRIAL PARK
MOBILE, ALABAMA
-------
1.;
ISLAND
<—l—f-f-H-)—t-
ROAD
REFINING
-T-s
0.8
0.4
DEER RIV
°^.<
Ofe«
1.0
DEGUSS/
'0.2,
0.8,
OB/LE
ROAD
0 O.S 1
SCALE IN KILOMETERS
/•* POINT OF PREDICTED MAXIMUM INCREMENTAL
CONTRIBUTION (1.2 ug/m') / /
Figure C.3
ISOPLETHS OF THE INCREMENTAL CONTRIBUTIONS
TO PREDICTED ANNUAL AVERAGE GROUND-LEVEL
SULFUR DIOXIDE CONCENTRATIONS (ug/m3),
PROPOSED CEMENT PLANT ONLY, THEODORE,
ALABAMA, 1980
SOURCE: Environmental Science and Engineering, Inc., 1977.
C-12
REGION IV
U.S. ENVIRONMENTAL PROTECTION
AGENCY ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
PROPOSED CEMENT MANUFACTURING
PLANT THEODORE INDUSTRIAL PARK
MOBILE, ALABAMA
-------
ISLAND
45
ROAD
-A
[FINING
JDEGUSSA
47.
•45'
DEER RIVER POINT
A12S3TPLAN?
,43
•43
BAY
LAURENDINE
ROAD
-
14 POINT OF MAXIMUM CONCENTRATION (48 ug/m')
* NOTE: CONCENTRATIONS INCLUDE A 35 ug/m3 BACKG
ND LEV*
0 0.5 1
SCALE IN KILOMETERS
Figure C.4
ISOPLETHS OF PREDICTED ANNUAL AVERAGE
GROUND-LEVEL SUSPENDED PARTICULATE MATTER
CONCENTRATIONS (ug/m3), WITHOUT THE PROPOSED
CEMENT PLANT IN OPERATION, THEODORE,
ALABAMA, 1980
SOURCE: Environmental Science and Engineering, Inc., 1977.
"^^^™"^"" C-13
REGION IV
U.S. ENVIRONMENTAL PROTECTION
AGENCY ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
PROPOSED CEMENT MANUFACTURING
PLANT THEODORE INDUSTRIAL PARK
MOBILE, ALABAMA
-------
45
ISLAND
ROAt
KERR-M/GE
45
FINING
47
DEER RIVER PCMNT
AIRCOf,-
45
45
43
43
LAURENDINE
ROAD
POINT OF MAXIMUM PREDICTED CONCENTRATION (5|
ElOTE: CONCENTRATIONS INCLUDE A 35 ug/m1 BACKGF
2
|fg/ms)
DUND
BELLEFO
SCALE IN KILOMETERS
Figure C.5
ISOPLETHS OF PREDICTED ANNUAL AVERAGE
GROUND-LEVEL SUSPENDED PARTICULATE MATTER
CONCENTRATIONS (ug/m3), WITH THE PROPOSED
CEMENT PLANT IN OPERATION, THEODORE,
ALABAMA, 1980
SOURCE: Environmental Science and Engineering, Inc., 1977.
REGION IV
U.S. ENVIRONMENTAL PROTECTION
AGENCY ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
PROPOSED CEMENT MANUFACTURING
PLANT THEODORE INDUSTRIAL PARK
MOBILE, ALABAMA
C-14
-------
0.4
ISLAN
ROAD
0.6
KRION>
0.8
DEGUfeSA
1.0
S1.5
0.6
R '
R POINT
0.4
OtffLF
LAURENDINE
0 0.5 1
SCALE IN KILOMETERS
ROAD
0.4
* POINT OF PREDICTED MAXIMUM INCREMENTAL
CONTRIBUTION (2.3 ug/m')
NTAINE
FigureC.6
ISOPLETHS OF THE INCREMENTAL CONTRIBUTIONS
TO PREDICTED ANNUAL AVERAGE GROUND-LEVEL
SUSPENDED PARTICULATE MATTER CONCENTRATIONS
(ug/m3), PROPOSED CEMENT PLANT, THEODORE,
ALABAMA, 1980
SOURCE: Environmental Science and Engineering, Inc., 1977.
REGION IV
U.S. ENVIRONMENTAL PROTECTION
AGENCY ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
PROPOSED CEMENT MANUFACTURING
PLANT THEODORE INDUSTRIAL PARK
MOBILE, ALABAMA
C-15
-------
ISLAND
ROAD
DEGUSSA
69(1
FINING
AIRCOf
PLANT
SITE
DEER RIVER POINT
Z(0)
AK32)
50(0)
•
J8(33)
MOBILE BAY
LAURtNDINE
ROAD
0 O.S 1
SCALE IN KILOMETERS
MOTE: NUMBERS IN PARENTHESIS INDICATE IDEAL'S
CONTRIBUTION TO THE TOTAL CONCENTRATION
Figure C.7
PREDICTED HIGHEST, SECOND HIGHEST 24-HOUR
SULFUR DIOXIDE CONCENTRATIONS (ug/m3),
AT THE CRITICAL LOCATIONS, ALL SOURCES AT
ALLOWABLE EMISSION RATES, THEODORE,
ALABAMA, 1980
SOURCE: Environmental Science and Engineering, Inc., 1977.
BELLEF
REGION IV
U.S. ENVIRONMENTAL PROTECTION
AGENCY ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
PROPOSED CEMENT MANUFACTURING
PLANT THEODORE INDUSTRIAL PARK
MOBILE, ALABAMA
C-16
-------
ISLAND
ROAD
LAURENDINt
0 0.5 1
SCALE IN KILOMETERS
»OTE:
PROPOSED CEMENT MANUFACTURING
PLANT THEODORE INDUSTRIAL PARK
MOBILE, ALABAMA
ROAD
NUMBERS IN PARENTHESIS INDICATE IDEAL'S
CONTRIBUTION TO THE TOTAL CONCENTRATIO
Figure C.8
PREDICTED HIGHEST, SECOND HIGHEST 24-HOUR
SUSPENDED PARTICULATE MATTER CONCENTRATIONS
(ug/m3). AT THE CRITICAL LOCATIONS, ALL SOURCES
AT ALLOWABLE EMISSION RATES, THEODORE,
ALABAMA, 1980
SOURCE: Environmental Science and Engineering, Inc., 1977.
C-17
-------
SCALE IN KILOMETERS
PROPOSED
/ i
PLANT
-x-'7/ 1
(JJ * I
I ^ 30 30
CX^ / ^ I
* POINT OF MAXIMUM HIGHEST, SECOND HIGHEST CONCENTRATION (38 ug/ffl')
Figure C.9
ISOPLETHS OF PREDICTED ANNUAL INCREMENTAL
HIGHEST, SECOND HIGHEST 24-HOUR GROUND-LEVEL
SULFUR DIOXIDE CONCENTRATIONS (ug/m3), FOR
THE IDEAL BASIC INDUSTRIES PROPOSED CEMENT
PLANT ONLY. THEODORE, ALABAMA
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
C-18
-------
PROPOSED PLANT
0 0.5
SCALE IN KILOMETERS
I
* POINT OF MAXIMUM HIGHEST, SECOND HIGHEST CONCENTRATION (23 ug/m>)
Figure C.10
ISOPLETHS OF PREDICTED ANNUAL INCREMENTAL
HIGHEST, SECOND HIGHEST 24-HOUR GROUND-LEVEL
SUSPENDED PARTICULATE MATTER CONCENTRATIONS
(ug/m3), FOR THE IDEAL BASIC INDUSTRIES PROPOSED
CEMENT PLANT ONLY, THEODORE. ALABAMA
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
C-19
-------
AIR QUALITY (PLANT SITE)
The highest, second highest 3-hour sulfur dioxide concentrations are not
shown, but were calculated based on a ratio technique relative to
24-hour concentrations from each significant source for each receptor
location.
All of these expected ambient concentrations are summarized in
Table C.I. This table presents three types of receptor concentrations:
maximum concentrations in 1980 from all sources operating; concentra-
tions in 1980 from all sources operating that represent maximum
degradation since 1974; and concentrations in 1980 from all sources
operating that reflect the proposed cement plant's maximum contribu-
tions. The air quality concentrations shown have been estimated by
mathematical modeling based on the meteorological conditions known to
have occurred in 1974 for all baseline concentrations and from 1971
through 1975 for all other concentrations (1980). The geographical area
affected by the emissions from the proposed cement plant is the area
under consideration in Figures C.I through C.10.
The specific receptor locations can be different for each of the five
standards represented by the vertical columns and for each of the three
emission situations. In addition, the concentrations of the annual
geometric mean for suspended participate matter are actually the annual
averages depicted in Figures C.4 and C.6, multiplied by a conversion
factor of 0.92.
Maximum Concentrations
Each of the values projected to occur in 1980 with the proposed project
in operation (first emission situation) is less than the respective air
quality standard, shown at the bottom of the table. This indicates that
the standards will not be exceeded at any location affected by the
proposed plant. As shown in the last column, the 24-hour suspended
particulate standard will nearly be exceeded. However, this condition
exists only in a very localized area near a present emission source
C-20
-------
AIR QUALITY (PLANT SITE)
(unrelated to the Ideal project) and will not be affected by the
emissions from the cement plant under the meteorological conditions
represented. All other meteorological conditions will produce lower
concentrations than shown.
The third emission situation shows the concentrations that are directly
related to the proposed cement plant during conditions of maximum
ambient concentrations. The only significant contributions of the
emissions from the cement plant are projected during the 24-hour and
3-hour criteria for sulfur dioxide. No reduction of sulfur dioxide was
accounted for in the modeling; actual levels are expected to be
substantially lower (up to 75 percent).
Therefore, the impact from this contribution to the projected maximum
ambient air quality concentrations for sulfur dioxide and suspended
participate matter is considered of low magnitude. The significance is
also rated low based on the small area affected by the plant's
emissions. Like all other air quality impacts during operations, they
will be long-term, but reversible.
Maximum Degradation
The central portion of Table C.I deals with the locations of maximum air
quality degradation, or the change between 1974 and 1980. The first row
shows the concentrations estimated during baseline conditions at the
points of maximum degradation. Next, the projected 1980 contribution
from all sources is presented. (The concentrations and receptor
locations for all the sulfur dioxide criteria are the same as those
during maximum ambient concentrations mentioned previously.) The total
changes in these air quality measures, presented in the row labeled
"Degradation," are the quantities covered by PSD regulations. In none
of these cases are the allowable federal increments exceeded. In addi-
tion, the portion of the increment remaining and its percentage of the
total are given in the next two rows. These values represent the remain-
ing portion of the increment after all projected emission sources are
C-21
-------
AIR QUALITY (PLANT SITE)
modeled at that specific receptor location and under the one day In five
years of meteorological conditions. At all other receptor sites and on
all other days, It Is assumed, based on the modeling methodology util-
ized, that the remaining Increment will be larger.
As shown by the row labeled "Ideal Impact," the proposed project will
utilize less than 5 percent of the allowable annual Increments of sulfur
dioxide and suspended partlculate matter at these locations (first and
fourth columns). The project will consume 31 percent and 28 percent of
the two short-term sulfur dioxide increments and will utilize 57 percent
of the 24-hour suspended partlculate increment.
Maximum Impact of Ideal
This emission situation considers the degradation due to emissions from
all sources at the points of the maximum impact (contribution) of the
emissions from the cement plant. The plant's impact is given first,
followed by its related usage of the allowable increment and the portion
of the increment remaining after all existing sources are considered.
The greatest effects of the proposed Ideal plant on annual mean con-
centrations will be to utilize 12 percent of the annual particulate
increment and 6 percent of the annual sulfur dioxide increment. The
plant will utilize up to 62 percent of the 24-hour particulate incre-
ment, and up to 42 percent and 39 percent of the 24-hour and 3-hour
sulfur dioxide increments, respectively. The points of maximum effect
by Ideal are not the points of greatest overall air quality degradation
since the available increments at these receptor locations during the
specific meteorological conditions associated with these concentrations
are all higher than those discussed above under "Maximum Degradation."
C-22
-------
AIR QUALITY (PLANT SITE)
The extent to which the proposed cement plant might limit allowable
emissions by other new sources (also subject to PSD review), and thereby
might influence future industrial growth could be a serious community
impact, since much of the land near the Ideal Basic Industries plant
site is intended for industrial development. The detailed air quality
forecasts indicate that the proposed project will not place significant
limitations upon future growth.
The growth limitation issue relates primarily to short-term air quality
increments, since the proposed project does not place significant stress
upon annual increments or annual ambient air quality standards. An
important characteristic of short-term air quality measures is that the
maximum values tend to involve highly specific combinations of emission
sources, geographic areas, and meteorological conditions. As an
example, the point of maximum consumption of the 24-hour sulfur dioxide
increment (88 percent total consumption, 31 percent due to Ideal) is a
location northwest of the proposed plant site near Island Road. A high
consumption of the 24-hour particulate increment (54 percent total
consumption, 22 percent due to Ideal) also occurs near this point. The
reason is that this location is aligned with two existing emission
sources as well as Ideal, so that winds from the southeast can cause the
location to be impacted by all three sources. However, there are few
sites where an industry could locate an additional emission source that
would contribute to this impact. The only possibilities would be
emission sources very close to the south bank of the ship channel, or
perhaps additional sources on the existing industrial sites. Even if a
plant were so located, there is sufficient increment remaining to
accommodate many types of industrial plants.
This characteristic applies to the areas in which the Ideal Basic
Industries project would consume significant shares of the short-term
air increments. The critical areas for the 24-hour particulate
increment (where total utilization by all sources in 1980 will exceed
50 percent) are situated close to the plant site, except for the
C-23
-------
AIR QUALITY (PLANT SITE)
location discussed above. In the case of the 24-hour sulfur dioxide
Increment, all of the high-utilization areas other than the location
discussed earlier will be affected only slightly by the proposed cement
plant.
The impacts of the proposed cement plant in utilizing these estimated
portions of the PSD increments are of a moderate magnitude. However, in
consideration of the area affected, the available increment remaining,
the conservative modeling methodology used, and the over-estimation of
the plant's sulfur dioxide emissions (no reduction assumed), the sig-
nificance is considered low. This impact is long-term and reversible.
Nitrogen Oxides
Nitrogen oxide emissions from the proposed cement plant were modeled on
a long-term basis by use of the Air Quality Display Model (see PSD
Modeling Report for a description of this model). This model estimates
annual average concentrations of non-reactive pollutants. The disper-
sion model results, therefore, reflect complete and immediate conversion
of all nitrogen oxide to nitrogen dioxide. In reality, during the
photolytic cycle which involves nitrogen oxide, nitrogen dioxide, hydro-
carbons, photochemical oxidants, and sunlight, the nitrogen oxide is not
converted immediately to nitrogen dioxide, but is converted at a rate
which is dependent on the concentrations of other participant pollutants
and meteorological factors (U.S. EPA, Air Pollution Control Office,
1971). Thus, the dispersion model tends to overestimate ambient concen-
trations of nitrogen dioxide.
To assess the air quality impact associated with nitrogen oxide emis-
sions, only the proposed cement plant was modeled. Any attempt to model
other sources of nitrogen oxides in Mobile County for their contribu-
tions to levels at the proposed plant site would yield highly unreliable
resul ts.
C-24
-------
AIR QUALITY (PLANT SITE)
Figure C.ll shows isopleths of estimated annual average ground-level
concentrations of nitrogen dioxide due to operation of the proposed
cement plant. The location of the point of maximum impact is indicated
by a star in the figure, and the annual average concentration at this
point is 0.7 ug/m3. These estimates are very conservative in nature,
and actual ambient concentration could be much lower. This maximum
concentration is well below the National Ambient Air Quality Standard of
100 ug/m3 annual average basis; therefore, this estimated concentra-
tion is considered a long-term, but reversible impact of low magnitude
and low significance.
C-25
-------
0 0.5 1
SCALE IN KILOMETERS
POINT OF MAXIMUM CONCENTRATION (0.7 ug/m1)
Figure C.11
ISOPLETHS OF THE INCREMENTAL CONTRIBUTIONS
TO ANNUAL AVERAGE GROUND-LEVEL NITROGEN
DIOXIDE CONCENTRATIONS (ug/m3), DUE TO
OPERATION OF THE PROPOSED CEMENT PLANT ONLY,
THEODORE, ALABAMA
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
C-26
-------
NOISE (PLANT SITE)
NOISE
CONSTRUCTION IMPACTS
Construction of the Theodore Ship Channel and the Ideal Basic Industries
cement plant will occur during the same time period and therefore the
effect of the channel construction project has been assessed to obtain
the combined impact of both projects, as well as to distinguish the
impact of the cement plant. The channel construction project can be
performed by using a 0.7-meter (27-inch) hydraulic dredge and an
assisting tug.
Ship Channel Construction: Noise Analysis
The major noise sources during the improvement and extension of the
Theodore Ship Channel will be the dredge, attendant boat, and the dredge
pump. For this noise analysis, the following assumptions were made:
1. The dredge, pump, and boat will work the inland area along the
barge canal.
2. The dredge will move along a straight line at the rate of
305 meters (1,000 feet) per month and will operate 24 hours per
day.
3. As a "worst case," the path followed by the dredge will be
30 meters (100 feet) from each noise monitoring station.
4. The critical time for both projects will be a three-month
construction period, during which the dredge will cover the
area from a point 152 meters (500 feet) to the east of the
Ideal Basic Industries property to the boundary between Ideal
Basic Industries and Airco, Inc., while the cement plant's
heavy equipment usage will be at a maximum level.
5. The dredge, pump, and boat combination will produce a sound
power level of 85 dBA at 30 meters (100 feet).
C-27
-------
NOISE (PLANT SITE)
The following results were obtained from the noise analysis of the ship
channel project:
1. An average three-month Leq(24) of 75 dBA will be observed
at each station along the barge canal.
2. An average three-month Ldn of 81 dBA will be observed at
each station along the barge canal.
Cement Plant Construction: Noise Analysis
Noise from the construction of the proposed cement plant will originate
from heavy equipment used in the clearing, excavation, foundation work,
and framing phases of construction.
Equipment associated with earthmoving, lifting, welding, paving, pile-
driving, and transportation will be the primary sources of construction
noise. Table C.2 lists the types and numbers of pieces of equipment
originally projected to be used at the site during the highest level of
construction activity and gives the noise characteristics of the
equipment. The analysis has assumed that there will be 1,750 one-way
vehicular trips to and from the plant site daily during the peak
construction period.
Construction activities are expected to last for two and one-half years.
Maximum construction-related activities will occur after approximately
one year of work. At that time approximately 120 pieces of heavy
equipment will be in use.
For this study, it was assumed that at any given time throughout an
eight-hour day, 75 percent of the equipment will be in operation.
Furthermore, it was assumed that the characteristics listed in Table C.2
are applicable since the noise levels listed have been mandatory for all
government contractors since 1973.
Since the spatial arrangement of construction equipment is impossible to
specify, some simplifying assumptions were made. It was assumed that
within the plant site the distribution of all pieces of equipment would
C-28
-------
NOISE (PLANT SITE)
Table C.2. Types, Numbers, and Noise Characteristics of Heavy Pieces of
Equipment Required During Busiest Phase of Construction
Equipment
Number3
Noise Level in dBA
at 15 metersb
Earthmoving
Dozers
Scrapers
Graders
Loaders
Rollers
Carry-alls
Lifting
Cranes
Forklifts
Welding
Welders
Compressors
Generators
Paving and Concrete
Backhoes
Mixers
Vibrators
Rollers
Concrete Finishers
Pile Drivers
Transporters
Trucks
3
2
2
3
1
3
3
4
10
8
3
8
4
10
1
5
80
88
85
79
89
83
47
81
78
85
85
76
89
101
91
Sources: a. Brown & Root, Inc., 1977.
b. Schemer and Homans, 1975. These are the old (July 1, 1973)
GSA standards for government contractors. They were super-
seded by lower noise level requirements on January 1, 1975.
Values from the old standards were used in the models for
conservative estimates of expected noise levels.
C-29
-------
NOISE (PLANT SITE)
be random. It was also assumed that the 120 point sources could be
simplified by nine large Identical point sources. Each theoretical
source has elements of the pavers, trucks, dozers, compressors, pile
drivers, etc., and Is evaluated at 99.5 dBA at a distance of 15 meters
(50 feet).
The combined contributions of the nine theoretical noise sources to
environmental noise levels are displayed In Figure C.12. The shape of
the contours Is due to the existence of more forested areas In certain
directions. Accordingly, corrections of 5 dBA per 30 meters (100 feet)
and 2 dBA per 30 meters (100 feet) were made for thick and sparse
plantings, respectively. A maximum of 10 dBA was used for the
vegetation's attenuation of the sound levels. If no other noise sources
existed In the area, the sphere of Influence of construction noise would
extend over 0.8 kilometers (one-half mile) south of the Ideal Basic
Industries property, approximately 0.4 kilometers (one-fourth mile)
north of the property, over 1.6 kilometers (one mile) west, and
0.8 kilometers (one-half mile) east of the property.
The noise values are given in terms of Ldn. The contours developed
are exclusive of contributions from the existing ambient noise levels,
construction-associated traffic, or improvement of the ship channel.
Predicted Noise Levels at Baseline Monitoring Stations
Since the ship channel will be extended whether or not Ideal Basic
Industries builds the proposed facility, the noise levels attributed to
the construction of the cement plant must be added to those caused by
the construction of an improved channel. The effects of the proposed
facility construction upon the original 12 monitoring stations in the
vicinity of the proposed site (Figure C.13) are presented in Table C.3.
The three "worst case" situations presented are:
1. The 3-month period of dredging in front of the plant site by
the U.S. Army Corps of Engineers (without plant construction);
C-30
-------
ROAD
60
ROAD
ROAD
'
JLAUOIA LANEX
LAURENOINE ROAD
MOBILE BAY
Figure C.12
EQUAL SOUND LEVEL (Ldn) CONTOURS DUE TO
WORST CASE CONSTRUCTION ACTIVITIES FROM
THE PROPOSED PLANT ONLY
0 0.9 1
SCALE IN KILOMETERS
SOURCE: Environmental Science and Engineering, Inc., 1977.
REGION IV
U.S. ENVIRONMENTAL PROTECTION
AGENCY ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
PROPOSED CEMENT MANUFACTURING
PLANT THEODORE INDUSTRIAL PARK
MOBILE, ALABAMA
C-31
-------
BAKER SOBREU ROAD
LAURENDINE ROAO
Figure C.i:
NOISE MONITORING STATIONS
PROPOSED CEMENT MANUFACTURING
PLANT THEODORE INDUSTRIAL PARK
MOBILE, ALABAMA
SOURCE: Environmental Science and Engineering, Inc., 1977.
C-32
-------
Table C.3. Noise Levels (dBA) at the Baseline Monitoring Stations and Predicted Levels for Three
"Worst Case" Situations
00
co
Baseline
Baseline Plus
Channel Construction
Baseline Plus
Cement Plant
Construction
Baseline Plus
Channel and Cement
Plant Construction
Station
1
2
3
4
5
6
7
8
9
10
11
12
Ldn*
55
54
48
72
48/55
65
55
55/55
53/55
54/55
67
67/55
Leq(24)*
48/70
49/70
45/70
66/70
45
61/55
53/55
48
51
52
59/70
66
Ldn
81 (26)
81 (27)
48 (0)
72 (0)
48 (0)
65 (0)
55 (0)
81 (26)
81 (28)
81 (27)
t (NA)
67 (0)
Leq(24)
75 (27)
75 (26)
45 (0)
66 (0)
45 (0)
61 (0)
53 (0)
75 (27)
75 (24)
75 (23)
t (NA)
66 (0)
Ldn
67 (12)
84 (30)
62 (14)
73 (1)
56 (8)
66 (1)
57 (2)
73 (18)
67 (14)
67 (13)
68 (1)
68 (1)
Leq(24)
67 (19)
84 (35)
61 (16)
69 (3)
55 (10)
62 (1)
55 (2)
73 (25)
67 (16)
67 (15)
64 (5)
67 (1)
Ldn
81 (26)
86 (32)
62 (14)
73 (1)
56 (8)
66 (1)
57 (2)
82 (27)
81 (28)
81 (27)
t (NA)
68 (1)
Leq(24)
76 (28)
85 (36)
61 (16)
69 (3)
55 (10)
62 (1)
55 (2)
77 (29)
75 (24)
76 (24)
t (NA)
67 (1)
* Second numbers refer to the sound levels requisite to protect public health and welfare according to
land use (see Table B.N.2).
t No estimate since site is in future turning basin.
NOTE: Numbers in parentheses are increases in equivalent sound levels over baseline conditions.
Source: Environmental Science and Engineering, 1977.
-------
NOISE (PLANT SITE)
2. The 3-month period of maximum usage of heavy equipment for
plant construction (with no Corps dredging); and
3. The simultaneous occurrence of both construction projects at
their individual "worst case" levels.
Sound levels at 7 of the 12 stations will be significantly affected by
the channel and/or plant construction. Of these stations, Nos. 1 and 2
will be unduly biased due to their on-site locations with respect to
plant construction activities.
The important stations are those just north of the plant site (Nos. 3
and 5) and those along the southern bank of the barge canal (Nos. 8, 9,
and 10). These stations represent levels at possible receptor locations
in the nearby residential areas.
The ship channel project is estimated to affect only those stations
along the channel, whereas the cement plant will affect these same
stations (but to a lesser degree) and will also affect the stations just
north of the plant site.
If these two worst case conditions coincide, the impact of the cement
plant's construction is overshadowed by the ship channel dredging at
stations 8, 9, and 10. Without assessing the noise generated from the
ship channel project, the cement plant's construction will substantially
raise the equivalent sound levels above baseline conditions at these
three stations.
In either case, the plant's construction activities will raise appreci-
ably noise levels at stations 3 and 5. However, since the two projects
are part of the overall industrialization occurring in the vicinity of
the proposed plant site, much of the area impacted by the Corps of
Engineers and Ideal Basic Industries projects will be changing in land
use designation from residential or vacant to industrial. For a more
detailed description, refer to the discussions of the 1992 environment
in Appendix B, Baseline, and in Appendix E, Alternatives.
C-34
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NOISE (PLANT SITE)
In relation to the EPA noise levels identified as requisite to protect
public health and welfare (see Table C.3), the noise levels from
construction activities for the cement plant only are expected to have
various effects. Within the zone of influence described by the area of
55 dBA (Ldn) or greater (see Figure C.12), the activities will increase
the noise levels to greater than those suggested for normal outdoor
speech communication at about 3 meters (10 feet). These levels should
be somewhat similar to those found in metropolitan residential areas
throughout the United States. The noise levels outside the plant
property should be below the suggested Leq (24) of 70 dBA that could
cause hearing loss over an extended time (40 years). Outside this zone
of influence, the effect of the construction activities at the plant,
although perceptible along the area bordering the 5b dBA contour, should
not cause disturbance with outdoor communication or activity.
In summary, the primary impacts of the plant construction on the local
noise levels are estimated to be of moderate magnitude due to the levels
projected within the zone of influence, but of low significance due to
the number of residences affected and the short duration (3 months) of
the worst case analysis period. Construction during the remaining
27 months will generate noise, but to a lesser degree. Table C.4 shows
the existing, 1980, and 1992 residential house counts for both the con-
struction and operation noise impacts of the proposed project. It is
estimated that during the construction period, between 60 and 75 resi-
dences may be affected by equivalent sound levels equal to or greater
than 55 dBA generated from the construction activities.
The cement plant's construction impacts will be reversible and
short-term. The secondary impacts are discussed in the Ecology and
Socioeconomics sections.
C-35
-------
NOISE (PLANT SITE)
Table C.4. Dwelling Counts within the Zone of Influence of the Noise
Levels from Construction and Operation of the Proposed
Plant
Dwellings Dwellings
Existing Present and Present and
Dwellings Occupied Occupied
Phase 1978 in 1980 in 1992
Construction Phase
Inside 65 dBA Contour 7 0
Inside 60 dBA Contour* 22 10
Inside 55 dBA Contour* 75 60
Operations Phase
Inside 65 dBA Contour
Inside 60 dBA Contour*
Inside 55 dBA Contour*
0
18
32
0
6
20
0
0
6
* The figures refer to the cumulative number of dwellings. For
example, the figures for the 55 dBA contour include all dwellings
inside the 60 dBA and 65 dBA contours.
Source: Environmental Science and Engineering, Inc., 1978.
C-36
-------
NOISE (PLANT SITE)
OPERATION IMPACTS
Noise from the operation of the cement plant will originate from the
specific equipment used during each step of the process, including raw
material and finished product handling and rail, barge, and employee
traffic. Table C.5 is a summary of the principal plant noise sources
during plant operation.
Equipment Noise
The process equipment will be the primary source of continuous noise
during plant operation. Table C.6 lists typical pieces of equipment
found at cement plants and their associated noise characteristics.
There are numerous other pieces of equipment which contribute to the
total noise emanating from a cement plant.
Noise Analysis of a Typical Plant
Because of the complexities and uncertainties involved in determining
contributions of each point source within the plant to environmental
noise levels away from the plant, an alternative method of analysis was
used. A noise survey was performed at a cement plant which utilizes the
dry process and which has one-third the capacity of the proposed Ideal
Basic Industries facility. Noise levels were recorded at various points
within and around the plant in order to gain information on typical
noise levels associated with operation of a cement plant.
The monitoring stations and the actual measurements taken at Cement
Plant "A" are shown in Figure C.14. The data from this figure were
recalculated and weighted towards nighttime effects and are shown in
Figure C.15. Contours of equal noise levels are shown in Figure C.16.
The data acquired from Cement Plant "A" indicate that most noise
emanates from the kiln and the raw grinding and finishing grinding
processes and shows the effects of distance and barrier attenuation.
C-37
-------
NOISE (PLANT SITE)
Table C.5. Sources of Noise During Plant Operation
Intermittent During Continuous During
Source Operating Hours Operating Hours
Raw Materials Handling X
Crushing Operation X
Kilns X
Finish Mills X
Finish Product Handling X
Employee Traffic X
Channel Traffic X
Haul Trucks X
Railroad X
Sources: Applied Science and Resource Planning, Inc., 1973.
Environmental Science and Engineering, Inc., 1977.
C-38
-------
NOISE (PLANT SITE)
Table C.6. Average Values of Sound Levels Measured in Operating Cement
Plants at Distances of 4.5 Meters (15 Feet)
Source Sound Level (dBA)
Finish Grinding Mill 105
Raw Grinding Mill (Dry) 103
Raw Grinding Mill (Wet) 97
Rotary Compressor 97
Bucket Elevator (Head) 88
Source: Johnson, 1972.
C-39
-------
61
• 69
LIMESTONE CLAY
HOPPER HOPPER
67
' 65
61
65
• 71
n
I
69
61
• 69
• 75
1 REVERSIBLE IMPACTOR
2 CLAY IMPACT CRUSHER/DRYER
3 LIMESTONE RECLAIM STORAGE (1 2.000-T)
4 ADDITIVE SILOS —CLAY
5 RAW GRINDING/DRYING
6 BAGHOUSE DUST COLLECTOR - KILN/MILL
7 KILN FEED BLENDING/STORAGE SILOS
8 COMPRESSOR BUILDING
9 GEPOL SYSTEM ROTARY KILN
10 KILN BURNER BUILDING
11 CLINKER SILOS (ONE FRINGE)
1 2 GYPSUM SILO (800-T)
13 FINISH MILLS
1 4 CEMENT SILOS/BULK LOADOUT
1 5 CONTROL ROOM/LABORATORY/OFFICE
16 ELECTRICAL SUBSTATION
1 7 MACHINE SHOP/WAREHOUSE
18 OIL PUMP HOUSE
19 OIL STORAGE TANK
20 WATER STORAGE (100.000 GAL)
• 69
Figure C. 14
SOUND LEVELS (L_J RECORDED AT CEMENT PLANT "A" (dBA)
eq
REGION IV
U.S. ENVIRONMENTAL PROTECTION
AGENCY ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
o 100
SCALE IN METER*
SOURCE: Environmental Science and Engineering, Inc., 1977.
PROPOSED CEMENT MANUFACTURING
PLANT THEODORE INDUSTRIAL PARK
MOBILE, ALABAMA
-------
67
| 75
LIMESTONE CLAY
73
71
'67
• 71
75
1 REVERSIBLE IMPACTOR
2 CLAY IMPACT CRUSHER/DRYER
3 LIMESTONE RECLAIM STOHAGE (12.000-T)
4 ADDITIVE SILOS —CLAY
5 RAW GRINDING/DRYING
6 BAGHOUSE DUST COLLECTOR — KILN/MILL
7 KILN FEED BLENDING/STORAGE SILOS
8 COMPRESSOR BUILDING
9 GEPOL SYSTEM ROTARY KILN
10 KILN BURNER BUILDING
11 CLINKER SILOS (ONE FRINGE)
1 2 GYPSUM SILO (800-T)
13 FINISH MILLS
14 CEMENT SILOS/BULK LOADOUT
1 5 CONTROL ROOM/LABORATORY/OFFICE
16 ELECTRICAL SUBSTATION
1 7 MACHINE SHOP/WAREHOUSE
18 OIL PUMP HOUSE
19 OIL STORAGE TANK
20 WATER STORAGE (100.000 GAL)
• 67
Figure C. 15
SOUND LEVELS (Ldn) CALCULATED AT CEMENT PLANT "A" (dBA)
REGION IV
U.S. ENVIRONMENTAL PROTECTION
AGENCY ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
0 100
SC*LE IN METERS
SOURCE: Environmental Science and Engineering, Inc., 1977.
PROPOSED CEMENT MANUFACTURING
PLANT THEODORE INDUSTRIAL PARK
MOBILE, ALABAMA
-------
n
i
-p>
no
1 REVERSIBLE IMPACTOR
2 CLAY IMPACT CRUSHER/DRYER
3 LIMESTONE RECLAIM STORAGE (1 2.000-Tl
4 ADDITIVE SILOS-CLAY
5 RAW GRINDING/DRYING
6 BAGHOUSE DUST COLLECTOR — KILN/MILL
7 KILN FEED BLENDING/STORAGE SILOS
8 COMPRESSOR BUILDING
9 GEPOL SYSTEM ROTARY KILN
10 KILN BURNER BUILDING
1 1 CLINKER SILOS (ONE FRINGE)
1 2 GYPSUM SILO (800-T)
13 FINISH MILLS
14 CEMENT SILOS/BULK LOADOUT
1 5 CONTROL ROOM/LABORATORY/OFFICE
16 ELECTRICAL SUBSTATION
1 7 MACHINE SHOP/WAREHOUSE
18 OIL PUMP HOUSE
19 OIL STORAGE TANK
20 WATER STORAGE (100.000 GAL)
Figure C.16
EQUAL SOUND LEVEL (Ldn) CONTOURS AT CEMENT PLANT "A" (dBA)
0 100
SCALE IN METERS
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
-------
NOISE (PLANT SITE)
Impacts of the Ideal Basic Industries Facility
The data generated from Cement Plant "A" is not entirely adequate for
impact predictions for the Ideal Basic Industries facility. Fortunately,
however, the major plant elements at Ideal Basic Industries will be
located within an area roughly equal to that of Plant "A." The assump-
tion was made that with three times the production, the sound power
levels from the Ideal Basic Industries facility would be roughly three
times as great as the levels at Plant "A." This assumption was made to
take into account the differences between the two plants and the three-
fold production increase and to present a reasonably conservative noise
level estimate of the plant during operations. Tripling the sound power
level amounts to a 5 dBA increase to the levels observed at Plant "A".
With an addition of 5 dBA to the levels observed at Plant "A," an
adequate projection of noise impacts of the proposed facility could be
made.
The sound contours from Plant "A" were overlaid upon the Ideal Basic
Industries property. Adjustments were made for attenuation due to
trees: 5 dBA for thick planting and 2 dBA for sparse planting per
30 meters (100 feet). In no case, however, was more than 10 dBA
deducted regardless of the thickness of the planting. The results of
the foregoing analysis are displayed in Figure C.17. For the most part,
the highest levels of noise generated by the proposed facility are
within the Ideal Basic Industries property and towards other industrial
areas, except the area south of the channel.
Automobile and Truck Traffic
It is estimated that 135 employees will work at the Ideal Basic Indus-
tries facility. These employees will generate over 200 one-way trips
to and from the proposed site per day. There will also be between
60 and 100 truck trips to or from the site per day. A comparison of the
figures given above with those presented in Figure B.N.3 (present traf-
fic) indicates that traffic to and from the cement plant will have only
C-43
-------
Figure C.17
EQUAL SOUND LEVEL (Ldn) CONTOURS DUE TO PLANT
OPERATIONS ONLY
PROPOSED CEMENT MANUFACTURING
PLANT THEODORE INDUSTRIAL PARK
MOBILE, ALABAMA
SOURCE: Environmental Science and Engineering, Inc., 1977.
-------
NOISE (PLANT SITE)
a small Impact on noise stations along Rangeline Road, Island Road, and
Dauphin Island Parkway. Noise due to the traffic associated with the
proposed cement plant will be no more than 1 dBA (as Leq(24) or Ldn)
greater than traffic noise without the proposed cement plant. Peak
traffic noise levels would increase by no more than 2 dBA (as I^Q) at
any site.
Predicted Noise Levels at Baseline Monitoring Stations Upon Completion
of the Proposed Project
Upon completion of the cement plant, the ship channel will not yet be
fully utilized. Initially, therefore, the operation of the Ideal Basic
Industries facility will have a major impact on noise levels in the
vicinity of the proposed site. The "start up" noise levels for the
operation of the cement plant are given in Table C.7 (see Figure C.13
for monitoring station locations).
Predicted Noise Levels at Baseline Monitoring Stations in 1992
The impact of the Ideal Basic Industries project in the vicinity of the
proposed site should be evaluated in relation to the differences between
future noise levels with and without the proposed cement plant. The
1992 no-action scenario is discussed in Appendix E, Alternatives. Data
from this analysis is included in Table C.8 for the purpose of comparing
the no-action alternative with the impact of the proposed cement plant.
The stations representing residential areas along the ship channel
(Nos. b, 9, and 10) should have initial noise level increases of from
5 to 10 dBA from the operation of the cement plant. However, by 1992,
background levels (without the cement plant) should increase at these
stations due to greater channel use. At this time the differential of
noise levels with and without the cement plant should range from 2 to
3 dBA.
C-45
-------
NOISE (PLANT SITE)
Table C.7. L«in and Leg(24) Noise Levels (dBA) Predicted in the
Vicinity of the Plant Site During Initial Operation of
Proposed Facility (1981)
Baseline
Station
1
2
3
4
5
6
7
8
9
10
11
12
Ldn*
55
54
48
72
48/55
65
55
55/55
53/55
54/55
67
67/55
Leq(24)*
48/70
49/70
45/70
66/70
45
61/55
53/55
48
51
52
59/70
66
Baseline and
Plant Operation
Ldn
63
80
58
73
55
66
55
62
63
63
t
68
Leq(24)
57
74
52
67
51
62
53
56
57
57
t
67
Change in
Noise Levels
Ldn
8
26
10
1
7
1
0
7
10
9
—
1
Leq(24)
9
25
7
1
6
1
0
8
6
5
—
1
* Second numbers refer to the sound levels requisite to protect public
health and welfare according to land use (see Table B.N.2).
t No estimate since the station is in the area of the future turning
basin.
Source: Environmental Science and Engineering, Inc., 1977.
C-46
-------
NOISE (PLANT SITE)
Table C.8. Ldn and Leq(24) Noise Levels (dBA) In the Vicinity
of the Proposed Site Predicted for 1992 (Exclusive of
Any New Industries)
1992
Without Ideal
Station
1
2
3
4
5
6
7
8
9
10
11
12
Ldn*
60
60
48
81
48/55
71
55
64
63
63
t
72/55
Leq(24)*
55/70
54/70
45/70
75/70
45
68/55
53/55
57/70
56/70
56/70
t
61
1992
With Ideal
Ldn
64
80
55
82
55
72
55
66
65
65
t
73
Leq(24)
59
74
51
76
51
69
53
59
59
59
t
61
Differences in
Noise Levels
Ldn
4
20
7
1
7
1
0
2
2
2
t
1
Leq(24)
4
20
6
1
6
1
0
2
3
3
t
0
* Second numbers refer to the sound levels requisite to protect public
health and welfare according to land use (see Table B.N.2).
t No estimate since the station is in the area of the future turning
basin.
Source: Environmental Science and Engineering, Inc., 1977.
C-47
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NOISE (PLANT SITE)
The stations that represent nearby residential areas not along the ship
channel are stations 3, 5, 6, 7, and 12. The differentials above base-
line levels range from 0 to 10 dBA during initial operations (1981) and
the differentials above the background levels (without Ideal) range from
0 to 7 dBA during 1992.
The plant's operations will have several effects in relation to the
noise levels suggested by EPA as requisite-to protect public health and
welfare. Noise levels which would result in hearing loss over a
long-term (40-year) period (Leq(24) of 70 dBA) are not projected for any
off-site areas. Within the plant site, workers will be protected from
excessive sound levels by the plant design which will comply with Mining
Enforcement and Safety Administration (MESA) regulations.
The area within the 55 dBA contour line on Figure C.I7 and the area
immediately outside this contour will have noise levels that could
interfere with outdoor communications and activities. Of the approxi-
mately 32 houses currently within the 55 dBA or greater area, about
12 will be taken by the ship channel project and another 14 residences
are expected to be vacated for industrial/commercial growth by 1992.
In summary, the primary impacts of the operation of the cement plant
will be of a moderate magnitude and of low significance due to the num-
ber of remaining residences immediately across the ship channel. These
impacts will be long-term, but reversible upon plant shutdown. In
addition, the noise analysis was conducted without considering the
attenuation effects of 20-meter (65-foot) high active and dead storage
limestone piles along the eastern boundary of the facility. Due to the
size and nature of these piles, significant reduction (10 to 15 dBA) in
noise levels can be expected in the area to the east of the plant site.
Therefore, the magnitude of the noise impact is slightly conservative
for this area. The secondary impacts of the noise generated from the
plant and its operation are discussed in the Ecology and Socioeconomic
sections.
C-48
-------
SOLID WASTE (PLANT SITE)
SOLID WASTE
CONSTRUCTION IMPACTS
The solid wastes generated from construction activities will be dredged
material from the dock facility, trees from land clearing, and various
construction debris.
Subject to the approval of the Alabama State Docks Department, 1t 1s
anticipated that the spoil from the dredging operations at the cement
plant will be deposited at a U.S. Army Corps of Engineers disposal area.
The primary Impact of this method of spoil disposal would be of moderate
magnitude due to the estimated quantity of 500,000 cubic meters (650,000
cubic yards). The significance of the disposal of dredged materials Is
considered low since the planned disposal area will also be receiving
much larger quantities of dredged material from the ship channel
project. However, the impacts will be irreversible and long-term.
The other construction wastes are to be disposed at the Irvington
Landfill. The wood wastes from land clearing and the construction
wastes from building and clean-up activities will deplete the available
life of the Irvington Landfill. This impact would be of low magnitude
and significance since these wastes are non-toxic and will not be a
major factor in reducing effective landfill life. However, use of a
portion of a landfill's capacity for a low-priority waste such as land
clearing debris may not be the best use of the available area. These
impacts are estimated to be long-term but reversible through future land
uses of the fill area. The large bulk portions, such as trees and
stumps, would most likely cause operational problems for the landfill in
compacting the wastes. Burning or chipping land-clearing wastes may be
used in lieu of or in combination with landfilling. The impacts of
burning are presented in the Air Quality Impacts section.
If all or part of the land-clearing wastes are chipped for on-site use
as mulch, there could be several impacts. First, a positive impact
could be the use of the mulch for erosion protection on the perimeter of
C-49
-------
SOLID WASTE (PLANT SITE)
the work site and for assistance in revegetating specific areas. Sec-
ond, the equipment needed for chipping would produce high-frequency
noise in addition to the other construction noise. However, it is
estimated that this additional noise would not significantly affect the
levels projected in the Noise section of this appendix and would be for
a short duration.
OPERATIONAL IMPACTS
The major components of solid waste from plant operation (refractory
bricks, sediment from settling basins, and raw mill rejects) will be
disposed at the Irvington Landfill. No adverse impact is expected from
landfill ing of these wastes (low magnitude and significance; long-term
but reversible).
The office and lunchroom paper wastes, as well as the packhouse wastes,
represent typical paper and putrescible solid waste and are not expected
to present a problem by being buried at the Irvington Landfill. There
is a potential leachate problem in relation to part of the oily main-
tenance wastes and coal mill rejects. However, in comparison to the
majority of wastes sent to the landfill from other sources, these wastes
are not of sufficient quantity to cause any serious impacts. The impact
of these wastes is of low magnitude and significance, long-term but
reversible.
A local collection firm will be contracted for transferring the solid
wastes to the Irvington Landfill. Removing 2.8 metric tons (3.1 tons)
of solid wastes per day and transporting it to the landfill should not
have a significant impact on the effective life of the landfill area.
In summary, the primary, long-term impact of the solid waste load from
the Ideal Basic Industries plant will be to shorten slightly the active
life of the landfill site, but this impact is expected to be of low mag-
nitude and significance due to the small quantities involved and of low
significance relative to the overall operation of the landfill.
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SOLID WASTE (PLANT SITE)
The reversibility of this waste disposal method is excellent since the
sites can be assigned alternate land uses such as parks, parking lots,
and office and small business complexes.
C-51
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WATER RESOURCES/GEOTECHNICAL (PLANT SITE)
WATER RESOURCES AND GEOTECHNICAL
CONSTRUCTION IMPACTS
Stortnwater Runoff and Erosion
Extensive land clearing and grading activities at the plant site could
result In land erosion and sediment transport during storm events.
Rill and gully erosion may occur In cleared or disturbed areas and
transport sediments into the fresh and salt marshes bordering North Fork
Deer River and into the ship channel. The proposed use of a settling
basin will not completely eliminate the solids content of most of the
runoff. Sediment transport could result in localized increases in tur-
bidity. However, turbidity effects on North Fork Deer River should be
minimal as the existing marsh will capture suspended particulates and
colloidal clays and silts which are washed into it. The impact of this
construction turbidity problem in the ship channel could be of moderate
magnitude. In relation to offsite stormwater discharges from the chan-
nel's entire drainage basin, the quality of the discharge from the Ideal
Basic Industries facility will not be significant. These impacts on
water quality will be short-term and reversible.
Rail Trestle and Access Road
The construction of the rail trestle and access roadway over North Fork
Deer River will cause localized short-term sediment and turbidity
impacts of moderate magnitude. The marsh should assimilate these pollu-
tants in a short time, and irreversible water quality degradation of the
North Fork Deer River system should not occur. Therefore, the impact is
estimated to be of low significance and reversible over the short term.
Ground Water
Clearing and grading, construction of buildings, and other activities at
the plant site will cause sealing and compaction of the clayey soils,
which will decrease the amount of infiltration and increase surface wa-
ter runoff. Because of the relatively small area affected, approximately
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WATER RESOURCES/GEOTECHNICAL (PLANT SITE)
20 hectares (50 acres), the decrease In Infiltration should have a
negligible Impact on groundwater elevations or quality.
Docking Facilities
Construction of the docking facilities will require dredging of 500,000
cubic meters (650,000 cubic yards) and driving piles along the 716-meter
(2,350-foot) waterfront. The bulkhead line will be approximately
60 meters (200 feet) from the toe of the new ship channel. It is antic-
ipated that the dredging for both the plant's dock and the ship channel
can be performed during the same time period, and the dredged material
can be taken to one of the approved disposal areas utilized for the ship
channel project. If these actions could be coordinated, the separate
impacts of both projects could be avoided.
The dredging and pile-driving activities of the construction of the
docking facility will affect the suspended solids concentrations and
the turbidity in the ship channel. This impact is considered to be of
moderate magnitude because of the increase in suspended solids concen-
tration and turbidity, but of low significance due to the small portion
of the channel affected and due to the short-term and reversible nature
of the action.
Oil Spill
Diesel fuel used to power heavy equipment could conceivably be spilled
at the plant site. Construction of a berm around the fueling area,
along with the exercise of normal safety precautions, will minimize the
likelihood that spilled oil would reach surface waters. The magnitude
of contamination of surface waters is thus considered very low, and the
significance is also low since the amount of water affected would be
small. The impact of the spill would be short-term and reversible.
The secondary impacts of the construction activities at the cement plant
are assessed in the Ecology section.
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WATER RESOURCES/GEOTECHNICAL (PLANT SITE)
OPERATION IMPACTS
Material Spills
Spillage of the raw materials used in the cement manufacturing process
could occur. The fact that all of these raw materials are solids rather
than liquids will limit the probable magnitude of spills (e.g., a lime-
stone spill would probably be limited to one clamshell load). These
materials would tend not to disperse in the environment if spilled and
are not considered toxic (Environmental Science and Engineering, Inc.,
1977). Containment and removal should not be a problem. Thus the
impacts associated with raw materials handling are considered to be of
negligible significance.
The present design of the plant shows a 380,000-liter (100,000-gallon)
fuel oil storage tank. The tank will be above ground and will have a
containment earthen berm of sufficient capacity to hold the entire
amount of oil in the tank. Two additional tanks—a 38,000-liter
(10,000-gallon) diesel oil tank and a 3,800-liter (1,000-gallon)
gasoline tank—are also planned, but are not of primary concern because
they will be located underground. The probability of any oil or
gasoline reaching the North Fork Deer River or the ship channel is very
slight. If a spill flows north, it will be contained by the stormwater
catchment area. If a spill flows south into the ship channel, cleanup
should be rather easy due to the poor flushing action expected in the
dead-end channel. Therefore, if a spill does occur, its magnitude and
significance are expected to be low. Any spill would have a short-term,
reversible impact.
Wastewater and Storage Pile Runoff
The wastewater from the plant will consist of approximately 140 cubic
meters (36,000 gallons) per day of cooling system blowdown, 6.6 cubic
meters (1,750 gallons) per day of truck and car washings, 17.7 cubic
meters (4,680 gallons) per day of floor washings, 1 cubic meter
(190 gallons) per day of runoff from the fuel oil tank and containment
berm, and 166 cubic meters (43,800 gallons) per day of runoff from the
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WATER RESOURCES/GEOTECHNICAL (PLANT SITE)
limestone and wet clay stockpiles. This wastewater will be mixed and
treated In the settling pond prior to being discharged Into the ship
channel. The projected quality of this discharge will meet all appli-
cable state and federal standards and should exceed the quality of
receiving waters In the ship channel In terms of critical pollutants.
Thus, the primary water resource Impacts are judged to be low In terms
of both magnitude and significance, but long-term and reversible.
Secondary Impacts are discussed In the Ecology section.
General Stormwater Discharge
Rainfall runoff from portions of the plant site other than material
storage areas and the fuel oil tank will be directed to a grassed catch-
ment area and subsequently discharged to the freshwater marsh north of
the plant. The Impacts associated with this plan Include Increased flow
Into the marsh and possible slight water quality deterioration of North
Fork Deer River. It Is expected that the runoff to the freshwater marsh
will about double due to the Increased runoff coefficient of the sur-
faced areas (buildings, pavements, etc.) and the compacted soils In
unpaved areas. In addition, since all of the runoff will be discharged
from the catchment area, It will Include quantities now draining along
the entire boundary of the freshwater and brackish marsh. The water
quality of the North Fork Deer River should deteriorate only slightly,
if at all, since the catchment area, as well as the marsh, should effec-
tively reduce levels of expected pollutants.
The anticipated magnitude and significance of this impact should be low,
but long-term and reversible. This impact could be avoided by discharg-
ing to the ship channel.
Ground Water
There are no plans to utilize groundwater supplies at the site; there-
fore, groundwater depletion will not be an impact. The only substances
with potential for infiltration into the groundwater supplies will be
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WATER RESOURCES/GEOTECHNICAL (PLANT SITE)
leachates from the uncovered stockpiles of clay and limestone. However,
infiltration should be minimal or non-existent because of the impervious
nature of the clayey soils and the non-hazardous nature of the mate-
rials. The impact of such infiltration would be of negligible magnitude
and significance.
Sanitary Wastes
Disposal of the sanitary wastes generated at the plant site will produce
no water resource impacts since the site will be served by municipal
sewer facilities.
Navigation Aspects
The proposed docking facilities are expected to have no adverse effects
on traffic in the ship channel due to the deep setback, 60 meters
(200 feet), required by the U.S. Army Corps of Engineers.
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ARCHAEOLOGY (PLANT SITE)
ARCHAEOLOGY
Research and on-site investigation have determined that no sites of
archaeological-historical interest will be impacted by either the
construction or the operation of the proposed cement plant. However,
should a site be encountered during construction, the Alabama Historical
Commission will be notified to appraise the discovery.
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ECOLOGY (PLANT SITE)
ECOLOGY
CONSTRUCTION IMPACTS
Land Clearing and Grading
Land clearing and grading activities will result in the loss of
approximately 20 hectares (50 acres) of modified longleaf pine forest.
Although this represents a loss of approximately 50 percent of the long-
leaf pine trees on the property, this impact is of low magnitude due to
the early successional state and disturbed condition of the remnant
forest (see the Ecology section of Appendix B, Baseline). Natural
contributions of nutrients and minerals to the marsh from this section
of the remnant forest will be eliminated; however, the amounts are not
considered significant. Loss of this modified forest is considered of
low significance, irreversible, and unavoidable.
In evaluating the impacts on wildlife habitats, the following standard
game management terms were used:
1. Most favorable habitat—areas which provide food and cover in
sufficient quantities to support game species at a relatively
high carrying capacity.
2. Favorable habitat—areas which support moderate populations of
game species, but do not provide optimum conditions.
3. Marginal habitat—areas with less than optimum conditions which
still support small populations of certain game species.
In relation to wildlife, land-clearing activities will eliminate approx-
imately 20 hectares (50 acres) of favorable rabbit and quail habitat and
approximately 0.6 hectare (1.4 acres) of favorable rail and nutria habi-
tat. Resident wildlife populations described in Appendix B, Baseline
(see Table B.E.2) will be disturbed due to the development of 34.4 hec-
tare (85 acres) of the property. These impacts are irreversible and
represent a long-term loss of natural wildlife resources at the plant
site.
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ECOLOGY (PLANT SITE)
The magnitude and significance of the loss are low for the area because
of the commonness of these wildlife populations throughout the
surrounding area.
The clearing and grading of the upland portion of the site will reduce
possible habitat of 11 animals and 14 plants considered endangered,
threatened, or of special concern (see Tables B.E.7 and B.E.8, Appen-
dix B, Baseline). The magnitude of this impact is low because of the
low probability of these species occurring on the site. The signifi-
cance of this impact is considered low because of the availability of
similar habitat in the area.
Land Access Corridor
The construction of the access road corridor will disturb about
0.5 hectare (1.2 acre)of wetlands, of which about 0.2 hectare (0.5 acre)
will be filled for the roadway embankment. The total freshwater wetland
on-site is about 3.0 hectares (7.3 acres).
The disturbed area represents potentially suitable habitat of the river
frog. This impact could be important because this species holds special
concern status; however, the magnitude of the impact is considered low
because of the uncertainty of the river frog's occurrence on this part
of the site and the significance of the impact is considered low because
of the small area affected.
The construction will also result in a loss of suitable habitat for the
nutria and other marsh-associated species, all of which are common. The
area affected is located at the edge of the marsh adjoining the Airco
access road. Since the freshwater marsh has been substantially altered
by the roadway embankment and grading for the Airco plant, this impact
is considered of low significance. Although this impact is long-term
and irreversible, the magnitude is considered low because such a limited
area will be affected.
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ECOLOGY (PLANT SITE!
Dredging
The ecological Impacts of the dredging for the plant's docking facility
are mainly related to water quality and are discussed in the Water
Resource/Geotechnical section of this document. The biological aspects
of the proposed dredging are considered to be of low magnitude because
of the small area of aquatic habitat affected. The significance is also
rated low in relationship to the intended use of the ship channel
primarily for transportation purposes. The impact of the dredging on
aquatic organisms and habitat is considered short-term and reversible in
relationship to the existing levels found in the barge canal.
Noise
Construction noise will affect a small natural area, but few species of
wildlife are likely to be disturbed. For these reasons, the impact of
construction noise on wildlife is considered of low significance and
magnitude, short-term and reversible.
Stormwater Discharges
Until the catchment area has been constructed (approximately 3 months),
runoff will be contained or slowed down by temporary berms or ditches
prior to flowing directly into the marsh. The resulting silt deposition
will lead to the disturbance of small portions of both the freshwater
and brackish sections of the marsh. However, since a small area will be
affected, the magnitude and significance of this impact are very low.
After the stormwater catchment area is constructed, the runoff from most
of the land being cleared and graded will drain into this area. The
sediment loading of the runoff should be substantially reduced prior to
discharging into the freshwater marsh. Due to the expected level of
treatment, the impact on the freshwater marsh is considered to be of low
magnitude.
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ECOLOGY (PLANT SITE)
The significance is also considered to be low since any loss of wetland
vegetation is expected to be minimal compared to the remaining wetland
area. This impact is regarded as short-term, reversible, and unavoid-
able.
The runoff into the ship channel will be minimal because the existing
topography and proposed grading of the plant site will cause most of the
runoff to flow to the north. The magnitude and significance of such
runoff and the resulting turbidity are negligible.
Oil Spills
As mentioned in the Water Resources/Geotechnical section, there could be
some impacts from on-site oil spills during the construction period
related to the fueling of the construction equipment. Since the quan-
tities, if any, are expected to be small because of a temporary contain-
ment berm, the magnitude of the impact is estimated to be low and the
potential harm to both aquatic and terrestrial species is minimal.
Therefore, the significance should be low, and the impact short-term
and reversible.
OPERATION IMPACTS
Air Emissions
Effects of sulfur dioxide emissions on plants and animals at the plant
site and surrounding areas are expected to be negligible. Injury to
conifers and hardwoods is reported to occur at annual average concentra-
tions greater than 0.03 ppm. Concentrations of 0.5 ppm for 10 hours in
1 month with momentary peaks over 2 ppm cause slight to severe vegeta-
tion injury of an acute nature (U.S. Public Health Service, National Air
Pollution Control Administration, 1969). Existing annual averages
(.005 ppm) and projected 1980 levels (.005 ppm) for the plant site are
well below the injury threshold, and projected 24-hour maximums
(.016 ppm) and 3-hour maximums (.145 ppm) are also below the injury
threshold.
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ECOLOGY (PLANT SITE)
Equivalent information on the injury threshold from particulate emis-
sions is lacking. However, it is considered that particulate levels
will not cause significant injury to vegetation on the plant site or
surrounding area (Darley, 1966). Overall air emissions impacts on vege-
tation during plant operation are expected to be of negligible magnitude
and significance.
Noise
Operation noise from the plant is predicted to range from 60 to 80 dBA
on the non-developed portion of the site. The highest levels will occur
on the plant site proper where little wildlife is likely to be found.
At the southeastern edge of the marsh, interruption of feeding and
reproduction of some wildlife species is expected (U.S. EPA, Office of
Noise Abatement and Control, 1971); however, these effects will be of
low magnitude due to the presence of vegetative and storage pile buffers
and of low significance due to the relative amount of land area
affected. Noise impacts should be long-term but reversible.
Highway Traffic
An increase in "road kills" of "important" (e.g., rabbits) and "non-
important" wildlife species (e.g., turtles and armadillos) will result
from the increase in traffic to and from the site. The significance and
magnitude of this impact are considered negligible in terms of the
numbers of animals killed relative to the natural population levels.
Waterway Traffic
Disturbance of shore and water birds is likely to occur as a result of
increased boat traffic in the ship channel. This impact is of low sig-
nificance and magnitude because of the ability of the birds to adapt,
the short durations of the disturbance, and the limited number of indi-
viduals that will be disturbed.
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ECOLOGY (PLANT SITE)
When the Theodore Ship Channel is completed, tug, barge, and ship traf-
fic will be many times greater than the present traffic on the barge
canal. Vessel movements and prop wash will increase vertical mixing of
water, thereby disrupting the present oxygen stratification. Lifting
oxygen-poor water to the surface could have some adverse effects upon
aquatic communities, although the magnitude of impact is difficult to
estimate.
The Ideal Basic Industries project will be only one of many possible
developments that will contribute to these impacts. Other traffic-
generating activities are difficult to forecast at present. However,
it is probable that the other developments occupying the ship channel
frontage should generate more total traffic than Ideal Basic Industries.
For this reason, the biological impact of the water traffic related to
the operation of the cement plant is considered negligible in both
magnitude and significance.
Wastewater Discharge
Effluent discharges from the Ideal Basic Industries operation are not
expected to produce serious ecological impacts, due in part to the
treatment provided by settling basins. Toxicity studies have been con-
ducted to stimulate the effects of storage pile runoff as realistically
as possible. The basic fish bioassays indicate that the runoff will be
non-toxic. It is concluded that the discharges from the Ideal Basic
Industries facility will be of a low magnitude and significance, and
will be long-term and reversible. Of the other portions of the waste-
water discharge, the truck and floor washes will be of similar chemical
nature as the piles; the algicide used in the cooling tower will be
approved by EPA for its chemical composition; and the containment berm
for the oil tank will discharge only stormwater runoff.
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ECOLOGY (PLANT SITE)
Stormwater Discharge
The stormwater runoff from the plant site will be drained north to the
catchment area, treated to reduce solids loading, and discharged to the
freshwater marsh. The quantity of water will be about double present
conditions due to increased runoff characteristics and diversion of some
natural drainage. The magnitude of this impact is considered to be low
since the level of solids will be reduced. The significance is also low
due to the ability of the vegetation to accept the increased flows and
loadings. This ecological impact is considered to be long-term but
reversible. This impact is avoidable by discharging the runoff to the
ship channel.
Oil Spills
As mentioned in the Water Resources section, permanent operations at the
Ideal Basic Industries facility will require aboveground storage of
about 380,000 liters {100,000 gallons) of fuel oil. A spill into either
the ship channel or the North Fork Deer River could have a serious
impact upon aquatic biota and waterfowl. However, the possibility of
spilled petroleum products reaching surface waters will be minimized by
use of a containment berm around the aboveground tank and by the plant
site draining into the stormwater catchment area to the north. There-
fore, if a spill occurs, its impact should be of low magnitude and
significance, short-term and reversible.
General Human Activities
The plant site, including remaining natural areas, will be fenced off.
Hunting and other recreational activities will be restricted, thus elim-
inating any possible impact due to human activities.
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SOCIOECONOMICS (PLANT SITE)
SOCIOECONOMICS
CONSTRUCTION IMPACTS
Introduction
The construction phase of the proposed Ideal Basic Industries project
will yield major economic benefits to the Mobile area and some adverse
social impacts. Since the project will rely heavily upon the resident
construction labor force, there will not be an influx of workers large
enough to affect the housing market, the adequacy of public facilities,
or other social conditions in south Mobile County. Adverse socio-
economic impacts of the construction project should be limited to very
localized effects involving highway traffic and sensitive land uses.
Economic Activity
The most important socioeconomic effect of the proposed Ideal Basic
Industries construction project is the stimulus provided to the regional
economy. Of the total cost of the project at Theodore, estimated at
more than $16b million in 1977 dollars, approximately $50 million will
be spent in the Mobile metropolitan area. During the 30-month construc-
tion period, the overall increment in personal income as a result of the
project will be between $30 million and $50 million, depending upon the
multiplier used to estimate the spending and responding of income within
the metropolitan economy. Although the income effect of the proposed
construction project will be widely dispersed throughout the Mobile
metropolitan area, at lea,st $10 million, or $5 million per year, should
accrue to residents of south Mobile County. The proposed project thus
will offset the temporary slump which will be created in 1978 by the
anticipated layoff of workers at the Ingalls shipyard in Pascagoula.
(Positive impact of a high magnitude and moderate significance of a
short-term nature.)
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SOCIOECONOMICS (PLANT SITE)
Highway Transportation
Construction activity at the proposed Ideal Basic Industries site will
have some effects upon highway traffic flows in the industrial park
area. The construction labor force will average approximately 360 work-
ers over the 30-month construction period and will peak at approximately
700 persons. In addition to the auto traffic generated by these workers,
some truck trips will be required to bring construction materials to the
site. Allowing for carpooling and truck traffic, the construction
activity will generate about 900 trips per day on the average, and
1,750 trips per day during the peak construction period (referring in
both cases to one-way trips). Access to the construction site will be
provided by a road extending north from the northwest corner of the
Ideal property to Island Road (Hamilton Boulevard). (Until this access
route is passable by construction vehicles and equipment, access will be
via a temporary roadway near the southeastern corner of the property.)
The relative importance of these traffic flows can be established
roughly by referring to the traffic counts at the Rangeline Road/Island
Road intersection mentioned in the baseline description. Table C.9
shows the percentage increases in traffic on Rangeline Road and Island
Road which will be attributable to the proposed construction project,
under the assumption that the existing counts are representative of con-
ditions without the project. It is assumed that traffic generated by
the project will utilize the western section of Island Road (linking to
U.S. Route 90 and Interstate 10) to a somewhat greater extent than the
eastern section extending to the Dauphin Island Parkway.
Table C.9 indicates that during the peak construction period, the pro-
posed project should not increase traffic on any highway segment by more
than 8.3 percent. The average traffic increments for the entire
construction period should be no more than 4.3 percent. Therefore,
given these relative magnitudes, the proposed construction project
should not create any new traffic-related problems in the Industrial
Park area, although the project could add to existing unfavorable
conditions.
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SOCIOECONOMICS (PLANT SITE)
Table C.9. Summary of Traffic Impacts
Island Road west
of Range! ine Road
Rangeline Road south
of Island Road
Island Road between
Rangeline and the
Ideal Access Road
Island Road east
of the Ideal
Access Road
Traffic
Count,
1977*
13,352
15,306
14,676
14,676
Increase in Number of Trips Due
to the Proposed Construction Project
Average
Number
540
90
630
270
Conditions Peak Conditions
Percent Number Percent
4.0 1,050 7.9
0.6 175 1.2
4.3 1,225 8.3
1.8 525 3.6
*Based upon a one-day count of traffic approaching the Rangeline Road/
Island Road intersection conducted by the Mobile County Highway
Department.
Source: Environmental Science and Engineering, Inc., 1977.
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SOCIOECONOMICS (PLANT SITE)
The principal traffic-related problems in the Industrial Park area at
present are peak-hour congestion at the Rangeline Road/Island Road
intersection and congestion and hazards elsewhere on Island Road. These
factors should be largely eliminated when Island Road is widened to
three lanes and the intersection with Rangeline Road is improved (see
the baseline discussion). Although there may be some overlap between
this highway improvement program and the Ideal Basic Industries
construction project, the Island Road improvements are expected to be
completed before the peak construction period of Ideal Basic Industries.
Therefore, the impacts of traffic generation by the proposed construc-
tion project are expected to be of moderate magnitude, low significance;
short-term and reversible.
Land Value and Land Use
The potential impacts of the Ideal Basic Industries construction project
on land use, land value, and general amenity will be limited to a small
number of sensitive land uses located near the plant site. Traffic gen-
eration should not be an important contributing factor in this regard
since the highway corridors to be utilized (i.e., principally Island
Road) contain very few sensitive land uses. The primary effects of the
proposed construction project on nearby properties are expected to be
higher noise levels and some slight Increases in settlcable dust levels.
The most sensitive land areas in question are the residential properties
located east of the plant site on the Dauphin Island Parkway and Deer
River Road, and the dwellings situated between the ship channel, Baker
Sorrell Road, and Claudia Lane.
Two important circumstances regarding these Impacts are: (Da sub-
stantial number of the properties under discussion will be taken for
construction of the Theodore Ship Channel; and (2) the Ideal Basic
Industries construction project will overlap substantially with the ship
channel project in terms of timing.
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SOCIOECONOMICS (PLANT SITE)
On the south bank of the canal, all of the present dwellings that are
directly exposed to noises transmitted across the waterway will be
purchased for the ship channel project. North of the canal, the land
takings will Include one of the two properties which are closest to the
Ideal Basic Industries plant site. The total number of dwellings that
are vulnerable to value and amenity Impacts should be reduced to fewer
than 25 In 1980 due to the ship channel project. The time overlap with
the ship channel construction project Is significant because the
relative noise Increments due to the Ideal Basic Industries project will
be smaller and less critical If the ship channel project Is underway
(see Noise section of this appendix).
Another Important consideration Is the 90-meter (300-foot) wooded buffer
strip which will be left along the eastern margin of the Ideal Basic
Industries property. This strip will constitute a visual screen and
will moderate noise and dust Impacts east of the Dauphin Island Parkway.
These factors, plus the temporary nature of construction activity and
the relatively small number of affected properties, mean that the land
value and amenity Impacts of the construction of the proposed plant are
considered moderate In magnitude, low In significance, short-term, and
reversible.
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SOCIOECONOMICS (PLANT SITE)
OPERATION IMPACTS
Introduction
Permanent operations at the Theodore site will resemble the construction
phase of the proposed project in that there will be very large economic
benefits but no adverse social impacts of great magnitude. A key fea-
ture of the project is that there will be an orderly transition of pro-
duction workers from the existing plant in Mobile to the new facility at
Theodore (after which time the existing plant may be operated by con-
tract labor). This fact will prevent the project from having any signi-
ficant impacts upon housing, public facilities, or social services in
south Mobile County, since there will be no sudden influx of residents
to the area. Adverse socioeconomic impacts will be limited, as in the
construction phase, primarily to transportation system usage and
localized effects on residential land use.
Regional Economic Impact
As mentioned in the project description, the proposed Ideal Basic
Industries manufacturing plant at Theodore will employ 135 persons,
including 26 management and professional workers and 109 skilled or
semi-skilled production workers. The total payroll at the plant will be
approximately $3 million per year in 1977 dollars (including fringe
benefits).
In addition, Ideal Basic Industries has not decided yet whether it will
own and operate its own marine equipment for transporting raw materials
and finished cement. In either case, approximately 50 persons will be
employed in marine transportation related to plant operations, with an
annual payroll of close to one million dollars.
As is typical of highly-capitalized manufacturing operations, the
indirect impacts of the proposed plant upon employment and income will
greatly exceed the direct impacts. The Ideal Basic Industries operation
will purchase a wide variety of commodities within the Mobile SMSA,
including transportation, fuels, electric power, water and sewer
C-7U
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SOCIOECONOMICS (PLANT SITE)
services, and other assorted services such as engineering. Purchases
from the trucking Industry alone will support roughly 75 full-time
drivers, exclusive of support and maintenance personnel.
The Income received by workers at the proposed plant and by employees of
firms providing services to the plant will be spent and respent within
the local economy and thus will create additional jobs. Local purchases
by the latter firms will contribute to this multiplier effect. It Is
estimated that the total employment Impact of the proposed facility
within the Mobile Standard Metropolitan Statistical Area (SMSA) will be
approximately 500 jobs. This estimate assumes an employment multiplier
of 2.7, applied to the 185 jobs directly created In cement manufacturing
and water transportation. Such an assumption appears reasonable because
the average multiplier for all "basic" employment 1n the Mobile SMSA 1s
commonly estimated at between 2.0 and 3.0.
The existing Ideal Basic Industries cement plant In Mobile employs
approximately 150 workers. As previously mentioned, most of these
workers will be transferred to Theodore upon start-up of the new facil-
ity. Contract labor will be utilized to keep the old plant in operation
at least until the new plant Is In full production, and perhaps for a
considerable period thereafter. Plans for the new facility have not
been predicated upon the Immediate closing of the old plant. However,
the employment Impacts attributed to the Theodore project should be
adjusted to reflect the fact that this project will probably accelerate
the shutdown of the older facility. Two considerations are relevant 1n
this regard:
1. The existing cement manufacturing plant In Mobile Is rapidly
approaching economic obsolescence, due In part to shifts In the
cost and availability of fuels and raw materials. Therefore,
It Is very unlikely that this plant would be In operation at
the end of the baseline forecasting period (1992) even If the
proposed facility at Theodore were not constructed.
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SOCIOECONOMICS (PLANT SITE)
2. Employment at the new facility will not exceed employment at
the existing plant (excluding water transportation), but the
Theodore facility will produce three times as much cement. The
indirect employment impacts of the new facility will thus be
substantially greater, due to the larger inputs of transporta-
tion and other goods and services required. It is estimated
that the total employment generated directly or indirectly by
the proposed plant at Theodore will exceed by more than 100
workers the corresponding employment effect of the existing
facility.
Table C.10 indicates the net employment impact of the Theodore project
under the worst-case assumption that the existing plant in Mobile will
close soon after completion of the new facility in late 1980. It is
assumed that, without the proposed project, the old plant would remain
in operation until 1985. The indirect impacts due to construction
activity during 1978-1980 are estimated conservatively by utilizing an
employment multiplier of only 1.9 (meaning that indirect employment
equals 0.9 times direct employment). An employment multiplier of 2.5 is
assumed for the existing cement plant.
For each of three time intervals, the first column of Table C.10 lists
the total number of workers employed by Ideal Basic Industries and their
construction contractors. The second column lists the estimated indi-
rect employment effects. The figures for 1978 through 1980 include
employment at the proposed construction project and the existing cement
plant, whereas the gross employment effects after 1980 consist of only
the proposed new plant. The right-hand portion of Table C.10 pertains
to the net effects of the new facility. The employment generated
directly and indirectly by the existing plant is subtracted from the
gross employment effects for both the 1977-1980 period and the 1980-1985
period, the latter because of the assumption that the old plant would
have remained in operation were it not for the new facility.
C-72
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Table C.10. Gross and Net Employment Attributable to Ideal Basic Industries Under Worst Case Conditions;
Mobile SMSA
o
co
Gross Employment Generated
By Ideal Basic Industries
Operations
Direct Indirect
Time Interval
1978-1980 510 550
(24 months)
1980-1985 185 315
1985-1992 185 315
Total Man-Years 3,240 4,880
Average Employment
for 14-Year Forecast
Period
Net Employment Attributable
to Proposed New Manufacturing
Facility
Direct Indirect Total
360 325 685
35 90 125
185 315 500
2,190 3,305 5,495
393
Comments
Construction phase
for new facility;
existing plant in
operation.
New facility in
operation; old
plant shut down as
a consequence of
new facility.
Old plant would be
terminated with or
without the new
facility.
SOCIOECONOMICS (PLANT
Source: Environmental Science and Engineering, Inc., 1977.
-------
SOCIOECONOMICS (PLANT SITE)
The fourth row of Table C.10 presents the total man-years of employment
in the Mobile SMSA which will be generated directly and indirectly by
Ideal Basic Industries over the period from 1978 to 1992, if the pro-
posed facility is constructed as planned. The total is more than 8,000
man-years, of which approximately 5,500 man-years represent the net
effect of the new manufacturing facility. About 25 percent of this net
effect involves construction of the plant, and 75 percent is attri-
butable to permanent operations. As shown by the last line of Table
C.10, the net effect amounts to an average of nearly 400 workers
employed in the Mobile SMSA because of the proposed project during the
14-year period. Thus, the project should provide a very substantial
boost to the local economy even under the worst-case assumption that the
existing cement plant is phased out as soon as possible. (Positive
impact of high magnitude and moderate significance; long-term.)
Transportation
The transportation requirements of the proposed project at Theodore are
discussed in the Resources Required section of Appendix A, Project
Description. There will be a heavy reliance on water transportation for
delivery of raw material inputs (limestone, clay, sand, iron ore, and
possibly gypsum and coal), and for shipments of finished cement. How-
ever, significant impacts on the waterway system are not expected to
result from this usage.
Ample dockage space will be provided to allow efficient utilization of
the waterfront area at the plant site. Sufficient vessel control will
have to be exercised to prevent overlapping limestone deliveries, and to
prevent deliveries of sand, clay, and iron ore from occurring at the
same time. However, the traffic created by the proposed cement plant
can be accommodated without disrupting the other anticipated traffic in
the ship channel. The downriver shipments of limestone, clay, sand, and
iron ore will increase by 5 to 10 percent the total tonnage passing
through the Mobile harbor area. Officials of the Alabama State Docks
Department feel that this additional traffic will not create any
C-74
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SOCIOECONOMICS (PLANT SITE)
significant congestion problems, although there may be occasions
when limestone tows are detained briefly while other vessels are
maneuvering (Alabama State Docks Department, 1977).
The Ideal Basic Industries limestone shipments down the Alabama River
will more than double the existing freight traffic on the Alabama-Coosa
river system. At present, this traffic consists largely of sand,
gravel, and crushed rock shipments originating In the southern reaches
of the Alabama River. The total volume of shipments In both directions
was only 695,000 metric tons (766,000 tons) In 1976 (see Table C.ll).
The traffic generated by the limestone quarry could thus represent a
300 percent Increase In waterborne commerce near the quarry site. Since
the present traffic Includes an average of only one barge tow and
2.5 other vessels per day In either direction, It does not appear likely
that the Increased waterway usage will create significant congestion or
hazards. (Negligible Impact.)
Rail transportation could be utilized for delivering up to 270,000
metric tons (300,000 tons) of materials per year to the Theodore site
and for shipping as much as 180,000 metric tons (200,000 tons) per year
of finished cement. The outbound rail shipments of cement are likely to
be substantially less than the latter figure, however, since rail trans-
portation lacks both the cost advantages of water transport and the
speed and flexibility of highway shipment. A potential impact of rail
transportation involves the fact that rail traffic to and from the Ideal
Basic Industries plant site must utilize a grade crossing of the State
Docks Terminal Railway and Rangeline Road (plus an additional grade
crossing of Island Road if the traffic is northbound). The Rangeline
Road grade crossing will ultimately be eliminated, but will probably be
in existence for some time after the Theodore plant is in operation.
The potential disruption of highway traffic at this point due to railway
usage is considered a very minor impact, however, since even the maximum
tonnage figures cited above would imply an average of only 2 unit trains
per week. (Negligible impact.)
C-75
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SOCIOECONOMICS (PLANT SITE)
Table C.ll. Alabama River Traffic through Claiborne Lock and Dam, 1976
Number of vessels
Barge tows
Individual barges:
Loaded
Empty
All other vessels
Total tonnage (metric
tons}
Total for Year
Up Down
176 181
74 423
420 75
434 502
105,500 589,700
Average per Day
Up Down
0.5 0.5
— —
— —
1.2 1.3
— —
Source: U.S. Army Corps of Engineers, 1977,
C-76
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SOCIOECONOMICS (PLANT SITE)
The highway traffic generated by the Ideal Basic Industries plant at
Theodore will include auto trips by employees and visitors, and outbound
shipments of cement by truck. Auto traffic will average roughly 300
one-way trips per day. Some of these trips will occur during off-peak
hours since the plant will be a 24-hour operation. Since this auto
traffic will constitute only about a 3 percent increase for Island Road,
it is considered a very minor impact. (Negligible impact.)
The truck traffic generated by the proposed facility at Theodore will
amount to an average of 380 outbound shipments per week ('or 760 one-way
truck trips per week), according to present plans. If a 50-hour work
week is assumed, there will be a truck entering or leaving the plant
site on an average of once every 4 minutes. Truck arrivals and depar-
tures actually will be distributed unevenly over time, so that much
higher volumes may occur during certain periods. The cement truck
traffic could have an appreciable impact upon traffic flows in the
Industrial Park area because of the slow acceleration of these vehicles
when fully loaded. The magnitude of this impact should decline in 1982,
however, when Rangeline Expressway is completed north to Interstate 10,
since the expressway should divert traffic away from Island Road. Truck
traffic is rated as an impact of moderate magnitude and low signifi-
cance, and is considered long-term but reversible.
Land Value and Residential Amenity
The proposed Ideal Basic Industries manufacturing facility could have
both positive and negative effects upon land value in nearby areas.
Positive effects would result from the employment opportunities created
at the plant and the general stimulus to economic growth in the
industrial park area. Negative effects would involve the reduced
desirability of the area near the plant site for residential
communities.
An evaluation of positive and negative influences on land value must
consider: (1) the distance of land areas from the proposed cement plant;
C-77
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SOCIOECONOMICS (PLANT SITE)
and (2) the Inherent marketability characteristics of existing proper-
ties. It is judged that any negative effects of the proposed facility
on residential amenity will be negligible beyond a distance of about
1.6 kilometers (1 mile) (assuming that traffic-related effects will not
be a problem). Noise impacts will dissipate rapidly over distance.
The marketability question has to do with the ability of residential
property owners to sell their properties on favorable terms. As noted
in the Socioeconomics section of Appendix B, Baseline, it is judged that
the owners who might lack flexibility in this regard would be those
whose property values currently exceed $40,000 (which would be generally
beyond the means of industrial workers as potential buyers). However,
most of the residential properties which fit this description, with the
exception of the Deer River properties discussed below, are located
2.4 kilometers (1.5 miles) or more from the proposed plant site, and
thus are not vulnerable to amenity impacts.
In several intermediate areas, located between 0.8 and 1.6 kilometers
(1/2 and 1 mile) from the proposed cement plant, there may be some
amenity impacts, but these are likely to be more than offset by the
positive influence of the Ideal facility on land value. These areas
include lower San Marino Drive to the north of the plant site and
Claudia Lane to the southeast. All of these properties would be highly
marketable to industrial workers because of their location, so that
owners should have the option of selling on favorable terms.
The residential properties which are considered most vulnerable to net
adverse impacts are those located within roughly 1 kilometer (0.6 mile)
of the proposed plant. As noted earlier, a number of the dwellings that
currently exist in this area will be removed for construction of the
ship channel or for conversion of land to industrial use. The land use
conversions will be related to opportunities for economic gain created
by the ship channel project and would occur with or without the proposed
Ideal Basic Industries cement plant. The outcome should be that the
C-78
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SOCIOECONOMICS (PLANT SITE)
number of residential properties vulnerable to net adverse impacts by
the cement plant will number fewer than 25 in 1980, and fewer than 10 in
1992. In summary, the land value impact of the operation of the cement
plant is considered to be of moderate magnitude but of low overall
significance, long-term but reversible.
Local Government
The proposed project may have some effect upon local government expend-
itures. There will be no major fiscal impacts on local government,
however, since the Ideal Basic Industries operation will not generate
significant demands for public facilities or services. Security and
fire protection for the site will be provided primarily internally. The
costs of all utilities provided to the plant will be covered by user
charges. Thus, the external costs generated by the Ideal Basic Indus-
tries operation should be limited primarily to the construction and
maintenance of transportation facilities. Waterways are developed and
maintained by the U.S. Army Corps of Engineers and do not involve local
expense. The construction of highway improvements serving the Theodore
Industrial Park area will be funded in large part by the State of
Alabama. Employment at the Theodore plant will not create significant
fiscal impacts by attracting new residents, who would add to public
service demands, because most of these workers will- transfer from the
existing plant in Mobile. Therefore, the main costs to local government
that might be attributable to the proposed Ideal Basic Industries
project will be a minor share of city and county roadway maintenance
expenditures, and perhaps a small increment in the general adminis-
trative costs of county government. (Negligible impact.)
C-79
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AIR QUALITY (QUARRY SITE)
QUARRY SITE
AIR QUALITY
CONSTRUCTION IMPACTS
Construction impacts associated with the quarry will be similar to those
described for the plant site. Actual emissions from construction activ-
ities are very difficult to quantify, but are dependent upon the types
of operations, the level of activity, and the meteorological conditions.
Construction activities at the quarry site will include land clearing,
grading, roadway construction, and heavy machinery operations. Fugitive
dust will be caused by these activities; suspended dust emissions from
heavy construction operations have been generally estimated at
2.7 metric tons per hectare (1.2 tons per acre) per month of activity
(U.S. Environmental Protection Agency, 1975).
If permitted by the Alabama Air Pollution Control Commission, the con-
struction wastes of trees and vegetation will be burned in an air-blower
type pit burner to reduce emissions.
As in the case of the plant site, effective methods of control such as
water sprays and controlled burning will mitigate impacts of construc-
tion on local air quality. These measures are discussed thoroughly in
Appendix E, Mitigating Actions.
Tentative construction plans for the quarry operation place an 18-month
duration on construction activities. The frequency of operations will
vary greatly during the construction period. Excavations and land
clearing and grading will last approximately 3 months, during which time
construction impacts on the local area will be greatest due to the
frequency and types of operations conducted.
In summary, construction activities at the proposed quarry site are
expected to have a short-term impact in the immediate vicinity of the
C-80
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AIR QUALITY (QUARRY SITE)
operations on the quarry property, primarily upon levels of suspended
particulate matter. Levels of this pollutant are expected to increase
during construction; however, ambient air quality standards are not
expected to be exceeded. Impacts in the area (off-site) are expected to
be of low magnitude and significance, as well as short-term and rever-
sible. The impact from burning vegetative wastes could be avoided by
chipping and landfill ing (see Appendix E, Alternatives).
OPERATIONAL IMPACTS
Emissions of fugitive dust from quarrying activities and their potential
impacts are difficult to quantify accurately. However, the impacts of
quarrying are expected to be similar to the impacts of construction
activities. Suspended particulate matter levels will increase on-site
during quarrying, and the impacts will be confined to the property
boundaries. Much of the fugitive dust generated will settle out in the
quarry area. Air quality standards are not expected to be violated.
Short-term, localized impacts will depend on the operations beijig con-
ducted, weather conditions, and the effectiveness of the fugitive dust
controls (water sprays) to be used. In addition, the naturally high
moisture content of the overburden and limestone should suppress dust
emissions.
Because fugitive dust will be the only pollutant emitted in signifi-
cantly measurable quantities, significant impacts associated with other
pollutant releases (such as those from vehicular exhausts) are not
expected. No perceptible increases in air quality levels of other
pollutants due to quarry operations are expected.
Primary impacts on-site are expected to be of moderate magnitude in the
quarrying areas but of low significance due to the lack of receptors.
The other process areas which could generate dust (breaker, conveyor,
stockpile, barge loader) will use water spray systems, and their primary
impacts are expected to be of low significance and magnitude due to the
effectiveness of the dust controls. These impacts would be long-term
but reversible. Secondary impacts are discussed in the Ecology section.
C-81
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NOISE (QUARRY SITE)
NOISE
CONSTRUCTION IMPACTS
Noise from construction activities at the quarry will originate from
land-clearing and grading operations and from the building of permanent
structures, docking facilities, and clarification basins.
Equipment Noise
Equipment associated with earthmoving, lifting, welding, paving, pile-
driving, and transportation will contribute to construction noise.
Table C.12 lists the types and numbers of equipment originally projected
to be used at the quarry site during the highest level of construction
activity. This table also includes noise characteristics of each piece
of equipment, assuming that each was retrofitted with the most feasible
noise suppression devices available in 1973.
Traffic Noise
There will be traffic noise due to the 250 workers who will be commuting
to the quarry site at the height of construction and to the associated
truck traffic. These noise sources are expected to be intermittent and
short-term and to have an impact of low magnitude and significance on
the local area.
Construction Noise Analysis
Construction activities are expected to last about 18 months. The
height of construction activity will occur between the ninth and twelfth
months, based on information from the contractor, Brown & Root, Inc.,
ba pieces of heavy equipment were assumed to be in use between the third
and sixth months (the period of greatest noise impact).
For the purposes of this study, it was assumed that at any given time
throughout an eight-hour day, 7b percent of the equipment will be
C-S2
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NOISE (QUARRY SITE)
Table C.12.
Types, Numbers, and Noise Characteristics of Heavy
Pieces of Equipment Required During Busiest Phase of
Construction at Quarry Site
Equipment
Welding
Welders
Compressors
Generators
Paving and Concreting
Backhoes
Mixers
Vibrators
Concrete Finishers
Pile Drivers
Transporters
Trucks
Number3
10
5
2
5
2
5
1
Noise Level in
dBA at 15 meters
(50 feet)b
Earthmoving
Dozers
Scrapers
Graders
Loaders
Rol 1 ers/ Compactors
Carry-Alls
Lifting
Cranes
Forklifts
7
8
4
4
3
4
2
2
80
88
85
79
89
--
83
—
23
81
78
85
85
76
101
91
Sources: a Brown & Root, 1977.
b Schomer and Homans, 1975. These are the old (July 1,
1973) li.S.A. standards for government contractors. They
were superseded by lower noise level requirements on
January 1, 1975. Values from the old standards were used
in the models for conservative estimates of expected noise
levels.
C-83
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NOISE (QUARRY SITE)
actually in operation. Furthermore, it was assumed that the character-
istics listed in Table C.12 were applicable.
With respect to the precise placement of the equipment, several simpli-
fying assumptions were made. It was assumed that the equipment will be
randomly distributed throughout an area measuring 730 by 850 meters
(2,400 by 2,800 feet). The effects of 88 point sources were combined
and reassigned to nine large identical theoretical point sources.
Construction Noise Impacts
The combined contributions of the nine theoretical noise sources to
environment noise levels are displayed in Figure C.18. Since there is
sparse forest in all directions, a correction of 2 dBA per 30 meters
(100 feet) was made. No more than 10 dBA were subtracted in this manner
at any location. The "acorn" shape is caused by the discontinuity of
the woods across the Alabama River.
Towards the north, south, and east, noise impacts will not extend off
the Ideal Basic Industries/McWill iams property. To the west, noise
levels will be above 55 dBA for at least 0.8 kilometer (0.5 mile).
Predicted Noise Levels at Baseline Monitoring Stations
All baseline monitoring stations were located on the east side of the
Alabama River and near the property boundaries. At none of the stations
will noise levels exceed 55 dBA during the construction phase.
In summary, the primary noise impacts of the quarry's construction
activity are estimated to be of low magnitude and significance,
short-term, and reversible. The secondary impacts are presented in the
Ecology section.
C-84
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(7) RANOONS CREEK
(7) EAST OF QUARRY SITE
NORTH OF QUARRY SITE
Figure C. 18
EQUAL SOUND LEVEL (l_dn) 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
C-85
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NOISE (QUARRY SITE)
OPERATION PHASE
Operation noise from the cement plant will originate mainly from
removing overburden, quarrying, loading material onto an apron-fed
breaker, stockpiling, and barge-loading. Other sources of noise will
include automobile traffic to and from the quarry site and tugboat
traffic moving the barges of limestone.
Equipment Noise
Equipment associated with earthmoving, lifting, and transportation will
contribute primarily to operational noise. Table C.13 lists the types
and numbers of equipment pieces to be utilized at the quarry site during
full-scale operation. This table also includes noise characteristics of
each piece of equipment, assuming that each was retrofitted with the
most feasible noise suppression devices available in 1973.
The noise characteristics of the material-handling equipment (conveyors)
are not known, but should be minimized by the fact that this equipment
is electrical.
Traffic Noise
Traffic noise will be due to tugs associated with barge traffic and due
to employee commuter traffic. The tugboat traffic, which will be of an
intermittent and short-term nature, should contribute only slightly to
day-night (Ldn) noise levels. Table C.14 lists various tug and
barge combinations and their noise characteristics at a distance of
30 meters (100 feet) from a channel. Since at most only two trips per
day will be made along the Alabama River by tow barges associated with
Ideal Basic Industries, these trips may be excluded from this analysis.
Commuter traffic was not analyzed because only 19 employees will work at
the site.
C-86
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NOISE (QUARRY SITE)
Table C.13.
Types, Numbers, and Noise Characteristics of Heavy
Pieces of Equipment Required During Operation of the
Quarry Site
Equipment
Number3
Noise Level in
dBA at 15 meters
(50 feet)b
Earthmoving
Dozers
Scrapers
Graders
Loaders
Tractors
Pickup
3
2
1
2
1
1
85
88
85
79
92
~ (85)*
Materials Handling
Apron-fed Breaker
Belt Conveyors
Stacker
1
2
1
- (85)*
- (85)*
- (85)*
* Assumed for this analysis
Sources: a Ideal Basic Industries, Inc., 1977.
b Schomer and Homans, 1975. These are the old (July 1,
1973) G.S.A. standards for government contractors. They
were superseded by lower noise level requirements on
January 1, 1975. Values from the old standards were used
in the models for conservative estimates of expected noise
levels.
C-87
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NOISE (QUARRY SITE)
Table C.14. Noise Levels Associated with a Tug and Associated
Barges (dBA)
Item
Tug Alone
Large Tug with 4 Barges
Loaded
Small Tug with 2 Barges
Loaded
Small Tug with Barges
Empty
Large Tug Pushing Barge
at Dock Area
LIO
49
56
56
55
64
1-50 LgQ
47 42
55 54
54 51
51 51
62 58
Source: USC, Incorporated, Consulting Engineers, 1974,
C-«8
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NOISE (QUARRY SITE)
Operational Noise Analysis
For this analysis, the following simplifying assumptions were made:
assumption of a flat plain, all noise coming from a single point source,
and the use of 100 percent of the equipment at any single time. This
assumption is conservative since the equipment used will normally be
downslope (towards the Alabama River) in the quarry cut (see Appendix A,
Project Description).
Logarithmic addition of the contributions to noise levels of the equip-
ment listed in Table C.13 yielded an equivalent point source of 97.5 dBA
at 15 meters (50 feet). Geometric attenuation accounted for a drop of
6 dBA for every doubling of distance from the theoretical point source.
A correction of 2 dBA for every 30 meters (100 feet) of sparse forest
was made, although no more than a 10 dBA drop was ever assigned any
point regardless of distance. No correction for atmospheric attenuation
was made so that the figures for noise levels should be rather conser-
vative. The quarrying plan involves several working faces that will
extend outward from the docking facility; therefore, the noise level
expected is shown as a 55 dBA line that would be formed approximately
1 kilometer (0.6 mile) from any area to be quarried. Results of the
foregoing analysis are displayed in Figure C.19.
Due to their distance from the active quarry sites [a minimum of 3 kilo-
meters (about 2 miles)], it is believed that the baseline monitoring
stations will record only a small increase in ambient noise levels.
In summary, the primary noise impacts of the limestone quarry's opera-
tion are estimated to be of low magnitude and low significance,
long-term, and reversible. No existing residences are projected to be
impacted by a noise level greater than 55 dBA from the quarrying activ-
ities. The secondary impacts are presented in the Ecology section.
C-89
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Figure C.I9
ESTIMATED BOUNDARY OF SOUND LEVEL, Ldnof
55 DECIBELS, SURROUNDING THE QUARRY SITE
DURING OPERATION S^-^Bi^^
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
C-90
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SOLID WASTE (QUARRY SITE)
SOLID WASTE
CONSTRUCTION IMPACTS
The solid wastes resulting from quarry construction include land-
clearing wastes (timber) and construction debris.
The proposed action is for the vegetative wastes from clearing
40 hectares (100 acres) to be burned or chipped. Since it is expected
that the marketable timber will be removed prior to quarry construction,
the remaining wastes will be bulky or will be small pieces of trees and
brush. The bulky items are not feasible to be chipped; therefore, they
will be burned in an air-blower type pit burner. This type of burning
is expected to create less smoke than typical open burning; however, it
could still have localized primary impacts of short duration (a 3-month
period) and of low magnitude. The significance of these impacts should
be low due to the large land area and the sparse population.
It should be feasible to chip the smaller pieces of vegetative waste to
be used for mulch on-site. The use of a chipper would produce high fre-
quency noise in the immediate area of clearing, but the impacts are not
considered significant off the property. The mulch would be beneficial
for use as erosion protection and for revegetation of disturbed areas
not to be quarried or utilized during the first few years of operation.
The other construction wastes (lumber, concrete, paper, and metal
scraps) will be hauled to the Monroe County Landfill for disposal. The
primary impact of this action should be of low magnitude because of
the expected small quantities and of low significance because of the
non-toxic nature of the wastes and the availability of additional land
for solid waste disposal in Monroe County. This impact will be
long-term and reversible.
C-91
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SOLID WASTE (QUARRY SITE)
OPERATION IMPACTS
As summarized in Appendix A, Project Description, the quarry operation
is expected to generate 137 metric tons (151 tons) of solid wastes per
year. About 4 metric tons (5 tons) will be disposed of off-site at the
Monroe County Landfill. The only potential problem involves the
oily-type wastes which are not feasible for recycling and which, if not
properly disposed, might produce a leachate. However, based on the
expected quantities, the magnitude of this leachate should be very small
and should not cause a serious problem. An advantage of off-site
disposal is that it will be performed by a qualified staff working with
quantities large enough to promote proper disposal techniques.
The remainder of the solid wastes, approximately 132 metric tons
(146 tons) per year, will consist of soil and rock particles removed
from the clarification basins. These solid wastes will be used for
reclamation and will have an impact of low magnitude and significance in
view of the total reclamation operations.
In summary, the primary impacts from the operations of the limestone
quarry, relative to solid waste disposal, are expected to have a low
magnitude and low significance due to the small quantities of wastes and
their methods of disposal. These impacts are considered long-term but
reversible since both methods will actually reclaim the disposal areas
to other land uses.
C-92
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WATER RESOURCES/GEOTECHNICAL (QUARRY SITE)
WATER RESOURCES AND GEOTECHNICAL
CONSTRUCTION IMPACTS
Clearing and Grading
The clearing and site preparation activities at the quarry will result
in increased erosion of the land surface during storm events, even with
the proposed erosion prevention methods discussed in the Environmental
Safeguards section of Appendix A, Project Description. However, most
stormwater runoff from the construction area will be routed through
clarification basins where solids levels can be reduced. A
settleability study using soils collected at the quarry site has been
conducted. Preliminary results indicate that for common hydrologic
events, sufficient settling should occur in the clarification basins to
allow the effluent to meet the federal suspended solids standard of
30 mg/1 if a detention time of 24 hours is maintained.
The outflow from the settling basins may not always meet the desired
discharge level during unusual hydrologic events, especially during
storms that exceed the 10-year, 24-hour design rainfall, which would
cause the basins to overflow. In addition, it will not be possible to
treat all stormwater runoff at the start of construction (for example,
during the construction of the retention dams). On the other hand, an
important characteristic of the project is that all land affected by
construction (other than the access roadway) and by the quarry start-up
drains either directly into the Alabama River or into the tributary
stream reaches that are inundated by the river at high water. The
suspended sediment concentrations in the Alabama River are already high
and, in fact, tend to exceed the proposed discharge limitation of
30 mg/1 except at low flow. Thus, sediment from the quarry construction
site should have a primary impact on water resources of a low magnitude
and low significance. This impact is reversible and short-term. The
secondary impacts are discussed in the Ecology section.
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WATER RESOURCES/GEOTECHNICAL (QUARRY SITE)
Docking Facilities
Construction of the docking facility at the quarry site will have mini-
mal impacts upon the Alabama River because no dredging will be involved.
The particulate material cast into suspension by pile-driving should be
of a small quantity. The water quality impact is considered to be low
in magnitude and significance, short-term and reversible.
OPERATION IMPACTS
Stormwater Runoff
Erosion and sedimentation will be controlled by contour terracing,
grading, vegetation, and clarification basins. Based on the findings
of the settleability study, the discharges from these basins should meet
the suspended solids standard of 30 mg/1 except during a storm greater
than the 10-year, 24-hour design storm (both state and federal regula-
tions allow for discharges greater than 30 mg/1 during storms greater
than a 10-year, 24-hour storm). Therefore, the quantities of solids in
the runoff from areas of quarrying and unvegetated reclaimed land
normally should be low and should not affect the water quality of the
Alabama River and Thompson Mill and Hoi linger creeks.
The impact of quarrying should not be as great as the current conversion
of forestland to improved pasture which does not include erosion or
sedimentation controls. The water quality impact of Stormwater runoff
should be of low magnitude because of the effect of the erosion controls
and clarification basins and of low significance relative to the effects
of land conversion to pasture and to the baseline water quality of the
Alabama River. These impacts are considered long-term but reversible.
Sanitary Waste
The sanitary wasteloads from the 19 employees of the quarry will be
treated in a septic tank and soil absorption system. This method of
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WATER RESOURCES/GEOTECHNICAL (QUARRY SITE)
sanitary waste disposal is not expected to have impacts on surface water
or groundwater quality (negligible impact).
Material Spills
The barge loading operation should not significantly affect the Alabama
River or its shoreline; however, it is possible that some of the lime-
stone will be spilled into the river. Large limestone spills would be
removed from the river channel; however, due to its chemical nature,
limestone will not adversely affect the water quality of the Alabama
River. Therefore, these impacts are assessed to be negligible. Oil
spills are not anticipated due to the use of an underground tank.
Navigation
The proposed barge-loading terminal should not significantly affect the
safety of navigation on the Alabama River. At the proposed site the
river is approximately 180 meters (600 feet) wide while the docking
facilities will protrude only about 28 meters (90 feet) from the east
bank. No adverse impacts are expected.
Topography and Drainage
The major geotechnical impact at the quarry site will be the change in
land forms resulting from quarrying operations. The elevation of the
land will be reduced by approximately 8-15 meters (25-50 feet) and will
result in a gently rolling terrain sloping to the southwest. The lower
areas will be elevated sufficiently above the river to be reclaimed for
pasture or other use. Whenever possible, slopes will be limited to a
maximum grade of 3:1, and surfaces will be graded so that there is a
smooth transition from disturbed to undisturbed areas. Overall land
slopes at the quarry site will be somewhat less than under present
conditions.
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WATER RESOURCES/GEOTECHNICAL (QUARRY SITE)
The reclaimed areas will contain a soil that will be a mixture of the
various baseline horizons. Topsoil will be replaced as the surface
horizon to help establish vegetation for pastureland and to control
erosion. A small amount of limestone 1"s expected to be removed during
overburden removal operations and will be mixed with the various
horizons.
The drainage areas for Thompson Mill (Marshalls) Creek and Hollinger
Creek will' also be altered slightly. Some of the tributary valleys may
be eliminated, but the channels of Thompson Mill and Hollinger creeks
will remain with at least a 30-meter (100-foot) setback from developed
areas. The final drainage pattern is expected to follow the quarry
floor in a southwest direction and to reduce the Thompson Mill Creek
watershed by about 10 percent. The areas south of the clarification
basins probably will drain into Hollinger Creek and thus would increase
slightly its watershed area.
Although irreversible and long-term, the overall geotechnical impacts
of quarrying operations are considered of low magnitude and significance
(see Ecology section for secondary impacts).
Ground Water
No adverse groundwater impacts are expected as a result of quarry
operations. The existing aquifer system includes sand/clay layers and
permeable limestone formations overlying the relatively impermeable
Yazoo clay. Given the present discharge situation along the creeks and
river (i.e., springs and seeps), it is likely that the water surface is
drawn down close to the Yazoo clay contact, which will be 3 to 5 meters
(10-15 feet) below the quarry floor.
During quarrying operations, the water table should not be affected at
distances greater than about 60 meters (200 feet) from the quarry face.
After reclamation, the sand/clay aquifer system at the site may be
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WATER RESOURCES/GEOTECHNICAL (QUARRY SITE)
re-established In the reclaimed land when the sediments are mechanically
redeposlted. Because of the reduced relief, Infiltration may be greater
than at present, and sediment transport may be lower than before the
quarrying operation. The aquifer systems beneath the Yazoo clay are
protected from infiltration of quarry runoff by the impervious nature of
the Yazoo clay.
Significant amounts of groundwater, other than for employee use
[1.8 cubic meters per day (475 gpd)] are not anticipated for the quarry
operation, so that drawdown in the lower aquifer is estimated to be
negligible.
The primary impact on groundwater supplies is of low magnitude due to
possible localized drawdown in the sand and limestone aquifer caused by
quarrying activities. Since this impact is estimated not to affect
off-property wells, it is of low significance but will be irreversible
and long-term.
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ARCHAEOLOGY (QUARRY SITE)
ARCHAEOLOGY
In accordance with the Ideal Quarry Plan, archaeological Site No. 8 will
not be disturbed by the quarrying activities. Site No. 6, however, will
probably be disturbed as it is located in the area expected to be quar-
ried within the first 15 years (see Figure C.20 for locations of these
sites).
A copy of the archaeological/historical survey of the quarry site was
sent to the Alabama Historical Commission on August 11, 1977, along with
a description of the Quarry Plan. The Commission concurred with the
archaeologist that disturbance of Site No. 6 could result in the irre-
trievable loss of potentially valuable information critical to our
archaeological-historical understanding of the past.
On August 29, 1977, the Alabama Historical Commission, office of the
state historic preservation officer, stated that their approval of the
quarrying activities would be contingent upon test excavations of Site
No. 6. The University of South Alabama Archaeological Laboratory was
then contracted to perform the necessary test excavations. The name of
Site No. 6 was changed to Site No. !Mn57 to conform to the standard
system of numbering archaeological sites in Alabama.
The test excavations have been performed and the archaeologist's final
report was submitted to the Alabama Historical Commission early in
March, 1978, with a complete account of the required test excavations.
This report included a description of the salvage activities, and the
approval of the Alabama Historical Connission is pending. Since the
area must be approved by the Alabama Historical Commission prior to
quarrying, the impact of mining the area should be of negligible magni-
tude and significance. However, if during construction or operation of
the quarry, another site is encountered, the Alabama Historical Commis-
sion will be notified to appraise the discovery.
C-98
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Y A IDEAL ARCHAEOLOGICAL
SITE NO. 8
IDEAL ARCHAEOLOGICAL SITE NO. 6
ALABAMA IDENTIFICATION SITE
NO. (1Mn57)
NOTE: SITE NO. 6 COVERS APPROXIMATELY 200 METERS FROM
NORTH TO SOUTH AND 75 METERS FROM EAST TO WEST
^^^^^^^^^^^^^^^^^^^^_ ^^^^^^_ ^^^j^^^^^^^^^^^^_^_
Figure C.20
LOCATIONS OF ARCHAEOLOGICAL SITES NO. 6 AND NO. 8
0 0.5 1
SCALE IN KILOMETERS
SOURCE. University of South Alabama, Archaeological
Research Laboratory, 1977.
REGION IV
U.S ENVIRONMENTAL PROTECTION
AGENCY ENVIRONMENTAL IMPACT
STATEMENT FOR IDEAL BASIC INDUSTRIES
PROPOSED GAILLARD QUARRY
MONROE COUNTY, ALABAMA
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ECOLOGY (QUARRY SITE)
ECOLOGY
CONSTRUCTION/OPERATION IMPACTS
Introduction
At the proposed quarry site, the construction and operation activities
will be similar and are considered one action. These actions will have
impacts on the population and community levels of the ecosystems on the
site.
The field investigations in the summer and fall of 1977 determined that
portions of the area south of Thompson Mill Creek are being timbered and
converted to pastureland. The impacts of this action are independent of
the quarry construction and operation since they would occur even with-
out the quarry facility. The worst-case conditions for assessing the
impacts on existing communities will occur if the timbering/pastureland
conversion is not completed by the start of construction activities. In
addition, because the ecological impacts of the conversion, construc-
tion, and quarrying activities are interrelated, they are discussed
together but distinguished where possible.
The construction of the access road, docking facility office, shop,
storage facility, clarification basins, and the initial conveyor
corridors will be accomplished in about 18 months. This activity,
which should be centered around the docking-storage area, will involve
clearing and grading about 40 hectares (100 acres).
The actual quarry operations will work away from this area at the rate
of about 14 hectares (35 acres) per year with an average quarrying area
of about 120 hectares (300 acres) at any time. The entire quarry site
encompasses 1,633 hectares (4,035 acres).
Quarrying may include up to 80 percent of the site during the life of
the project. Overall, the negative impacts of quarrying after conver-
sion to pasture are considered small. These impacts are not reversible
over the short term (approximately 20 years); however, depending upon
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ECOLOGY (QUARRY SITE)
the management practices, they could be reversed to some extent over the
1ife of the quarry.
Impact Identification
Land Clearing
Much of the information available on soil-vegetation disturbance
describes timbering (clearing) and heavy machinery impacts. Since the
equipment is similar to that used in facility construction and
quarrying, the impacts are considered comparable.
The initial disturbance of existing vegetation in the first 15 years
represents the most immediate impact. As the land is cleared and the
topsoil removed, 120 hectares (296 acres) of cultivated croplands or
pasturelands, 139 hectares (343 acres) of hardwoods, and 30 hectares
(74 acres) of remnant forests will be eliminated from these uses.
These actions will alter significantly the present ecological functions
and attributes of the site. The system will have the functional charac-
teristics of an early successional state (Odum, 1971).
For example, forests and pasturelands are very important as stabilizers
of slopes (Bullington, 1971). Removal of the vegetation will increase
erosion and nutrient leaching of any remaining soil and will cause soil
compaction as a result of decreased mechanical disturbance from root
penetration.
Moehring (1970) suggests three major influences of logging activities on
soil structure: compaction, puddling, and soil displacement. Compac-
tion and puddling essentially cause increased surface runoff since per-
colation and macropore volume are reduced. These two processes decrease
the permeability of the soil to both roots and water. Establishment of
plants following compaction and puddling is slow. If the soil does not
erode severely and if disturbance is not deep, soil displacement will
allow mixing of mineral and organic layers of the soil and increased
aeration and thus can be beneficial to future vegetation. Soil
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ECOLOGY (QUARRY SITE)
disturbance which results in scalping or erosion usually permanently
reduces the potential of a site (Moehring, 1970). The effects of
quarrying are comparable but should be better controlled and less severe
due to the reclamation program planned for the quarry area.
Any forests which are left on the site during the quarrying activities
may be affected by the quarry. Some of the lower floodplain forest may
remain; however, the increased surface runoff, insolation, and airflow
will cause changes in composition and production of these remnant
areas.
Surface runoff will increase greatly with compaction of the soil, and
the removal of topsoil and vegetation on upland areas. The more hydric
species will remain in lower areas, whereas mesic or xeric species will
shift up the slopes to drier regimes. However, if the drier areas are
being actively quarried, the mesic to xeric species will simply lose
their niche in that immediate area (the site).
Insolation of the remnant forests will increase, causing increased tem-
peratures within the forests. The opened areas will develop more weedy
species and primary woody invaders, such as pine and sweetgum (Chapman,
1946; March and Skeen, 1976). Most of the forest areas remaining after
excavation will be hardwood bottomlands, since the pine-oak upland areas
will have been destroyed during the quarrying.
Although the plant communities which will be affected are not unique,
the impacts represent a major change in the natural systems of the site.
The magnitude of these impacts is considered low because of the
abundance of the existing forested areas in the area. The significance
of the secondary impacts on soil and erosion is low because these
actions will probably not have a long-term effect on subsequent land
use.
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ECOLOGY (QUARRY SITE)
At least 56 hectares (138 acres) of most favorable rabbit and quail
habitat, 93 hectares (230 acres) of most favorable turkey habitat, and
21 hectares (51 acres) of most favorable squirrel habitat will be lost
in the first 15 years. An additional 122 hectares (302 acres) of mar-
ginal rabbit and quail habitat, 85 hectares (210 acres) of marginal
turkey habitat, and 158 hectares (389 acres) of marginal squirrel habi-
tat will also be lost. Continued clearing of the hardwood forest and
subsequent conversion to pastureland will destroy soft mast-producing
plants (oaks, beech, and gum) and hard mast trees (hickory and walnut).
In addition, many forage plants associated with the upland forest will
be lost. These actions will reduce current population levels of deer,
turkey, and squirrel on the site. If the bottomlands are harvested to a
great extent, additional food supplies, plus cover, denning, and nesting
sites for some animals will be destroyed. Animal species which commonly
utilize these areas for feeding, cover, or denning sites include deer,
turkey, squirrel, bobcat, raccoon, opossum, mink, gray fox, and wood-
cock. At most, 178 hectares (440 acres) of favorable rabbit and quail
habitat and a similar amount of marginal squirrel habitat will be lost.
In general, the impact of these on-site activities is the resulting
changes in wildlife populations from forest types to old field/pasture
types; however, the magnitude of these changes is low because of the
relatively small amount of affected area in comparison to the areawide
abundance of available forest habitat. The significance of this wild-
life habitat loss is low because of the frequent occurrence of the
species involved in the surrounding area. All the populations in the
area are currently self-sustaining.
The major impact of these activities on rare and endangered species will
be reduced habitat for those animals which inhabit forest or forest/
field communities. The disturbance of sensitive fauna inhabiting
aquatic environments will be minimal. The overall impacts should not
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ECOLOGY (QUARRY SITE)
be significant because of the small areas to be affected and the availa-
bility of suitable habitat in nearby areas.
In summary, the land clearing activities associated with both conversion
to pasture and quarrying can be expected to have impacts of low magni-
tude and significance on the area. Impacts are considered unavoidable
and reversible over the long term. If pasture conversion is complete by
the time quarrying activities begin, the significance and magnitude of
the impacts described above will be lower since major transitions in
ecosystem types, wildlife habitat types, and wildlife populations will
have occurred. However, at this time it is not certain how much of the
land conversion will be done before facility construction and before
each area is to be quarried.
Erosion and Stormwater Runoff
Erosion and stormwater runoff from the proposed quarry site during
construction and operation will be controlled by berms, grading, and
clarification basins; however, it is expected that some moderate net
increases in the loads of particulate material carried by tributary
streams will occur. The presence of this material could be detrimental
to aquatic organisms (e.g., through damage to membranes), and the accom-
panying increase in turbidity could reduce primary productivity. In
addition, settling of particulate material on the substrate could
smother bottom-dwell ing organisms. These impacts are considered of
limited significance because erosion controls will limit sediment loads
and the ecological adjustment to elevated turbidity levels should have
already occurred during the conversion of the site to improved pasture.
Repeated sediment deposition on creek bottom areas, resulting in per-
manent coverage of the original substrate, could have very significant
effects upon aquatic species composition in the tributary streams. The
overall effect of sedimentation, organic loadings, and land clearance
will be to increase the prevalence of facultative aquatic organisms.
Siltation can be expected to create more soft-bottomed habitats which
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ECOLOGY (QUARRY SITE)
would favor burrowing forms (worms, chironomids, burrowing mayflies)
over root, rubble, sand, or gravel inhabitants. Filter feeders
(Hydropsychid caddisflies, blackflies, etc.) may be expected to prosper
so long as available attachment substrate remains exposed. The removal
of trees and their detrital compone ~s, such as leaves, twigs, and bark,
may eliminate the larger gr~-ers and carnivores of the present system
(mayflies, elmid beetles stoneflies, dragon and damsel flies, and
members of the Megalopteraj.
In Thompson Mill and Hoilinger creeks, such effects will occur first as
a consequence of land conversions to improved pasture, and later as a
joint result of agricultural land use and the quarrying project. The
net sedimentation effects of the Ideal Basic Industries project alone
would probably not be sufficient to cause pronounced changes in ecolog-
ical conditions. This impact related to quarry activities is judged to
be of low magnitude based on the erosion/sedimentation controls planned.
The significance is low by itself and considered even lower due to the
changes that should have occurred due to the conversion to and use as
pasturelands. Impacts should be long-ter,.. (life of the quarry) and
mostly reversible.
Fugitive Dust
As presented in the Air Quality section, limestone dust may enter the
atmosphere from quarry operations. Brandt and Rhodes (1972) showed
reduced productivity of plants which were exposed to limestone dust.
These results indicate the possibility of reduced productivity of the
remaining forest species at the perimeter of the quarry. The effects
are considered to be of low significance and magnitude because of the
commonness of the species involved and the relatively few trees to be
affected, and the effects will be long-term but reversible when the
quarry area is reclaimed.
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ECOLOGY (QUARRY SITE)
Noise Disturbance
Noise resulting from construction and quarrying (see Noise section) will
have adverse effects on some species of wildlife, such as the turkey,
which requires a fairly high degree of isolation. This disturbance
could contribute to the reduction of some wildlife populations remaining
on the site. It is not considered significant to the area and region
because of the frequent occurrence of the species. This impact is
considered of low magnitude and long-term, but highly reversible.
Reclamation
Once reclamation is completed, the expected changes in topography will
not affect plant or animal communities relative to pasture activities,
and no adverse ecological impacts are expected.
Land Transportation
Increased traffic in the area because of the quarrying operation will
increase "road kills" of wildlife in the area. The significance and
magnitude of this impact are considered negligible because the species
involved (e.g., armadillos, opossums, mice, turtles, and deer) are
common and occur in large numbers in the area.
Water Transportation
The increased barge traffic, especially in the immediate vicinity of the
site, could disturb activity patterns of water-associated birds, such as
eagles and waterfowl, and could affect alligators in the area. In all
cases, the disturbed species will relocate or adapt to the conditions.
These impacts are of low significance and magnitude, long-term and
reversible.
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ECOLOGY (QUARRY SITE)
Clarification Basins
Clarification basins will have the positive impact of creating addi-
tional habitat for aquatic-related species such as herons and waterfowl.
This impact is mentioned because of the potential use of these basins by
little blue heron and other important species after active quarry slopes
are no longer drained into the basins. This positive impact is consi-
dered to be of low significance and low magnitude for the area because
of other existing ponds in the area.
Drainage Patterns
The drainage patterns created as part of the limestone quarrying and
reclamation process could reduce the drainage area of Thompson Mill
Creek by about 10 percent. This change in drainage area could reduce
the base flow of the stream and thereby reduce the extent of flushing,
the size and depth of pools, and the length of stream reaches containing
water during dry-weather conditions. Such flow reductions would affect
aquatic communities. However, since major effects on base flow should
not occur, the related impacts are estimated to be of low magnitude and
significance but irreversible and long-term.
Material Spills
Some small quantities of limestone may occasionally be spilled into the
Alabama River during barge-loading operations. Gravel-sized and larger
rock would sink to the bottom with no discernible impact. Fine parti-
cles would form a scum on the water surface and would slowly settle into
the water column as they were transported downriver. Spillage should
have no measurable adverse effects on river organisms because the lime-
stone is non-toxic. Spillage of coarse material may not be detrimental,
and the material involved might provide better substrate for benthic
organisms than the present river bottom (negligible impact).
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ECOLOGY (QUARRY SITE)
Since the proposed fuel oil tank will be underground, oil spills from
the tank are not considered a possible Impact. However, as a result of
the use of tugboats and heavy duty equipment, there Is the possibility
that small fuel oil spills could occur. Spills would have localized
ecological Impacts but would not be sufficient in volume to affect a
substantial reach of the Alabama River (negligible impact).
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SOCIOECONOMICS (QUARRY SITE)
SOCIOECONOMICS
CONSTRUCTION PHASE
Pre-mining activities at the quarry site will provide an important eco-
nomic stimulus for Monroe County and surrounding areas. The 18-month
construction phase at the quarry site will require 200 man-years of
labor. During this period, employment will average 133 workers and will
peak at 250 workers. The latter figure will amount to roughly 3 percent
of the total at-place employment in Monroe County. The total wages paid
during the course of the construction project at Gail lard will exceed
$3,000,000. Also, through the operation of multiplier effects within
the Monroe County economy, the project will generate at least $1,000,000
in additional income, and approximately 60 more employed workers. These
positive impacts are considered moderate in magnitude and significance.
Timing of the proposed construction activity is fortunate in that the
project will follow closely the construction of the Parsons and
Whittemore pulp mill at Claiborne. The Parsons and Whittemore project,
which is much larger in scale than the quarry project, will be phasing
out at the same time that the labor force buildup is occurring for the
quarry construction. This situation may allow some direct shifts of
personnel and will permit the construction workers to utilize housing
and public facilities that currently are used by the Parsons and
Whittemore labor force.
The construction labor force residing in Monroe County is somewhat
limited because of the small scale of the local economy. Therefore, a
majority of the workers on the quarry project will necessarily live
elsewhere. Some of these workers will commute to Monroe County on a
daily or weekly basis; a few will establish residence in the area for
the duration of the project; and several may move to Monroe County on a
permanent basis. Currently, transient accommodations and rental housing
units are in relatively short supply in Monroe County because of the
Parsons and Whittemore project, but this situation should change by
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SOCIOECONOMICS (QUARRY SITE)
the time the Ideal Basic Industries construction project Is underway.
Relatively few of the non-resident workers at the quarry construction
project are expected to bring dependents to the area, because of the
limited duration of the project. Therefore, the construction phase 1s
not expected to have negative Impacts In terms of public services or
municipal finance. Regarding possible social Impacts due to the popu-
lation influx, the experience of the Parsons and Whittemore project
indicates that the Ideal Basic Industries construction phase will have
no significant adverse consequences for the Monroe County community.
OPERATIONS IMPACTS
Permanent operations at the proposed Gail lard quarry will benefit Monroe
County by providing a small but significant number of highly stable,
well-paying jobs. The quarry will employ a minimum of 19 workers and
will generate approximately $400,000 in wages annually. Local purchases
of supplies and services by Ideal Basic Industries (and multiplier
effects created by the spending and responding of personal income) will
provide additional stimulus to the Monroe County economy. Therefore, it
is estimated that the indirect employment impact of permanent operations
at the quarry will amount to at least 25 additional workers. These
economic impacts are rated moderate in magnitude and significance for
Monroe County.
Projections of the overall socioeconomic effects of the proposed quarry
are presented in Table C.15. It is estimated that, of the 44 total jobs
attributable to the quarry, the number held by Monroe County residents
will be approximately 32 in 1985, and 38 in 1992. Thus the project will
increase the Monroe County population by about 92 persons in 1985, rela-
tive to the projected baseline, and by about 102 persons in 1992. The
increases in the number of households will be approximately 30 and 34,
respectively. In each case, the increase will amount to one-half of
1 percent or less of the baseline value. Therefore, although the quarry
will represent an important economic benefit to the community, its scale
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SOCIOECONOMICS (QUARRY SITE)
Table C.15. Summary of Quarry Impacts on Monroe County Population
and Employment
Impacts Attributable
to Gal Hard Quarry
Operation
Direct Employment
Indirect Employment
Total Jobs
Resident Employment
Population
Population per
Household
Number of Households
1985
19
25
44
32
92
3.1
30
1992
19
25
44
38
102
3.0
34
Quarry Impacts as
Percent of Baseline
Quantities
1985 1992
0.53% 0.46%
0.39% 0.41%
0.39% 0.41%
Source: Environmental Science and Engineering, Inc., 1977.
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SOCIOECONOMICS (QUARRY SITE)
will not be sufficient to create stress upon housing, public facilities,
or transportation.
The quarry site is very isolated relative to residential areas and other
land uses that might be sensitive to nuisances or amenity impacts.
Therefore, quarrying operations are not expected to have any direct
effects upon off-site land use or land value. A possible indirect
effect of the Ideal Basic Industries facility and the Parsons and
Whittemore pulp mill might be an increase of land value (for further
industrial development) in the Claiborne/Perdue Hill area. However,
this would be a very long-term effect probably of minor degree. The
quarry project will have no permanent effects on land use at the site
since the land will be returned to its intended original condition,
improved pasture.
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APPENDIX D
ITIGATING ACTIONS
-------
PLANT AND QUARRY SITES
APPENDIX D. MITIGATING ACTIONS
INTRODUCTION
This appendix presents a summary of environmental safeguards which Ideal
Basic Industries has incorporated into the project plan to prevent or
lessen potentially adverse environmental impacts (see Project
Description for additional details about these safeguards).
The appendix also identifies and describes additional measures which
might be taken to mitigate the adverse impacts which are assessed in
Appendix C. Each mitigating measure is described and is evaluated in
terms of its practical use.
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AIR QUALITY (PLANT SITE)
PLANT SITE
AIR QUALITY
CONSTRUCTION
Construction activities at the plant site will consist of land clearing,
grading, roadway construction, excavating, and other heavy machinery
operations. These construction activities can be expected to increase
particulate matter (fugitive dust) levels in the local area on a short-
term basis. In addition, burning of land-clearing wastes may also
affect air quality on a short-term basis.
Fugitive Dust Emissions
Environmental Safeguards
The State of Alabama's fugitive dust regulation requires the use of
"reasonable precautions to prevent particulate matter from becoming air-
borne." Ideal Basic Industries has chosen the most practical method of
mitigating dust emissions from unpaved roads and heavy construction
operations, i.e., watering on an as-needed basis. The degree of control
achieved through watering is dependent on the frequency of application
in relation to other factors (frequency of operations, soil, and weather
conditions). Watering will induce a crust surface which is partially
resistant to traffic movement and will thereby reduce dust emissions.
It has been estimated that waterings twice a day can reduce emissions by
up to 50 percent (U.S. EPAV Office of Air Quality Planning and Stan-
dards, 1975). Water will be applied to dust-generating surfaces, either
by portable water sprayers or watering trucks.
In addition, the construction schedule for development of the plant site
shows that the main access road will be surfaced as soon as possible,
and this action should also reduce the fugitive dust potential related
to transportation.
D-2
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AIR QUALITY (PLANT SITE)
Mitigating Measures
As an alternate mltigatlve measure to watering, chemical stabilizers can
be used to suppress dust emissions. There currently are over 100 chemi-
cal products which can be used for this purpose. However, this control
is effective only for inactive areas. In areas where traffic or opera-
tions occur, these activities will tend to break down the stabilizer.
It is estimated that chemical stabilizers can reduce dust emissions from
barren, inactive areas by 80 percent (U.S. EPA, Office of Air Quality
Planning and Standards, 1975). However, since emissions from inactive
areas are generally small in comparison to active areas, this action
will not greatly mitigate overall emissions. Two chemical stabilizers
are available: a surface stabilizer, and a stabilizer that is actually
worked into the soil. Both types generally involve frequent applica-
tions and are more costly than watering for dust control.
A second option which could mitigate dust emissions from construction
activities would be reduction of the wind speed across exposed surfaces,
thereby reducing the amount of wind-entrained dust. Typical methods
include enclosures, coverings, or the placement of tall grasses and
vegetation adjacent to the barren areas. Because of the relatively
short duration of construction activities and the types of activities
conducted, these control measures are usually not practical.
A third method of reducing dust emissions is the paving of all con-
struction roads. This method would be impractical during construction
activities because the heavy machinery traffic would quickly break up
the road and thus necessitate repaying.
Burning of Vegetative Wastes
Environmental Safeguards
A burning permit issued by the local air pollution control agency is
required in order to burn vegetative wastes in Mobile County. The major
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AIR QUALITY (PLANT SITE)
permit requirements in order to lessen possible effects include burning
only during days with proper dispersion conditions (no stagnant air
masses) and starting and maintaining fires without using fuel oil or
tires.
The wastes will be allowed to dry for a few days. The dried wastes will
be burned in an air-blower type pit burner for a substantial reduction
in smoke emissions relative to open burning. Burning will be conducted
only during favorable dispersion conditions and will be supervised at
all times to prevent fire hazards.
Mitigating Measures
There are no additional practical actions which could be performed to
lessen the projected impacts from burning vegetative wastes.
OPERATIONS
Adverse air quality impacts associated with plant operation include:
fugitive dust generation, particulate matter, nitrogen oxide and sulfur
dioxide emissions, and increased consumption of the available Prevention
of Significant Deterioration air quality increments for sulfur dioxide
and particulate matter.
Environmental Safeguards
To minimize adverse air quality impacts, Ideal Basic Industries will
develop an air pollution episode emergency action plan, a routine main-
tenance and inspection program, a process monitoring program, and an
environmental monitoring program. In addition, the best available
technology has been used in designing the process and its pollutant
controls (baghouses). Storage areas and handling systems will have a
water spray dust suppression system to reduce the amount of dust
generated. In addition, the plant area will be landscaped to reduce
dust emissions.
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AIR QUALITY (PLANT SITE)
Process Selection
The plant's process design has inherent features which reduce air
pollution potential:
1. Use of a suspension preheater places a constraint on the amount
of sulfur which can be contained in the fuel and, as a result,
limits the sulfur dioxide emissions.
2. The kiln/raw mill system combines the exhaust gases with the
raw material, and the alkaline nature of the raw materials
reduces sulfur dioxide emissions.
3. The precalciner will burn about 60 percent of the fuel in the
kiln and thereby will reduce the amount of combustion air that
will be in contact with the hot end of the kiln. This tech-
nique possibly reduces the amount of nitrogen oxides formed in
the process (Bauer, 1977).
4. All dust collected in the baghouses will be recycled into the
process, thereby eliminating dust emissions from waste
stockpiles.
Particulate Matter Controls
The use of "best available control technology" on all particulate matter
emission sources is required to insure use of the latest, most practical
methods of emission reduction. The design plan of Ideal Basic Indus-
tries provides that all stack emissions of particulate matter (including
the kiln/cooler/raw mill exhaust streams) will be controlled by the use
of baghouse dust collectors, which are considered Best Available Control
Technology (BACT). This design feature means that for these sources at
the proposed plant, particulate matter emissions will be reduced to near
zero visible emissions and to less than 1 percent of their potential
emission rate. It has not been demonstrated practical to control stack
emissions of particulate matter to a greater degree than is afforded by
the proposed baghouse collectors.
D-5
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AIR QUALITY (PLANT SITE)
Fugitive Dust Controls
The use of landscaping and revegetation will help to reduce fugitive
dust emissions from areas disturbed in the construction process. During
plant operations, fugitive dust emissions from storage piles, transfer
points, barge unloading, stockpiling, and coal crushing operations will
be reduced by the following plant design features:
1. Providing water sprays on transfer points, drop points, and on
storage piles where appropriate;
2. Installing baghouses at major transfer points and loading
operations;
3. Covering coal, dried clay, iron ore, sand, and gypsum storage
piles.
In addition to the water sprays, the inherent moisture content (approxi-
mately 22 percent) of the uncovered storage piles of clay and limestone
will tend to prevent the generation of fugitive dust.
Sulfur Dioxide Controls
Sulfur dioxide emissions from cement plants are not limited by emission
regulations; however, two design features of the proposed cement plant
will directly mitigate sulfur dioxide emissions. The first is the use
of moderate to low sulfur coal with an expected maximum sulfur content
of 1.5 percent. With the use of higher sulfur coal, the operation of
the preheater unit servicing the kiln is anticipated to be impractical
because of formation of sulfate deposits that would restrict gas flow.
The second design feature which will mitigate the potential sulfur
dioxide emissions is the inherent removal of sulfur dioxide through the
intimate contact of S02-S03 laden gases with the alkaline cement
dust in the kiln/cooler/raw mill gas stream. The following two factors
increase the possibility of gas-solid phase contact:
1. All the kiln exhaust gases pass through the preheater and raw
mill and thereby have a long contact time with the alkaline
material.
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AIR QUALITY (PLANT SITE)
2. The participate matter control devices servicing the kiln/
cooler/raw mill exhaust gas streams will be glass fabric fil-
ters, on which a dust cake will form. The exhaust gases must
pass through this dust cake thus allowing additional contact of
exhaust gases with cement dust. Estimated sulfur dioxide
removal inherent in this process is 75 percent (U.S. EPA,
Office of Air Quality Planning and Standards, 1975).
Nitrogen Oxide Controls
New Source Performance Standards pertaining to emissions from portland
cement plants are currently not applicable to nitrogen oxides. However,
nitrogen oxides are a product of combustion, and emissions are dependent
largely on temperature of combustion and excess air in the combustion
chamber. A degree of control over nitrogen oxide emissions will be real-
ized by maintaining these operating parameters within the constraints of
the cement manufacturing process. Optimum design of the kiln burning
system and the raw mill furnaces will also reduce nitrogen oxide
emissions.
As stated under Process Controls, state-of-the-art methods to control
nitrogen oxide emissions from cement kilns are at an early stage of
development. Ideal Basic Industries will incorporate design features
consistent with the latest available technology to help control nitrogen
oxide emissions.
Mitigating Measures
Stack Design
Stacks for the kiln/cooler/raw mill at the proposed cement plant will be
approximately 90 meters (300 feet) high. The other baghouses are not
planned to have high stacks, but will discharge from approximately the
height of the fan outlets.
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AIR QUALITY (PLANT SITE)
Higher stacks on all emission sources at the proposed plant could
further mitigate the impact of emissions on the surrounding area by
causing greater dispersion and dilution of emissions before the pollu-
tants reach ground level. Increasing stack heights would also decrease
the possibility of downwash of the effluent plume, which could create
short-term air quality problems. This mitigating action would be very
costly for sources with low emission rates; however, a multiple use
stack could be used for combining flows.
Fugitive Dust
There are no additional actions that could be taken to mitigate the low
impacts of fugitive dust emissions.
Lower Sulfur Coal
Since sulfur dioxide emissions are a direct function of the coal's
sulfur content, the use of lower sulfur coal is an additional measure
which could further mitigate sulfur dioxide emissions. However, the
resulting decrease in sulfur dioxide emissions would be slight given the
inherent reduction by gas-solid (alkaline) reaction. This decrease
in emissions would not warrant the additional expense of purchasing coal
with less than 1.5 percent maximum sulfur content. In addition,
obtaining a continuous supply of such lower sulfur coal would be
somewhat questionable in today's energy market.
D-8
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NOISE (PLANT SITE)
NOISE
CONSTRUCTION
Increased noise levels are typically unavoidable for construction of
facilities as large as the proposed-cement plant.
The functions of earth-moving, transportation, lifting, framing, and
laying foundations all require the use of machinery which will produce
noise that may be objectionable to workers on the site and to some local
residents.
Environmental Safeguards
Adverse effects of construction equipment noise will be lessened by the
following factors:
1. Use of noise suppression equipment which complies with the
Walsh-Healy Act and OSHA regulations. The protection of
workers from excessively high noise levels will also reduce
noise levels around the site.
2. Whenever possible, construction activities will occur during
the daylight hours.
3. The sparse to thick tree plantings surrounding the plant will
attenuate noise levels.
OPERATIONS
There will be unavoidable noise due to the operation of tugs, materials
handling and conveying, grinding, crushing of coal, truck and rail
traffic. Since the major process operations occur 24 hours per day,
some level of noise will emanate from the plant continuously.
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NOISE (PLANT SITE)
Environmental Safeguards
Noise impacts will be mitigated by the following factors:
1. Most pieces of equipment (with the exception of parts of the
kiln as required for heat dissipation) will be enclosed within
buildings.
2. The design contractor will perform a detailed noise study in
order to determine appropriate measures and requirements for
its equipment suppliers in relation to enclosures, barriers,
and machinery arrangement.
3. The continued presence of sparse to thick plantings of trees
along the plant's northern and eastern boundaries will
attenuate noise levels.
4. An access road will be located along the western boundary away
from residential areas.
5. The 20-meter (65-foot) high limestone active and dead storage
piles will be located along the eastern edge of the facility.
Mitigating Measures
One mitigating measure would be installing noise suppression equipment
on baghouse fans which meet manufacturer's specified sound power levels.
In addition, all process components and/or the entire facility could be
completely enclosed. The cost of either of these actions is somewhat
questionable in relationship to the potential benefits. The No. 2
safeguard mentioned above might be expanded to address this issue.
However, a complete enclosure of the plant's facilities is probably
impractical.
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SOLID WASTE (PLANT SITE)
SOLID WASTE
CONSTRUCTION AND OPERATION
The construction and operation of the plant will result In the genera-
tion of debris, metal scraps, used refractory bricks, trees from clear-
Ing, and other forms of solid wastes.
Environmental Safeguards
Most of the wastes will be taken to the Irvlngton Landfill for proper
disposal. The land-clearing wastes will probably be burned on site (see
discussion In the Air Quality section), chipped for mulch, and/or taken
to the Irvlngton Landfill. It Is anticipated that the dredged material
will be disposed at one of the approved spoil sites used by the
U.S. Army Corps of Engineers for their ship channel project. The
remaining wastes (metal scraps and waste oils) will be recycled, if
possible.
Mitigating Measures
Mitigating measures, in addition to the proposed action, are limited due
to the low level impacts of the final disposal techniques. The
discussion of alternatives in Appendix E addresses other disposal
methods that could be used instead of those planned.
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ARCHAEOLOGY (PLANT SITE)
ARCHAEOLOGY
In mid-1977, an on-site "walk-over" archaeological-historical survey was
conducted on the cement plant site. No archaeological or historical
sites were recorded. The Alabama Historical Commission has sent a
letter of approval which stated that the cement plant site "will have no
adverse effect on any cultural resources included in or eligible for the
National Register of Historic Places" (see Permit and Approval section
of the Summary Document).
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WATER RESOURCES/GEOTECHNICAL (PLANT SITE)
WATER RESOURCES AND GEOTECHNICAL
CONSTRUCTION
Adverse impacts of plant construction include stormwater runoff and
erosion, effects of railroad trestle and access road construction,
effects of dock construction and possible oil spills.
Environmental Safeguards
During site construction, the following methods of erosion and sediment
control will be implemented:
1. Storm water will be directed to the general stormwater catch-
ment area north of the plant site and to the main wastewater
settling basin. The catchment area will discharge its overflow
directly to the freshwater marsh, and the settling basin will
discharge its effluent to the ship channel.
2. Major access roadways will be temporarily surfaced.
3. In order to lessen the adverse impacts of railroad trestle and
access road construction, berms and artificial barriers will be
constructed to detain and slow down stormwater runoff.
4. Some vegetative wastes will be chipped for use as mulch to
reduce erosion and to assist with the revegetation of disturbed
areas.
It is anticipated that the dredging of the docking area will be con-
ducted at the same time the U.S. Army Corps of Engineers conducts their
dredge operations for the ship channel project. The dredged material
probably will be disposed at one of the approved U.S. Army Corps of
Engineers disposal areas. Thus, there should not be separate adverse
impacts of dredging and material disposal. The potential impacts of oil
spills will be minimized by the construction of berms around the
temporary diesel oil storage tank and the refueling area.
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WATER RESOURCES/GEOTECHNICAL (PLANT SITE)
Mitigating Measures
To mitigate further adverse water quality impacts of plant construction,
the following measures could be taken:
1. Slopes could be graded in order to reduce the velocity of
runoff. However, due to the relatively flat terrain, slopes
are already expected to be minimal.
2. Temporary stabilization could be performed with nettings and
chemical binders.
3. Natural buffers (such as a strip of natural vegetation) and
installed buffers (such as contour strips and sod inlet
filters) could be used for sediment control.
4. Artificial structures (such as gravel inlet filters, sediment
traps, sediment basins, dikes, ditches, and terraces) could be
used for sediment control.
Most of these measures are feasible; however, because of the planned
safeguards, they are not considered necessary but should be considered
at various stages of construction.
OPERATIONS
The adverse water quality impacts associated with plant operation relate
to stockpile runoff, cooling water blowdown, stormwater runoff, truck
and area washings, and possible materials spills.
Environmental Safeguards
Adverse impacts due to stockpile runoff will be avoided by enclosing
all raw materials except the limestone and wet clay. The runoff from
these piles will be collected and transported to a settling basin. The
process cooling water blowdown, stormwater from the oil tank containment
berm, truck/car wash, and various area washes will also be drained into
the settling basin. In order to promote settling of particulate
materials, the wastewater will be detained in the basin prior to being
D-14
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WATER RESOURCES/GEOTECHNICAL (PLANT SITE)
discharged into the ship channel. The settling basin has a capacity of
16 million liters (4.2 million gallons). Based on the average detention
time of about 17 days, the effluent from the basin will meet the limi-
tations of EPA and the Alabama Water Improvement Commission (AWIC).
In order to avoid water quality problems associated with general
stormwater runoff, the runoff from areas of the plant site other than
material storage piles and oil tank will be directed to a catchment area
for settling of suspended solids and adequate detention time prior to
discharging into the marsh area.
The aboveground fuel oil tank will have a containment berm which will
hold the capacity of the tank. All other tanks will be below ground.
Mitigating Measures
A possible mitigating measure is the chemical treatment of wastewaters
in the catchment area and the settling basin. Such action could provide
better solids removal prior to discharge; however, the need for such
treatment is questionable since the discharges should meet all
applicable standards.
D-15
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ECOLOGY (PLANT SITE)
ECOLOGY
CONSTRUCTION
Adverse ecological Impacts associated with plant construction Include
effects of land clearing and grading and effects of access road and
railroad spur construction. The main impact of these activities
involves destruction of wildlife habitat and loss of plant communities.
Environmental Safeguards
Normal precautions will be taken so that intrusion into the marshlands
is minimized during clearing operations. Encroachment into wetland
areas is limited to the access roadway corridor. These precautions will
be especially beneficial to the eastern half of the site where the plant
is adjacent to the edge of the brackish marsh.
The construction of the access road and railroad spur will be accom-
plished with minimal loss or damage to the marsh area by locating the
proposed roadway and bridge as close as possible to the existing Airco
road and culvert and thus allowing natural/existing flows to continue.
In addition, the cattail marsh will filter the road drainage. The
cattail marsh is separated from the tidal marsh by higher ground and
prevents direct water flow.
Dredging and pile driving will be required to construct the docking
facility. In order to lessen the impacts, it is anticipated that the
dredging will be done at the same time that the dredging for the ship
channel project is being conducted by the plant site. This scheduling
should cause less impact than having the area disturbed during two
separate time periods.
Mitigating Measures
There are no significant mitigating actions in addition to the general
rule of minimizing intrusions into undeveloped areas and attempting to
maximize the wildlife habitat that will remain after construction.
D-16
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ECOLOGY (PLANT SITE)
Alternative access routes are discussed in Appendix E, Alternatives.
OPERATIONS
Adverse ecological impacts resulting from plant operation include noise
disturbance of wildlife, effects of vessel movements, stormwater and
wastewater discharges, and possible oil spills. Possible mitigating
actions are limited, but the following measures will be implemented to
offer some ecological protection.
Environmental Safeguards
Noise Disturbance
To preserve wildlife habitat, as well as to act as a noise buffer, the
greenbelt on the eastern edge of the property will be maintained.
Forest vegetation in this area will insure some cover continuity for
small mammals and songbirds along the eastern property boundary.
Waterway Traffic
Bow and prop wash will increase due to ship channel construction and
use. As an environmental safeguard, Ideal Basic Industries will install
rock riprap or sheet piles to stabilize unvegetated portions of the
riverbank. Rock riprap would extend to the edge of the existing shoul-
der. In addition to reducing erosion and sediment stirring, riprap will
provide excellent substrate for invertebrate development.
Oil Spills
Possible ecological impacts resulting from oil spills will be mitigated
by the following factors:
1. The fuel storage tank will be surrounded by a berm capable of
holding at least 100 percent of the volume of the tank.
2. The entire plant site will be designed to drain into a storm-
water retention area, so that there would be a second chance
for containment in the event that the berm were ineffective.
D-17
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ECOLOGY (PLANT SITE)
Mitigating Measures
The preceding sections of this appendix present other possible miti-
gating actions to lessen the air, noise, and water Impacts. There are
no additional mitigating measures specific to terrestrial, or aquatic
Impacts.
D-18
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SOCIOECONOMICS (PLANT SITE)
SOCIOECONOMICS
CONSTRUCTION
Safeguards
Importation of construction workers for large projects can result in
various social impacts. However, this class of impacts will be largely
prevented by Ideal's policy of recruiting construction workers locally,
rather than utilizing an imported labor force. The feasibility of this
policy has been demonstrated by the past success of Ideal's engineering
contractor (Brown & Root, Inc.) in drawing upon local labor for other
construction projects of similar scale in the Mobile area. Other
safeguards relating to socioeconomic impact will be the noise and air
controls which will minimize effects of construction activity on land
value and amenity.
OPERATIONS
The most prominent socioeconomic impacts of permanent operations at the
plant site are the positive effects involving employment and income.
The classes of negative impact that theoretically might be addressed by
mitigative measures are: (1) traffic generation; (2) land value and
amenity effects; and (3) labor force effects (including effects on
community facilities). Since Ideal Basic Industries employees will make
little contribution to highway congestion, and since most of the raw
materials will arrive at the plant site by water or rail, only the truck
trips for delivery of finished cement are capable of producing signifi-
cant traffic impacts. The impacts of truck traffic will be reduced
because of the relief provided by future highway improvements.
Safeguards
Land Value and Amenity
The plant facility will be designed so that a 90-meter (300-foot) wooded
buffer strip is left along the eastern margin of the Ideal Basic Indus-
tries property and that two 20-meter (65-foot) high limestone storage
D-19
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SOCIOECONOMICS (PLANT SITE)
piles separate the plant facilities and this greenbelt. These design
features should reduce noise levels from the plant and create an
acceptable natural appearance along Dauphin Island Parkway. Other
environmental safeguards are discussed In the Noise and Air Quality
sections.
Labor Force
A highly significant action which will minimize labor force impacts is
the planned transfer of workers from the existing Ideal Basic Industries
plant in Mobile to the new facility at Theodore. This step will require
the use of contract labor at the Mobile plant during the start-up at
Theodore and perhaps for an extended period thereafter. The worker
transfer will mean that the opening of the Theodore plant will bring
few, if any, newcomers to the Mobile area. Many of the workers trans-
ferred to Theodore eventually will move to south Mobile County, but this
transition will occur gradually so that there will be no sudden stress
on community facilities such as schools and housing.
Mitigating Measures
The temporary traffic impacts associated with cement deliveries by truck
theoretically could be mitigated by scheduling shipments to avoid peak-
hour traffic flows on Rangeline Road and Island Road. (Similarly,
traffic impacts during construction could be minimized by carefully
scheduling construction shifts.)
D-20
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AIR QUALITY (QUARRY SITE)
QUARRY SITE
AIR QUALITY
CONSTRUCTION
As at the plant site, construction activities at the quarry site will
include land clearing, grading, roadway construction, excavating, and
other heavy machinery operations. Air quality impacts will involve
primarily particulate matter levels in the local area.
Environmental Safeguards
Because of the similarities in activities and impacts at the plant and
quarry sites, mitigating measures to alleviate potential impacts will be
similar. However, the soils and rock strata at the Gaillard properties
contain much more moisture than at the Theodore site. Therefore, the
watering of the excavation and grading area need not be scheduled as
frequently. Equipment will be available to wet the area as needed.
Burning of some wastes will require a state permit. To minimize air
pollution and forest fire problems, the material will be burned in an
air-blower type pit burner. A continuous fire watch will be observed,
and burning will be conducted only under favorable pollutant dispersion
conditions. If air stagnation conditions develop, the fire will be
extinguished. Chipping of some of the trees and brush for mulch will
reduce the amount of wastes to be burned.
As discussed in the project description, the access road will be sur-
faced, which should further reduce the amount of fugitive dust generated
by employee traffic.
Mitigating Measures
Chemical stabilizers and wind breaks could be used to decrease fugitive
dust emissions (see the air quality discussion in the plant site con-
struction section). However, these measures might not be cost-effective
D-21
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AIR QUALITY (QUARRY SITE)
since the effects of water sprays and normal moisture content are
expected to be satisfactory.
OPERATIONS
The only adverse impact associated with quarry operations is the
emission of fugitive dust.
Environmental Safeguards
During operations, fugitive dust impacts on the local area will be
lessened by the use of water sprays in the following areas on an
as-needed basis:
1. Limestone breakers
2. Conveyor belt transfer points and drop points
3. Limestone storage pile
4. Barge loading points
5. Quarry areas and roadways (water sprayed from a tank truck).
In addition, the use of "boot" type loaders at the barge loading
facility and the inherent moisture content of the wet limestone will
suppress dust emissions.
Mitigating Measures
A possible mitigating measure would be the use of chemical stabilizers
in certain areas of the quarry, such as in inactive but unvegetated
portions. The overburden storage and partially reclaimed areas could be
treated to provide more effective control of fugitive dust.
D-22
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NOISE (QUARRY SITE)
NOISE
CONSTRXTION AND OPERATIONS
The noise levels projected are of low magnitude and significance. The
noise will come from construction activities of land clearing and
grading, dock construction and erection of facilities, and the general
operational activities of removing, crushing, and transporting the
1 Imestone.
Environmental Safeguards
Noise Impacts will be mitigated by the use of noise suppression
equipment which complies with the Walsh-Healy Act and OSHA regulations.
In addition, the surrounding elevation differences and the forests will
attenuate some of the noise.
Mitigating Measures
There are no feasible mitigating measures which would reduce noise
levels at the quarry site.
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SOLID WASTE (QUARRY SITE)
SOLID WASTE
CONSTRUCTION AND OPERATIONS
The construction and operation phases of the quarry will generate
wastes, such as vegetation, metal scraps, waste oil, lumber, sediment,
office papers, and lunchroom trash.
Environmental Safeguards
The trees and other vegetative wastes will be burned on-site (see Air
Quality section) or will be chipped for mulch, depending on the size of
the wastes. The majority of the metal scraps and oily wastes will be
recycled. The sediment wastes from the clarification ponds will be used
as reclamation material. The remaining wastes will be taken to the
Monroe County Landfill.
Mitigating Measures
The mitigating actions, in addition to the above safeguards, are limited
because the safeguards are proper disposal techniques with low environ-
mental impacts (for alternatives to these proposed actions, see
Appendix E).
D-24
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ARCHAEOLOGY (QUARRY SITE)
ARCHAEOLOGY
A preliminary survey conducted in July, 1977, revealed 8 archaeological
and 7 historical sites on the quarry property. Of the 15 sites, only
two (Sites 6 and 8) contained some artifacts of interest and were
recommended to be further investigated. However, only Site No. 6 would
be impacted, since it is situated in a proposed quarry area.
ENVIRONMENTAL SAFEGUARDS
To more clearly define the value of Site No. 6 and to salvage its
contents prior to quarrying, an extensive archaeological investigation
was authorized by Ideal Basic Industries.
During October, 1977, archaeological test excavations of Site No. 6 were
conducted by the University of South Alabama. A total of ten 2x2
meter test squares of arbitrary depth were investigated. Artifacts
retrieved were sent to the University of South Alabama Archaeology
Laboratory for cleaning, cataloging, and analysis.
A final report on the findings of the excavations was completed in
March, 1978. A copy was sent to the Alabama Historical Commission,
office of the state preservation officer, in accordance with their
instructions of August 29, 1977, and a request for approval of quarry
operations was also submitted. A complete description of the findings
is included in the Archaeology section of Appendix B, Baseline.
MITIGATING MEASURES
No additional action is considered necessary.
D-25
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WATER RESOURCES/GEOTECHNICAL (QUARRY SITE)
WATER RESOURCES AND GEOTECHNICAL
CONSTRUCTION AND OPERATION
Adverse water resource and geotechnical impacts during the quarry
construction phase can result from land clearing and grading, roadway
construction, and stockpile construction. Adverse impacts during the
operations phase can be associated with stormwater runoff, the barge
loading terminal, and land reclamation.
Environmental Safeguards
Drainage/Erosion
The drainage plan for the quarry has been designed for the efficient
operation of the quarry and the adequate control of erosion and sedimen-
tation so that discharges from the site will comply with the effluent
limitations for suspended solids. The major sources of sediment will be
cleared areas, overburden stockpiles, active quarry areas, roadways, and
areas being reclaimed.
Quarry operation will reduce erosion and sedimentation by minimizing the
total amount of cleared and disturbed areas which are exposed at any
given time. It will also reduce the total length of time these areas
are subjected to rainfall without some protective vegetative cover or
mulch. The location of permanent roads and mining haul roads will be
planned to minimize disturbance or modification of drainage patterns.
During quarry construction, the clarification basins will be constructed
as soon as possible and drainage routed to them to prevent direct runoff
into the Alabama River or into on-site streams. Prior construction of
the basins, berms, and small temporary holding ponds will be utilized
wherever practical. Chipped vegetative wastes will be used as mulch to
prevent erosion and reestablish vegetation in areas not to be mined for
at least several years.
During quarry operation, several environmental safeguards will mitigate
adverse water quality impacts. First, the quarry plan calls for the use
of clarification basins to hold runoff so that suspended materials will
D-26
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WATER RESOURCES/GEOTECHNICAL (QUARRY SITE)
settle out. These basins will serve all areas disrupted by active
quarrying and overburden storage. The basins, which will be designed to
contain runoff from a 10-year, 24-hour storm, represent the primary
method of sediment control during quarry operation.
To assure that the effluent from these basins meets applicable standards
for pH and suspended solids, the discharge water will be monitored
regularly. To maintain the retention volume, sediment trapped in the
basins will be removed periodically.
In order to minimize adverse impacts related to reclamation of mined
areas, contour terracing of restructured overburden will be used to
encourage infiltration, decrease surface-flow velocities, and decrease
slope lengths. The overburden will be replaced to try to reestablish
the natural groundwater flow patterns.
Mitigating Measures
The mitigating measures which could be employed involve the greater use
of erosion control devices, such as mulching, seeding, netting, berms,
localized ponding, and vegetated buffer strips. The planned safeguards
appear to be adequate to prevent significant sedimentation in the
Alabama River and adjacent creeks; the additional actions suggested are
to further prevent erosion.
D-27
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ECOLOGY (QUARRY SITE)
ECOLOGY
CONSTRUCTION AND OPERATIONS
Adverse ecological Impacts associated with quarry construction and
operations Include effects of land clearing, suspended material
loadings, sediment deposition, noise disturbance, base flow reduction,
and limestone dust.
Environmental Safeguards
The adverse ecological Impacts will be mitigated to some degree by the
control measures mentioned In the previous sections on air, noise, solid
waste, water, and geotechm'cal. In summary, these are dust suppression
water sprays; noise suppression equipment; disposal of solid waste by
chipping some vegetative wastes for mulch, pit-burning, landfill Ing, and
recycling; erosion controls (contour terracing and bermlng) and clarifi-
cation basins; and reclamation of soils to maintain natural groundwater
flows. In addition, a 30-meter (100-foot) setback from major streams
and a revegetation program to return the quarry to pastureland have been
planned. Livestock use of newly reclaimed areas will be controlled.
Mitigating Measures
The major mitigating action not already discussed in a previous section
is a revegetation program to develop healthy biologic communities as a
wildlife asset along the edges of the mined areas. These "blend" zones
would become ecotones between biotic communities and would be managed to
produce more varied assemblages of plants and animals than would be pos-
sible for either community alone. A variety of wildlife food and cover
plants are available from public sources. Other species which would
naturally volunteer and produce significant browse would include woody
species such as maples, persimmon, sassafras, and oak, and herbaceous
natural plants such as beggar ticks, vetch, lespedeza, and sumac.
Since the reclaimed land will be utilized as pasture, the area for
which beneficial wildlife plantings will be feasible is rather small,
D-28
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ECOLOGY (QUARRY SITE)
consisting of: (1) blend zones between mined and unmined land; (2)
potentially difficult areas such as drainageways where erosion may
occur; and (3) other areas requiring stabilization, such as the faces of
retention dams. This option is currently under consideration by Ideal
Basic Industries and may be included in the quarry reclamation
activities.
D-29
-------
SOCIOECONOMICS (QUARRY SITE)
SOCIOECONOMICS
No environmental safeguards have been Identified for the quarry site
since no adverse socioeconomic Impacts are associated with quarry
construction or operations.
D-30
-------
APPENDIX E
ALTERNATIVES
-------
PLANT AND QUARRY SITES
APPENDIX E. ALTERNATIVES
INTRODUCTION
This appendix contains a discussion of alternatives to the proposed
action. The distinction between an alternative and a mitigating measure
(see Appendix D) is that the former is a replacement for the action
causing the impact, whereas the latter is a measure to be taken along
with the proposed action to lessen its impact. Economic and environ-
mental factors have been considered in the selection of alternatives for
evaluation, and emphasis has been placed on alternatives with signifi-
cant implications for environmental impact.
The actions presented are considered to be the most practical alterna-
tives to the proposed action. Actions which may be physically feasible,
but not practical to accomplish, are not described in this appendix.
The alternative actions for each project are presented in the following
categories:
1. No action (no project).
2. Site location,
3. Process or resources, and
4. Abatement measures.
The site location section discusses the various geographical areas
analyzed by Ideal Basic Industries. Each site was rated on a series of
criteria tor overall suitability as a quarry or cement plant.
The no-action section assesses the environmental aspects of the proper-
ties in 1992, if the quarry and the cement plant are not constructed. A
more complete discussion of each discipline area (air, water, noise,
etc.) is given in the appropriate sections of Appendix B, Baseline.
In the process/resources section, other operating processes, equipment
arrangements, raw materials, and energy sources are discussed.
E-l
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PLANT AND QUARRY SITES
The sections on abatement measures review other actions that could be
taken to reduce the projected environmental impacts discussed in
Appendix C, Impacts. Due to the low level (magnitude and significance)
of the majority of the adverse impacts, the use of alternative actions
are typically not warranted on a cost-to-benefit basis.
The majority of alternatives for the proposed project, other than the
no-action alternative, involve either site selection or project activi-
ties affecting the environmental parameters of air, water, solid waste,
and noise. The rejected alternatives had excessive environmental
impacts, were too costly, or were relatively inefficient. In the case
of site alternatives, numerous factors have been responsible for the
ultimate selection of the Theodore and Monroe County locations.
E-2
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NO ACTION (PLANT SITE)
PLANT SITE ALTERNATIVES
NO-ACTION ALTERNATIVE
The present discussion considers the environmental and social conditions
which would prevail in 1992 without the proposed Ideal Basic Industries
cement plant at Theodore.
FUTURE LAND USE
Projected land use in the vicinity of the Ideal Basic Industries prop-
erty is presented in Figure E.I. The area west of the proposed site and
south of Island Road is projected to be industrial land in 1992. Indus-
trial use is also projected for most of the ship channel frontage east
of the turning basin and for a portion of the Mobile Bay waterfront just
north of the Alabama State Docks terminal facility. Some commercial and
residential development is expected on the north side of Island Road
near the intersection with Rangeline Road.
The Ideal Basic Industries property is valuable for a variety of indus-
trial purposes and could probably be sold for alternative industrial use
if the cement plant were not built. Therefore, it is assumed that there
would be some other form of industrial development at the site by 1992.
AIR QUALITY
A projection of baseline air quality levels 15 years into the future
requires assumptions about both future industrial growth and fuel
availability. The Theodore Industrial Park area is expected to continue
development, so that by 1992 manufacturing employment in this area will
be two to four times its present level. Problems of fuel availability
might force some existing industries to use fuels with high sulfur
content, and thus sulfur dioxide emissions could be increased. However,
E-3
-------
••. THEODORE SHIP CHANNEL
RIGHT-OF-WAY
UURENDING ROAD
INSTITUTIONAL
AGRICULTURAL
NURSERY
INDUSTRIAL
PROPOSED CEMENT MANUFACTURING
PLANT THEODORE INDUSTRIAL PARK
MOBILE, ALABAMA
Figure E.1
PROJECTED LAND USE IN THE VICINITY OF THE
PROPOSED IDEAL BASIC INDUSTRIES PLANT SITE,
1992
0 OS 1
SCALE IN KILOMETERS
SOURCE: Environmental Science and Engineering, Inc., 1977.
E-4
-------
NO ACTION (PLANT SITE)
air quality modeling studies have indicated that, even though ambient
concentrations of atmospheric pollutants generally will increase over
the next 15 years, air quality standards and allowable increments will
not place serious constraints upon future industrial growth near Theo-
dore. The factors responsible are the high degree of air emission
control that could be applied, the relatively low spatial density of
industrial development, and the prevailing atmospheric dispersion
patterns.
NOISE
Noise levels are expected to increase due to: (1) traffic on the
Theodore Ship Channel; (2) increased highway traffic; and (3) increased
noise contributions from industrial activity. The quantitative noise
projections do not cover new industrial sources, or traffic increases on
secondary roads.
The environmental impact statement for the ship channel project included
forecasts of noise levels at various points along the ship channel
(USC Incorporated, Consulting Engineers, 1974). The highest projected
noise levels were obtained for stations located on both sides of the
channel from the Dauphin Island Parkway to the turning basin.
The baseline estimates obtained in the present study apply to different
stations and are expressed as L(jn and Leq(24). These projections are
presented in Table E.I, along with the sound levels suggested by EPA as
requisite to protect public health and welfare. The suggested outdoor
levels are 70 dBA for industrial land use which could cause hearing loss
over the long term (40 years) and 55 dBA for residential and institu-
tional land use which could interfere with communication.
Noise levels are expected to increase appreciably at all but two of the
stations between 1977 and 1992 (see Appendix B, Baseline, for the loca-
tions of these stations). At stations 6 and 12, the noise levels are
E-5
-------
NO ACTION (PLANT SITE)
Table E.I. Ldn and Leq(24) Noise Levels (dBA) at Baseline Monitor-
ing Stations in 1977 and in 1992 (exclusive of any new
industries)
1977
Station
1
2
3
4
5
6
7
8
9
10
11
12
Ldn*
55
54
48
72
48/55
65
55
55/55
53/55
54/55
67
67/55
Leq(24)*
48/70
49/70
45/70
66/70
45
61/55
53/55
48
51
52
59/70
66
Ldn*
60
60
48
81
48/55
71
55
64
63
63
t
72/55
1992
Leq(24)*
55/70
54/70
45/70-
75/70
45
68/55
53/55
57/70
56/70
56/70
t
61
* Second numbers in the columns refer to sound levels requisite to
protect public health and welfare according to the land use (see
Table B.N.2).
t No estimate since site is in future turning basin.
Source: Environmenta-1 Science and Engineering, Inc., 1977.
E-6
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NO ACTION (PLANT SITE)
already higher than the recommended values due to existing vehicular
traffic along Island Road (Hamilton Boulevard) and its intersection with
Dauphin Island Parkway. At station 4 (located on Rangeline Road), the
recommended level will be exceeded by 1992. In the case of stations
8, 9, and 10 (located along the south side of the ship channel), recom-
mended noise levels will not be exceeded only because land at these
stations is expected to convert from residential to industrial use, and
thus the recommended maximum levels will be raised. The conclusion from
these projections is that there would be moderate, but not severe, noise
levels in the vicinity of the Ideal Basic Industries property if the
proposed cement plant were not constructed. Again, this conclusion does
not consider the impacts of alternative industrial development at the
Ideal site.
WATER RESOURCES AND AQUATIC ECOLOGY
Water resources in the vicinity of the Ideal Basic Industries property
will undergo major changes by 1992 as a result of the ship channel con-
struction project, which will include a bay channel, a land cut, and a
turning basin of 12-meter (40-foot) depth. A barge canal extension of
3.7-meter (12-foot) depth will extend further inland.
The existing barge canal (Middle Fork Deer River) has poor flushing
characteristics, and this situation will probably prevail for the
enlarged ship channel. Thus, wastewater effluents might not be removed
effectively, with the result that water quality could be degraded below
existing levels. This prospect would become increasingly likely as
industrial development and maritime activity expand in the ship channel
corridor. However, a critical factor for water quality in the ship
channel would be the construction of the proposed common wastewater
outfall, which could serve existing and future industries, and possibly
carry municipal effluents as well. This project is currently undergoing
the EIS review process for COE approval of construction permits.
E-7
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NO ACTION (PLANT SITE)
The North Fork Deer River, which crosses the Ideal Basic Industries
property, could degrade significantly in the future due to effluents
coming onto the property from the west. This aquatic system is poorly
flushed, but subject to natural cleansing action by marsh vegetation.
The most likely condition in 1992 would be moderate water quality
degradation.
TERRESTRIAL ECOLOGY
The vegetation on the proposed site has been affected by recent logging
activity and thus represents a very early serai stage of a southern
mixed deciduous forest. If there were no development of the property,
the area would evolve as a pine forest in approximately 80 years and as
a mixed deciduous forest in 140 to 170 years. The major influence upon
terrestrial fauna over the next 15 years will be the gradual reduction
of disciimax shrub and understory areas. The density of birds and
mammals may decline during this mid-success!onal period, although some
species can be expected to increase (e.g., squirrels). The changes in
mammal populations will generally be quantitative rather than qualita-
tive, since most of the later serai stages of mammals are already
present.
The marsh is a relatively stable system which would remain largely
unchanged in the absence of development on the plant property. There
would be continued buildup of organic material at the land surface,
which would cause marsh and bog areas to become somewhat smaller over
time, but the basic structure and function of the marsh should not
change in the next 15 years under the conditions assumed.
SOCIOECONOMIC CONDITIONS
Future socioeconomic conditions in south Mobile County have been dis-
cussed in some detail in Appendix B, Baseline. In summary, the popula-
tion of south Mobile County is expected to increase from 47,400 in 1977
to 65,40U in 1992. There will be an increase in resident employment
E-8
-------
NO ACTION (PLANT SITE)
from 17,310 workers to 25,500 workers over this period, and the total
number of dwelling units will increase by more than 50 percent, from
15,080 in 1977 to 22,800 in 1992. This population growth will require
substantial expansion and/or upgrading of public facilities, notably
schools, highways, and water and sewer facilities.
Most of the land along the ship channel and the adjacent Mobile Bay
shoreline is expected to convert to industrial use.
E-9
-------
SITE LOCATION (PLANT SITE)
SITE LOCATION
INTRODUCTION
The selection of the Barrett site at Theodore as the location of the
proposed Ideal Basic Industries cement plant has been the culmination of
a 5-year planning process. The following discussion summarizes the
steps whereby the Theodore site was identified (by Ideal Basic Indus-
tries) as the most favorable alternative. Although not performed
specifically for this EIS, the site selection study demonstrates that
the selection of the proposed plant location is environmentally sound as
well as economically feasible.
The driving force behind the cement plant location studies has been the
observation that strong demand exists for new cement manufacturing
capacity to serve an established market within the immediate coastal
confines of Florida, Alabama, Louisiana, and Mississippi. The existing
customers of the Ideal Basic Industries plant and terminal facilities at
Baton Rouge, New Orleans, Lake Charles, Mobile, and Tampa would become
the clientele of a new manufacturing operation. The company has con-
cluded not only that the Gulf Coast market currently is large enough to
support a major increase in capacity, but that this geographic area has
all of the elements necessary for future growth. Three distinct options
considered in the planning studies have been: (1) modernization and
expansion of the Ideal Basic Industries existing plants; (2) multiple
new plant locations; and (3) consolidated productive capacity at a
single new location. These are described in the sub-sections which
follow.
MODERNIZED AND EXPANDED FACILITIES AT EXISTING PLANTS
Because cement manufacturing is an extremely capital-intensive process.
early consideration was given to the feasibility of modernizing and
expanding existing Ideal plants which might supply the Gulf Coast mar-
ket. Table E.2 summarizes the suitability of these sites for expanded
capacity.
E-10
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Table E.2 Profile of Ideal Plants Serving Southern Markets in 1974: Expansion Possibilities
PLANT LOCATIONS
Plant Characteristics
1974 Cement
Eq. Production:
Metric Tons
(Tons)
Kiln Data (No. & Age)
Process Employed
Fuel Consumption per
Million Calories/Bbl.
(Million Btu's/Bbl.)
ADA
560,000
(620, UOO)
2 (1958)
Wet
0.30
(1.2)
OKAY
327,000
(360,200)
2 (1929 & 1947)
Wet
0.38
(1.5)
MOBILE
408,000
(450,000)
5 (1943)
Wet
0.40
(1.6)
BATON ROUGE
381,000
(420,000)
5 (1943)
Wet
0.43
(1.7)
Primary Fuel
Standby Fuel
Present Fuel Source
Natural Gas
None; Coal System
Possible in Long
Range Future
Boettcher Oil & Gas
Oklahoma Nat. Gas
High Lime Source
Suitability of Present
Site as a Location
for an Additional
3 Million Barrels of
Capacity
Limestone
New installation
could be included
with present
plant
Natural Gas
None; Coal System in
Preliminary Planning
Stage
LNT
Limestone
New installation
could be built on
an adjacent site
but not on present
property.
Gas, No. 6 Fuel Oil
None
Gas (One-third supply)
United Gas Pipeline
Fuel Oil (two thirds
of supply)
Oyster Shells
Gas, Fuel Oil
System Being
Installed
None
Monterey Gas Co.
(1-year contract)
Oyster Shells
Not feasible without demolition of existing
facilities. Demolition costs and loss of
revenue and market share during construction
make these sites infeasible for new capacity
CO
o
o
co
Source: Ideal Basic Industries, 1974.
-------
SITE LOCATION (PLANT SITE)
Engineering investigations carried out in late 1972 and early 1973
concluded that the Ada and Okay plants could accommodate substantial
additional production. However, this new capacity would be signifi-
cantly removed from the coastal market to be supplied. Therefore, the
delivered price of cement in the marketplace would be governed by
whatever rail rates the company might be able to negotiate. Also, any
capital cost savings accruing to expanded capacity at either of these
locations would be offset, to a degree, by the costs of operating
terminal-transfer facilities in the Gulf Coast market area.
Neither the Mobile nor the Baton Rouge facility could accommodate
expanded production without demolition of existing plants. The demo-
lition cost, plus the loss of revenues to Ideal Basic Industries during
demolition and reconstruction, would render both of these alternatives
highly infeasible. This approach would also reduce the company's cement
production for several years and would thereby make the market very
vulnerable to other sources of cement. Finally, the Mobile site has
limited acreage, and additional land is not available.
From these early investigations, it was concluded that Ideal's future in
the Gulf Coast would best be served from one or more entirely new plant
sites.
MULTIPLE NEW PLANT LOCATIONS
A detailed analysis compared the capital and operating costs of a single
large plant of 1.4 million metric tons (1.5 million tons) per year vs.
two smaller plants of 0.7 million metric tons (0.75 million tons) each.
Of the many two-plant alternatives considered, construction of new
facilities near the existing Baton Rouge ana Mobile plants was the most
favorable. Even in this most favorable two-plant case, capital costs
would be 60 percent higher than for a single large plant centrally
located on the Gulf Coast. Operating costs would also be substantially
E-12
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SITE LOCATION (PLANT SITE)
higher because of a larger total labor force in two separate facilities.
Considering annual capital costs, as well as operating, distribution,
and marketing costs, the study concluded that total costs per unit
capacity would be 25 percent less -for the single larger facility. Fur-
ther planning efforts were therefore directed towards selection of an
entirely new plant location.
CONSOLIDATED PRODUCTIVE CAPACITY AT A SINGLE NEW LOCATION
Evaluation Criteria
A large number of potential plant sites were evaluated by a rather elab-
orate series of procedures and criteria. Eleven well-defined criteria
were applied in the screening process, including six "first level"
criteria and five "second level" criteria. As indicated below, the
first-level criteria related primarily to the economic feasibility of
plant operation at a given site. However, environmental factors entered
prominently in the pre-screening of sites, in the environmental compati-
bility criterion, and in the final evaluation process.
Brief descriptions of the criteria are presented in the following
listing:
FIRST-LEVEL CRITERIA
1. Site availability.
2. Physical suitability and engineering feasibility. Relates to
the existence of sufficient acreage to accommodate an efficient
plant layout; the dimensions of waterfront areas; the existence
of soils with high load-bearing capability; and the availability
of power, gas, water and sewer services, skilled labor, and
equipment repair services.
3. Access to deep water transportation. Relates to the critical
importance of transportation cost in determining Ideal's ability
to serve a geographically dispersed market, plus the influence
of transportation upon input costs. The potential advantages of
E-13
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SITE LOCATION (PLANT SITE)
water transportation relative to land transportation vary with
the depth 01 water available. Deep draft, ocean-going vessels
are the most economical.
4. Location with respect to expected markets. Refers to the
advantages of central location within the market area discussed
previously.
5. Location with respect to raw material supply sources.
6. Capital and operating cost economics. Refers to geographical
variations in the costs of plant construction, fuels, electric
power, local taxes, labor and similar factors, plus the degree
of operating flexibility and project risk.
SECOND-LEVEL CRITERIA
7. Highway, rail, and other supporting facilities.
8. Envi ronmental compatibi 1 i ty. Defined in terms of probable
acceptance of the project by responsible local officials and by
citizens. Determined by contacting state, county, and municipal
agencies and by studying recent events and policies in individ-
ual communities.
9. Community resources. Refers to the existence of community ser-
vices such as police and fire protection, schools, and hospitals
needed by project personnel, plus the size, training, and sta-
bility of the local labor force.
10. Land use compatibility. Relates to the existing land uses found
near a potential site, the most favorable being industry and the
least favorable being recreational and residential land uses.
11. Natural hazards. Refers to the susceptibility of sites to wind
and water damage.
Descriptive ratings, termed "site evaluators," were assigned to each
site for each of the eleven criteria. A summary of the results of the
first-level screening and of the reasons for the ultimate selection of
the Theodore site is presented in the following pages.
E-14
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SITE LOCATION (PLANT SITE)
Site Evaluations
A total of 27 potential sites were considered in the formal screening
process. These sites were identified through an investigation and
analysis of five general areas: (1) southwest Alabama; (2) the Pensa-
cola-Panama City area of Florida; (3) the Gul fport-Pascagoula area of
Mississippi; (4) the Apalachicola-Chattahoochee River area in Georgia;
and (5) the Louisiana delta.
The south Alabama area was most intensively studied because it most
nearly satisfied the first level site evaluators. Twelve alternative
plant locations were identified and investigated with the assistance of
the Industrial Development Division of the Alabama Development Office,
the Industrial Development Department of the Mobile Area Chamber of
Commerce, and the Industrial Development Department of Merchants
National Bank of Mobile.
Site investigation in the Pensacola-Panama City area of Florida began in
1973 in consultation with state and city development agencies and power
company representatives. Attention was focused on potential sites in
the Pensacola area, the Port of Panama City (St. Andrews Bay), and Port
St. Joe (St. Joseph Bay). These investigations determined that there
were no industrial sites bordering on 12 meters (40 feet) of water and
that the only sites with access to water depths of 8 to 9 meters (25 to
30 feet) were non-contiguous tracts smaller than 6 hectares (15 acres)
each. The only available industrial acreage of suitable size and con-
figuration was situated along water depths of about 3 meters (10 feet),
which would limit inbound and outbound water movements to shallow draft
vessels. These findings were verified in June, 1974.
Site investigations in coastal Mississippi were carried out with the
assistance of the Mississippi Agricultural and Industrial Board, the
Industrial Development Department of Mississippi Power Company, and the
industrial development boards and port authorities of Forest, Hancock,
and Jackson counties. Five potential sites were identified, including
E-15
-------
SITE LOCATION (PLANT SITE)
one site at the Port of Pascagoula and two each in Hancock and Harrison
counties.
Because the sites studied in Georgia were geographically removed from
the company's principal cement consuming markets in the Gulf Coast and
because waterborne transportation would be restricted to 2.7-meter
(y-foot) draft barges, the findings of these investigations were
generally unfavorable.
Investigations in Louisiana, which yielded six potential sites, were
conducted in consultation with the Louisiana Department of Commerce and
Industry; the Industrial Development section of Louisiana Power and
Light; the Industrial Development Department of the Southern Railroad;
and the Baton Rouge, New Orleans, and Lake Charles chambers of commerce.
Table E.3 presents in simplified form the outcome of the first-level
site screening process. The table indicates those first-level criteria
for which a given site received a relatively unfavorable rating.
Nineteen of the potential plant sites failed to qualify in four or more
first-level criteria. Because these sites were clearly unacceptable as
potential locations for the project, they were not subjected to
"second-lev el" evaluation.
Second-Level Site Evaluations
Jhe following eight sites survived the first-level screening:
1. Jacijrtojrort--Owned by Louisiana Land and Exploration Company,
and situated on the Mobile River approximately 8 kilometers
(5 miles) north of the Mobile City limit.
2- Old Chickasaw Shipyard—Held in « union trust and located just
north of Mobile on the Mobile River in Chickasaw, Alabama.
E-16
-------
SITE LOCATION (PLANT SITE)
Table E.3. First-Level Site Evaluation
FIRST-LEVEL CONSIDERATIONS
POTENTIAL SITES
CO
4-> +J O» 0»
>>>> C O CO O O C
•M4J O t/> .* COO »-i--^ a) .00 a: «} ac a>->-
-O +* •!- C
••-> _a 3 co -f-a* -i- t- -o o
•^lOCOU- C X4-* Stt* CO
COr— COW y -4-> 1X3 UJ
••- ^- • cot. ca> cm
*O (O O) O ^~ O O- O 5£ ^~ 4-^
>OC O -i-X'f- «0 Vt
LiJ 4->2 -MO
CO ^C
*j oo oa: o.
>o o 4-> o 10
3 _I -10 O
ALABAMA
Jacintoport (Mobile) • I
Old Chickasaw Shipyard • I
Monroe Park I • • •
Blakely Island • I I
Theodore--Barrett Site
Theodore—McWane Site •
Theodore—Mobile Deep Water Property I
Buck's Crossing • • I I
Twenty-Four Mile Bend • • • I I
Ladd Property (21 Mile Bluff) • • I I •
Chastang Site (River Mile 35) • • • I •
Gail lard Property • •
FLORIDA
Port of Pensacola • • • I •
Port of Panama City • • I • I
Port St. Joe • • I • •
E-17
-------
SITE LOCATION (PLANT SITE)
Table E.3. First-Level Site Evaluation (Continued, Page 2 of 2)
FIRST-LEVEL CONSIDERATIONS
to
4-> •«-> 01 O»
>>>» c o to o o c
+J +J O O> -t-» O i- •>-
•F- •!- ••- Q. Q» Q. 3 4J
r— r- CL4-> «/) ^ «/> O fO «/>
>> •!-•!- O) 1- S- O
•i- iQ-i-ai- s .— o.e
i— •!->«/> O J= J= (O O O
~o *» ••- c
•4->.O 3d) 4-> 1/1 -i- O) •!- I- T3 O
•f--> 5 a> co
co r— «/> (o ui
•r- i— • tO S_ CO) C I— O CL O ^» i~ 4J
> oc o -t- x ••-
UJ 4->2 4->O
^ Q> fQ *O IO '^ C-J
•*-> O O O QC Q.
o to
2—1 —I O O
POTENTIAL SITES
MISSISSIPPI
Port Bienville (Hancock County) • • • • t
Bay St. Louis (Hancock County) • I • • •
Port of Gulfport (Harrison County) • • • • •
Biloxi (Harrison County) • • I • •
Pascagoula (Bayou Casotte) • • •
GEORGIA
Bainbridge I • • •
LOUISIANA
Westport (Jacintoport, N. Orleans) • • • • I
Lake Charles (Old Lone Star Site) I • •
Braithwaite (Plaquemines Parish) • • • •
Meraux (St. Bernard Parish) • • • •
McMaster (St. Bernard Parish) • • • •
Poydrate (St. Bernard Parish) • • • •
Key: • = An unfavorable rating.
Source: Ideal Basic Industries, Inc., 1974.
E-18
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SITE LOCATION (PLANT SITE)
3. Mobile Deep Water Property at Theodore—Adjacent to the old
ammunition depot dock on the Mobile Bay shoreline, along the
route of the Theodore Ship Channel project.
4. Blakely Island—An approximately 28-hectare (69-acre) site owned
by the Frisco Railroad on the western shore of Mobile Harbor,
almost directly across from the Ideal Basic Industries existing
Mobile cement plant.
5. Barrett Site in Theodore Park—A 71-hectare (175-acre) tract
situated on the northern side of the inland portion of the
Theodore Ship Channel, bounded on the east by the Dauphin Island
Parkway and to the west by the Airco, Inc. operation.
6. Ideal's Gal Hard Site--A 740-hectare (1,830-acre) tract on the
eastern bank of the Alabama River (Marshall Bluff) in Monroe
County, some 22 kilometers (14 miles) southwest of Monroeville,
Alabama.
7. Port of Pascagoula--The Bayou Casotte industrial complex.
8. Lake Charles—The old Lone Star Cement plant sfte consisting of
154 hectares (380 acres) on the Calcasieu River in Ward 4 in
Calcasieu Parish, Louisiana.
These eight potential locations were evaluated in considerable detail.
Six of the sites were rejected for the following reasons:
Lake Charles (Old Lone Star Site)—Major disadvantages included:
(1) remoteness of the site from potential supply sources of
limestone, clay, and coal, resulting in substantial transportation
diseconomies; and (2) location of the site at the western end of
Ideal's Gulf Coast market.
Blakely Island—The primary disadvantages were: (1) very low ele-
vation which would require substantial fill, soil, and site work;
E-19
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SITE LOCATION (PLANT SITE)
(2) poor highway access to the major cement consuming markets in
the Mobile area; (3) absence of a railroad, which would necessitate
ferrying of railcars across Mobile Harbor via barge; (4) con-
straints upon process flow imposed by the physical configuration of
the site; and (5) environmental constraints.
Pascagoula—The economic disadvantages of this area included the
following factors: (1) the site was located several kilometers
from the existing terminal facilities, so that double handling of
materials and a costly conveying system would be required; (2) the
utilization of port facilities at this site would involve payment
of inbound and outbound charges on very substantial volumes of raw
materials and finished cement products; (3) the plant would be
distant from raw material supply sources; (4) location at Bayou
Casotte ultimately would require the company to establish a new
terminal operation in Mobile.
Jacintoport (Mobile)--Major site disadvantages to Ideal Basic
Industries included: (1) a site elevation which makes much of the
property flood-prone and requiring substantial fill, soils, and
site work; and (2) local objections to industrial development of
Jacintoport at the time of site investigations (late 1973).
Old Chickasaw Shipyard—The primary problems were: (1) the site's
elevation ranged from 0 to 3 meters (0 to 10 feet) msl, making the
area flood-prone; (2) it would be necessary for Ideal to use
pilots and assisting tugs to navigate the Cochrane and L&N bridges;
(3) the existing waterfront and dock structures do not lend them-
selves to the material flow of a cement manufacturing operation;
and (4) the Chickasaw site might be environmentally unsuitable for
cement manufacturing because of its proximity to the heavily
industrialized area of Mobile.
Mobile Deep Water Properties (Theodore)--Major disadvantages of
this site included: (1) low elevation and soil conditions;
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SITE LOCATION (PLANT SITE)
(2) limited waterfront area and the physical configuration of the
site; and (3) open exposure to the Bay and potential risk of plant
damage in the event of hurricanes.
Site investigations and economic studies conducted from late 1973
through the middle of 1974 thus reduced the number of alternative new
plant sites meeting the company's criteria to two locations: the Ideal
Basic Industries Gaillard property in Monroe County and the Barrett
property in the Theodore Industrial Park. The reasons for the ultimate
selection of the Theodore site are outlined in the following paragraphs.
Cost Analysis
If the manufacturing operation were located at Gaillard, it would be
necessary to transport virtually the entire plant output via shallow-
draft barge to Mobile for transfer to deep-draft barges and other
transportation modes. For purposes of analysis, the Barrett site in the
Theodore Industrial Park was assumed to be the terminal/transfer point
under this alternative.
The construction cost of the cement plant would favor a Gail lard loca-
tion by approximately 15 percent. However, this saving would be offset
by the additional capital costs associated with: (1) construction of a
terminal transfer point and (2) the purchase of more costly equipment to
transport finished cement on the Alabama River than would be needed to
transport limestone over this route. (Open barges could transport
limestone and clay, whereas closed, air-tight barges would be required
to transport finished cement.) The total construction cost of a plant
located at Gaillard with a terminal-transfer station at Theodore would
be several million dollars greater than the construction cost of a
Theodore plant.
A similar situation would apply to labor force requirements. A savings
in the number of hourly and supervisory persons required for a plant at
Gail lard would be more than offset by the work force necessary for a
Theodore terminal operation.
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SITE LOCATION (PLANT SITE)
In terms of operating costs, the Gail lard plant would result in a
5 percent saving per ton of output relative to the Theodore plant
location. This cost saving would be attributable to a manpower reduc-
tion of 12 persons, plus an input cost reduction amounting to the cost
of transporting limestone from Gaillard to Theodore. On the other hand,
marketing costs would be roughly 37 percent greater at Gail lard than at
Theodore. These costs include selling and administrative expense,
transportation of finished cement from the plant to terminals, and
terminal operating costs. With regard to transportation, it has been
computed that the total cost difference in barging finished cement
versus limestone, after provision for depreciation, would be approxi-
mately 3 percent in favor of barging limestone. (The difference in
capital outlays for transportation equipment would amount to $2.7 mil-
lion in favor of limestone.)
When both production and marketing cost differences associated with the
two sites are considered, the total estimated expenses for the Gaillard
plant location are approximately 3 percent more per ton than for the
Theodore plant. This percentage does not represent a major economic
difference between the two plant location schemes.
Analysis of Operating Conditions and Transportation
Operating flexibility and project risk were important selection factors.
The remote location of a Gaillard plant site could be a complicating and
costly factor from a labor standpoint, during both the construction and
operation phases. Large equipment for the plant at Gaillard could pos-
sibly be delivered via the Alabama River during the plant construction
period, but the Gaillard waterfront would need to be improved substan-
tially for this purpose. Major equipment could likewise move to the
site via rail or highway; however, added costs might be incurred because
of the upland location of the site and the added assembly cost of equip-
ment brought to the site in smaller sections.
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SITE LOCATION (PLANT SITE)
Whereas the Theodore site would have ready access to rail and interstate
highway connections, the Gail lard site lacks major transportation con-
nections. Approximately 18 kilometers (11 miles) ot railroad would need
to be constructed to connect the plant with the Frisco mainline to the
east of the site. Right-of-way acquisition through easement or purchase
could be both difficult and expensive. Furthermore, a plant located at
Gail lard would require an access road connecting the operation to the
county road approximately 3 kilometers (2 miles) distant (assumed to be
a two-lane, heavy-duty paved road as opposed to a gravel-surfaced road
required tor just a quarrying operation).
Although the extensive technical services a cement plant sometimes
requires are readily available in the Mobile area, major equipment
repairs and machine shop work for a Gail lard plant location would entail
hauling major equipment to Mobile or Montgomery. This transportation
problem could increase plant downtime and repair expenses. The avail-
ability of a suitable labor force in Monroe County would be uncertain.
and technical and managerial employees might be unwilling to transfer to
the comparatively undeveloped and remote location offered by a Gail lard
plant.
In-depth studies of the navigability of the Alabama River and the
problems uncovered in these investigations were very important in the
company's choice of a plant site. This river is noted for its periods
of high and low water, fog, and restricting bends. Location of the
proposed plant at Gail lard would make the overall operation highly
vulnerable to potential problems involving this waterway. A Theodore
location, on the other hand, would increase Ideal's marketing flexi-
bility due to the availability of deep water, rail access, and direct
highway links to interstate highways 1-10 and 1-65.
Approximately one-third of the annual output of the proposed new plant
potentially can be marketed in the Mobile metropolitan area. The
Theodore plant location would maximize Ideal's effectiveness in reaching
this market. The deep water access afforded by the Theodore Channel
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SITE LOCATION (PLANT SITE)
would permit the use of alternative raw materials and/or coal from other
sources. Likewise, If the company should desire to Import clinker or to
export cement, these activities could be accomplished most readily and
economically from the deep water Theodore site.
Assessment of Environmental Impacts
Environmental Impacts associated with a Gal Hard versus Theodore plant
location were assessed as part of the site selection process (see
Table E.4). This analysis Indicates that there would be some environ-
mental Impacts at either plant location and that these Impacts might be
less severe on the whole at the Theodore site.
In view of these factors, plus the currently favorable prospect for
timely completion of the Theodore Ship Channel, the management of Ideal
Basic Industries formally recommended in May of 1977 that the proposed
cement manufacturing facility be constructed at the Theodore location.
During the course of performing their site review, Ideal Basic Indus--
tries has discussed the proposed project with the following local and
state agencies: the City of Mobile, the Mobile County Commissioners,
the Industrial Development Boards of the City of Mobile and the City of
Monroeville, the Alabama Development Office, the State Industrial
Development Authority, and the Alabama Commissioner of Revenue.
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SITE LOCATION (PLANT SITE)
Table E.4. Comparative Environmental Evaluation for Location of the
Proposed Plant at Theodore Versus Gail lard (Performed by Ideal
Basic Industries)
Environmental
Parameter
Theodore
Gail lard
Fish
Weather
Land Use
Transportation
Sanitary
Wastes
A minor resource. Will be
influenced little. Impor-
tant to protect estuary.
Subject to storms and
coastal salt effects.
High tides and hurricane
floods could be problems.
Will fit in with surround-
ings in Industrial Park.
Available close by. No
special environmental
assessment.
Will be handled by regional
wastewater system.
A major resource. Care,
control, and consideration
in handling runoff and dis-
charges would be required.
A protected area. No salt
problems or high tides.
Will be a major change.
Only one land use of its
kind in area.
Will require additional
environmental assessment
work for railroad. Will
need additional road access
work, causing disturbance.
Will need a separate
facility with treatment.
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SITE LOCATION (PLANT SITE)
Table E.4. Comparative Environmental Evaluation for Location of the
Proposed Plant at Theodore Versus Gail lard (Performed by
Ideal Basic Industries) (Continued, page two of two)
Environmental
Parameter
Theodore
Gal Hard
Water
Air
Soils
Physiography
Vegetation
Subsurface—condltlons
known, no apparent prob-
lems. Surface—water
quality control relatively
easy. Discharge to Indus--
trial canal or Industrial
Park wastewater system.
Ambient conditions—low
quality. Classified in
lower quality status.
No sensitive runoff areas
as long as estuary is
protected.
Flat.
Low quality.
Subsurface--conditions not
known. Surface-control
wi 11 requi re more effort
and possible expense than
Theodore. Discharge to
navigable stream with
multi-resource usages.
Ambient conditions--high
quality. Classified in
higher quality status.
Has sensitive runoff
areas. Runoff control may
be difficult due to
irregular terrain.
Rolling and irregular.
High quality. Potential
for degradation thus
greater than at Theodore.
Source: Ideal Basic Industries, 1976.
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PROCESS/RESOURCES (PLANT SITE)
PROCESS/RESOURCES
Two basic alternatives for the manufacture of portland cement are "wet"
or "dry" processing. In both processes, the raw materials are mined,
crushed, and blended before grinding. Ideal Basic Industries proposes
to use a dry cement process with several fuel-saving options, such as a
combined kiln/clinker cooler/raw mill exhaust system and a kiln suspen-
sion preheater. The possible alternatives are a wet process and the use
of other types of raw resources.
WET PRXESS VERSUS DRY PROCESS
In the wet process, raw materials are mixed with water and pumped to the
kiln as a slurry. In the dry process, raw materials are dried prior to
feeding into the kiln. The two processes are otherwise the same.
About two-thirds of the currently operating cement plants use the wet
process (Reding, ejt a_K, 1975), but many of these are old plants.
Modern dry process plants are more energy efficient than wet process
plants and thus are ecologically preferable.
Because the water in the slurry must be evaporated in the kiln, a wet
process plant uses twice as much energy per ton of clinker as a dry
process plant does. Furthermore, in the dry process, waste heat from the
kiln and from the clinker cooler is used to dry the raw materials; such
fuel conservation practices cannot be applied in the wet process.
An advantage of slurrying raw materials is that no dust is produced.
However, in both processes dust can be generated from the clinker cool-
ers, finish mills, and bulk handling systems. Baghouses remove at least
99 percent of this dust. A dry process plant uses additional baghouses
to control dust, and the wet and dry processes do not differ signifi-
cantly in the quantity of air emissions per unit of output (U.S. EPA,
Office of Air Quality Planning and Standards, 1975).
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PROCESS/RESOURCES (PLANT SITE)
There are several disadvantages of the wet process. Spills of the
slurry and leaching of recycled kiln dust can cause wastewater dis-
charges. The slurry tends to clog lines and mixing tanks and thereby
creates maintenance problems. Finally, a much larger amount of exhaust
gases, produced because of the steam from the water, necessitates a
larger and more costly air pollution control device on the kiln
exhaust.
By using waste heat to remove the moisture in the raw materials, the dry
process plant becomes very economical. Fuel requirements for the dry
process are estimated to be 0.78 million calories per metric ton
(3 million Btu per ton) of clinker versus over 1.7 million calories per
metric ton (6 million Btu per ton) of clinker for the wet process.
For reasons of fuel efficiency, ease of maintenance, lesser environ-
mental impact, and overall lower cost, Ideal Basic Industries plans to
use the dry process at the projected new cement plant.
RAW MATERIALS
Limestone comprises about 80 percent of the raw materials needed in
cement manufacturing. Alternative sources of limestone are considered
in the section which discusses the quarry site.
Other raw material needs include argillaceous materials, siliceous
materials, ferrous materials, and other minor ingredients. Clay, shale,
staurolite, bauxite, aluminum dross, pumice, and volcanic ash are all
argillaceous substances which could be utilized. Ideal Basic Industries
has an existing clay pit and therefore will use clay at the proposed
plant. The usable reserves of clay at the existing quarry amount to
approximately a 5-year supply. Therefore, other sources of argillaceous
material will be necessary in the future. Of the siliceous materials,
including sand, sandstone, and quartz, Ideal Basic Industries will use
silica sand taken from the clay quarry.
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PROCESS/RESOURCES (PLANT SITE)
Ferrous materials Include Iron ore, pyrites, mill scale, and other Iron
bearing materials. Iron ore will be used at the Theodore plant; how-
ever, the source of this iron ore has not yet been determined. Other
possible materials for the cement manufacturing process Include gypsum,
anhydrite, blast furnace slag, or fly ash. The proposed cement plant
will use gypsum from a currently unidentified source. The reasons for
selecting the specific raw materials have Involved availability, econo-
mics, and compatibility with the chemistry of raw mix.
EQUIPMENT ARRANGEMENT
The present plant design has undergone many changes In the planning pro-
cess. The changes were made to allow for modification to the settling
basin and the stormwater catchment area, to Increase the height of the
main stacks, to provide a 20-meter (65-foot) high dead storage pile to
form a noise buffer, to eliminate encroachment Into the brackish marsh
and minimize disturbance of the freshwater marsh, to cover the piles of
the drier raw materials to reduce dust emissions and stockpile runoff,
and to allow for many process design changes.
The arrangement of equipment and facilities, although flexible to some
degree as shown by the above changes, does not have substantive alterna-
tive arrangements other than those abatement actions to be discussed in
the next section.
FUELS
Coal is the preferred energy source for the proposed facility because of
energy concerns and economics. Ideal Basic Industries is planning to use
bituminous coal with a 1.5 percent maximum sulfur content by weight.
The use of higher sulfur coal would involve two sets of problems:
1. Operational difficulties associated with the preheater, and
2. Increased atmospheric emissions of sulfur dioxide.
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PROCESS/RESOURCES (PLANT SITE)
Alternative fuels which could be used Include oil and natural gas.
Natural gas, however, may not be readily available for Industrial use In
the coming years, and oil Is becoming Increasingly scarce and subject to
rapidly escalating costs. Fuel oil will be used to Ignite the coal on a
pilot basis and as a stand-by fuel, but use of significant quantities is
not projected.
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ABATEMENT MEASURES (PLANT SITE)
ABATEMENT MEASURES
AIR EMISSIONS
The main construction Impacts relative to air emissions are smoke from
burning and fugitive dust from site development activities. Alterna-
tives to the burning are discussed 1n the Solid Waste section. The
activities which generate the dust emissions, although mitigated some-
what (see Appendix D, Mitigating Actions), do not have practical
alternative actions.
Proposed Action. Use of Baghouses. Water Sprays. Process Design
Baghouses will be used during plant operations to reduce the emissions
of dust particles from all process exhausts. These devices have col-
lection efficiencies of greater than 99 percent and are considered Best
Available Control Technology (BACT).
Dust may be generated at the raw materials unloading operations, con-
veyor transfer and drop points, and from the uncovered storage piles.
These sources are controlled by the use of water sprays for dust
suppression.
Emissions of sulfur dioxide, nitrogen oxides, and hydrocarbons normally
are not controlled at cement plants. Emissions of sulfur dioxide and
nitrogen oxides will be subjected to some degree of control at the
proposed plant by process operating parameters. However, there Is no
existing technology for reducing hydrocarbon emissions from cement
plants.
Exhaust gases from the kiln will be vented through the raw mill where
much of the sulfur dioxide will be removed by contact with the raw
materials. A further reduction should be produced when the exhaust
gases are forced through the alkaline dust cake which builds up on
the bag filters In the baghouse systems.
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ABATEMENT MEASURES (PLANT SITE)
Possible alternatives to the proposed actions are the use of scrubbers,
cyclones, electrostatic precipitators, and enclosing sources of fugitive
dust.
The other major air quality related impacts are the use of the PSD
increments for suspended particulate matter and sulfur dioxide (see Air
Quality section of Appendix C, Impacts) and the effects on the ambient
air quality levels in the general area. There are no alternative
actions that would reduce these impacts associated with the operation
of the plant.
Alternative I. Scrubbers
Wet scrubbers can reduce particulate emissions by 90 percent or more.
However, they are not more efficient than baghouses, and they have a
number of disadvantages. Scrubbers produce a wastewater which becomes a
disposal problem and a wet waste product which is difficult to recycle.
Scrubbers have high energy requirements, and there are maintenance prob-
lems due to plugging of the system. This latter problem is particularly
serious at a cement plant because cement dust will harden after wetting.
Therefore, scrubbers are not practical for dust control. However,
scrubbers could function to reduce sulfur dioxide emissions after gases
are precleaned by a baghouse or an electrostatic precipitator. Since a
baghouse is expected to remove at least 75 percent of sulfur dioxide, it
is doubtful that scrubbers would achieve substantial further reductions
that would be cost-effective. In addition, baghouses usually demonstrate
better control efficiencies and have a higher reliability factor.
Alternative II. Cyclones
Multi eye Tones can be utilized effectively for pretreatment along with
some higher efficiency device. The cyclones will remove larger
particles but not the finer dusts. Therefore, cyclones usually assist
other control devices by acting as precleaners and are not used as a
final control system.
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ABATEMENT MEASURES (PLANT SITE)
Alternative III. Electrostatic Preclpitators
Electrostatic precipitators are, In general, employed only on large
volume exhaust gas streams (I.e., from the kiln, cooler, and raw mill)
since their cost Is prohibitive for smaller applications. In addition,
they have several other shortcomings, Including: (1) explosion potential
under certain upset conditions because of the combustible gases and coal
dust in the gas stream and high voltage sparks produced by the precipi-
ta tor; and (2) the need for conditioning the particles for the correct
range of resistivity prior to entry into the precipitator.
Alternative IV. Venting of Fugitive Dust Sources
The raw materials handling and storage facilities could be enclosed and
vented to baghouse systems. The advantage of these enclosures would be
a more efficient control plan to reduce the potential for fugitive dust
emissions from the plant. However, not every source could be enclosed
because of the need for entry of the barge unloading clamshell and heavy
equipment. Enclosed storage buildings would be a negative pressure and
would require a very large fan and control system for adequate capture
velocities throughout the structure. Since about 85 percent of the raw
materials will be limestone and wet clay with a moisture content of
about 22 percent, the covered storage area for the drier materials and
the planned water spray dust suppression equipment are considered
adequate so that additional reduction would not be necessary or
economically feasible.
Rationale for the Proposed Action
The proposed use of baghouses on all the vented exhausts was based on
the lack of practical alternatives for the numerous smaller sources at
the plant and problems with an electrostatic precipitator for the larger
sources. Additional fugitive dust controls would not be warranted on a
cost-to-benefit basis.
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ABATEMENT MEASURES (PLANT SITE)
NOISE
The construction of the plant facilities, which will take about
30 months, will cause some noise impacts in the surrounding area. Due
to the type of equipment involved and tasks to be performed, there are
no practical alternatives that can be taken. The noise aspects of the
operational phase of the project are discussed below.
Proposed Action. Layout of Plant Site for Efficient Production
The proposed plant layout will place the kilns and other elements of the
cement manufacturing process near the center of the developed site area.
To the east would be the 20--meter (65*-foot) high raw material storage
piles and the 90-meter (300«-foot) greenbelt, and to the west would be
the parking area, office, wastewater settling basin, and undeveloped
land. Immediately north of the plant site are the marshland and
36.4>-hectare (90>-acre) wooded area. South of the site will be the
210-meter (700>-foot) wide ship channel waterway.
This layout reflects the latest of many previous designs and serves to
reduce somewhat the noise generation characteristics of the site while
not reducing the functional requirements of the facility.
Alternative I. Plant Layout to Minimize Noise Impact
An optional layout in terms of noise would involve locating the major
noise-producing elements as far to the west as possible. The raw
material storage piles, a'nd possibly other noise barriers, could be
located to provide maximum buffering of noise effects to the east,
south, and north.
Rationale for the Proposed Action
The proposed action does not differ greatly from Alternative I in that
the raw material storage piles will provide a substantial reduction of
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ABATEMENT MEASURES (PLANT SITE)
noise effects to the east, the direction In which the most sensitive
land uses will be located. No alternatives providing greater noise
protection are considered feasible in terms of process flow and other
site requirements.
The proposed plant layout (see Appendix A) was chosen as the most prac-
tical use of the rather confined facility site considering a balance of
ecological and noise factors. However, the design consultants are con>-
tinuing their study to determine the noise reduction effects of layout
and equipment changes. If specific types of equipment are determined'to
generate lower noise levels, have practical operating requirements, and
be cost-effective, they will be used.
SOLID WASTE
Proposed Action. Landfill
The proposed plant construction and operation will generate industrial
solid wastes that will be transported to the Irvington Landfill for
di sposal.
Alternative I. Burial On-Site
The construction and operation wastes could be buried on the property.
Since most of the waste will be suitable for fill, this alternative
would merely raise the elevation of a portion of the property.
Alternative II. Burial Off-Site
The wastes, except the putrescible and Teachable wastes, could be used
as "fill" for an off-site area. The wastes could be transported to the
site on an as-needed basis.
Rationale for the Proposed Action
All three methods of disposal are environmentally sound. The use of the
Irvington Landfill would be the easiest and most practical since both
E-35
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ABATEMENT MEASURES (PLANT SITE)
the putresdble and "fill" type wastes could be handled In the same
vehicle. However, as mentioned in the impacts section., there will be a
slight trade-off since the areas will tend to reach capacity faster.
On-site burial would be achievable but not very practical due to the
lack of available land at the plant site and the high water table 1n the
area. In addition, operation of a private industrial landfill is not a
desirable action from an environmental viewpoint as proper disposal
could be better achieved on a regular basis by trained operators at a
public landfill.
The method of off-site burial, while not the proposed action, is still a
viable action if an acceptable area could be found. This alternative
could not be used for the putresdble and Teachable wastes for the same
reasons previously mentioned for an on-site landfill.
The planned use of the Irvington Landfill provides an environmentally
sound disposal method and is the most practical choice of the three
options.
Proposed Action. Disposal of Vegetative Wastes
The land-clearing wastes will be burned, chipped for mulch, or taken to
the Irvington Landfill for disposal. The amount of wastes that will be
disposed by each method will be determined during the construction
period. All of the wastes could be disposed by any one of these methods
without significant environmental impact (see Appendix C, Impacts). The
alternatives are to cut the wastes for firewood, to sell them to a pulp
mill or a waste wood boiler, or to bury them on the plant site.
Alternative I. Use as Firewood
The land-clearing wastes would be cut for fireplace-size logs and kin-
dling and either sold or given away. The action would require smaller-
sized pieces than would be used in the air-blower type pit burner and
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ABATEMENT MEASURES (PLANT SITE)
would require extra time and manpower. In addition, hauling the wastes
to a more accessible location would probably be necessary to provide
public access to the wood.
Alternative II. Selling Wastes for Use in a Pulp Mill or Waste Wood
Boiler
The majority of the trees are from the remnant longleaf pine forest and
should be of the size that could be cut and sold to several of the
nearby pulp mills or waste wood boilers. Additional time, labor, and
expense for cutting and transportation is expected not to be offset by
any monies received for the wood.
Alternative III. On-Site Burial
The land clearing wastes could be buried on--site in an area that would
not be developed for plant operations.
Rationale for Proposed Action
The first two alternatives are practical actions that could be utilized.
However, their principal problem, which is shared somewhat with the
proposed chipping and landfill (off-site), is the extra time and expense
required to completely dispose of the vegetative wastes. These
alternative actions are difficult to defend since the burning of the
wastes would be conducted in an efficient manner and performed under a
permit from the local health department. Any smoke generated would be
less than that of typical open burning and would have a short*-term
impact.
The on-site burial alternative would cause a soil stability problem when
the wood decays and forms a subsurface void. In addition, the land area
needed to bury the waste would require clearing. Due to the lack of
available dry land, the wastes would probably be buried on the area
north of the marshland which Is presently planned not to be developed.
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ABATEMENT MEASURES (PLANT SITE)
In summary, the three proposed methods of disposal of the land-clearing
wastes are probably more easily accomplished than any of the alterna-
tives. Of all the proposed actions and alternatives, the controlled
burning of the wastes would be the most practical but would have a
slightly higher environmental impact than the other actions (except
on-site burial). However, the significance of this greater environmental
impact is considered to be low.
SANITARY WASTES
Proposed Action. Regional Sewage Treatment Plant
It is proposed that during operations the municipal system be used to
deliver wastewater to the McDuffie Island sewage treatment plant.
Alternative I. On-site Treatment During Operations
A septic tank and absorption system sufficient to serve the 135 operat-
ing personnel would require a large land area and periodic maintenance.
A package treatment system would require very little space, but a quali-
fied operator would be needed, and effluent would be discharged to the
ship channel or to marshland.
Rationale for the Proposed Action
The use of the municipal system during permanent operations is the
preferred environmental alternative because it requires the least
involvement by cement plant personnel and is the most satisfactory
method of waste treatment and disposal.
PLANT WASTEWATER
Proposed Action. Settling Basin and Discharge to the Ship Channel
A settling basin is planned for collection and treatment of cooling
water blowdown, stockpile and oil tank runoff, and wastewater from
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ABATEMENT MEASURES (PLANT SITE)
various washdown areas. The effluent would be discharged to the ship
channel.
Alternative I. Settling Basin with Effluent to the Marshes
The freshwater marshes to the north of the plant site could receive the
treated effluent from the settling basin. This alternative would not
have a discharge directly Into the ship channel and would achieve some
additional sediment removal from the marsh prior to flowing Into the
channel on the east side of Dauphin Island Parkway.
Alternative II. Common Outfall In Mobile Bay
A common outfall for wastewaters from the Theodore Industrial Park has
been proposed by the Board of Water and Sewer Commissioners of the City
of Mobile. A pipeline would carry wastes from a holding pond at the
Industrial park to an outfall about 5.6 kilometers (3.5 miles) Into
Mobile Bay (see Figure 1.2). An Environmental Impact Statement Is pres-
ently being prepared prior to the U.S. Army Corps of Engineers' final
decision on an application for construction of this pipeline.
Ideal Basic Industries could use the proposed pipeline for the discharge
of wastewaters except general stormwater runoff.
Rationale for the Proposed Action
The planned treatment of wastewaters to be discharged to the ship chan-
nel has been designed to provide an effluent quality better than the
limits specified In the NPDES permit (see Permit and Approval section of
the Summary Document), and the stockpile runoff has been shown to be
non-toxic (Environmental Science and Engineering, Inc., 1977). For the
effluent from the cement plant, discharge to the marsh, use of the
common outfall pipeline, and discharge to the ship channel are all
environmentally acceptable alternatives. Thus, Ideal Basic Industries
E-39
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THEODORE
* APPROVED P )INT OF DIS6HARJGE
DEER RIVER POINT
HOLLINGERS ISLAND APPROACH CHANNEL j\ \
BILE BAY
Figure E.2
PROPOSED WASTEWATER OUTFALL IN MOBILE BAY
0 2
SOURCE: Board of Water and Sewer Commissioners of the City of Mobile, 1977. SCALE IN KILOMETERS
Environmental Science and Engineering, Inc., 1977.
fvt
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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ABATEMENT MEASURES (PLANT SITE)
has chosen one of several possible alternatives that are relatively
equal In terms of environmental considerations.
STORMWATER RUNOFF
Proposed Action. General Runoff Catchment Area—Discharge to Marsh
Natural drainage of most of the plant site Is to the north, Into the
marshes. It Is proposed that general runoff during construction as well
as during operations be drained Into a 2-hectare (5-acre), bermed area
to the north of the site. This area would discharge into the freshwater
marshes bordering the North Fork Deer River. The natural function of
the vegetation in the basin and marshland will reduce the organic and
solids loading of the runoff. The runoff quantity will be about double
that which naturally drains to the marsh (due to greater area and less
retention and percolation). This system will contain about 50 minutes
of a 10-year, 1-hour storm and is considered consistent with the best
management practices for stormwater control.
Alternative I. General Runoff Basin—Discharge to Ship Channel
The plant site could be drained to have the general runoff collect in a
catchment area, probably along the waterfront. The area would contain
the first flush of the runoff, then overflow to be discharged into the
ship channel. This alternative is similar to the proposed action but
with a different receiving body of water. A possible benefit of this
scheme is to promote a greater flushing action in the channel due to
the addition of an expected average daily flow of 910,000 liters
(240,300 gallons) from the runoff.
Alternative II. General Runoff Basin—Discharge to Both the Marsh and
Ship Channel
A single or multiple basin system would be designed to collect the gen-
eral stormwater runoff, but would discharge to both the marsh and ship
channel. This alternative would possibly promote a better flushing
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ABATEMENT MEASURES (PLANT SITE)
action In the channel while effectively maintaining the natural flow
quantities into the marshland.
Rationale for the Proposed Action
The location or locations at which stormwater runoff from the plant site
is discharged is an important issue because of the nature of existing
water quality problems in the industrial park area. Degraded conditions
in the barge canal/ship channel are due in large part to the lack of
adequate flow in the waterway.
Drainage of all or part of the storm water from the proposed plant site
into the ship channel, as provided in the last two alternatives, might
provide additional flushing action and dilution of existing pollutant
loads.
The proposed action of utilizing a catchment area north of the plant
site and having the discharge flow through the freshwater marsh would
provide some reduction of turbidity and suspended solids and would not
decrease the quantity of storm water entering the marsh.
Alternative I would provide the same degree of treatment in the
catchment area, but would not utilize the additional filtration of the
marshland vegetation. This alternative would require redesigning the
plant's drainage and modifying the present plot plan in order to locate
the catchment area near the waterfront. An adverse -impact of this
action would be the provable shrinkage of the marshland due to a
reduction of the runoff it is presently receiving.
Alternative II, splitting the discharge to both the freshwater marsh and
ship channel, would provide adequate treatment of the discharges while
not reducing the base flow into the marsh area. Similar modification to
the facility drainage and layout, as mentioned for Alternative I, would
be necessary.
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ABATEMENT MEASURES (PLANT SITE)
From an environmental viewpoint, the proposed action and Alternative II
are basically equivalent, while Alternative I would be less desirable
because of Its effect on the freshwater marsh. However, the two alter-
natives would require a different catchment area location somewhat
closer to the ship channel so that the discharge to the channel would
flow by gravity.
The proposed action Is one of the better environmental designs for pro-
viding best management practices In treating general stormwater runoff
from the plant site and would not require redesigning the facility lay-
out and drainage.
OIL SPILLS
The 380,000-liter (100,000-gallon) fuel oil tank will be aboveground and
will have a containment berm capable of holding all the oil In case of a
tank rupture. The alternative of storing this amount of oil In an
underground vessel Is considered Impractical and Is therefore not
assessed.
DREDGING
The construction of the docking facility will require about 500,000
cubic meters (650,000 cubic yards) of dredging. It Is anticipated that
this material will be disposed In one of the U.S. Army Corps of Engi-
neers spoil disposal areas. There are no practical alternatives to
these actions.
LAND CLEARING AND GRADING
About 20 hectares (50 acres) of the 34.4 hectares (85 acres) to be
developed on the site will be cleared. This action has no practical
alternatives.
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ABATEMENT MEASURES (PLANT SITE)
PLANT ACCESS
Proposed Action. Access to Island Road North Along Western Plant
Boundary
The proposed action, as stated in Appendix A, Project Description, is
for an access roadway to be constructed from Island Road (Hamilton
Boulevard) to the facility site.
In addition, a railroad spur will be constructed from the State Docks
Railroad to the site. These two roadbeds will parallel the western
boundary of the property and will form a corridor about 47.2 meters
(155 feet) wide through the existing vegetation and freshwater marsh and
across the North Fork Deer River. The roadway will have a 15-meter
(50-foot) bridge across the river and fill in a 150-meter (500-foot)
section of the marsh. The railroad spur will have a 170-meter (560-foot)
long trestle across the river and marsh.
The alternatives to this access route are access from Dauphin Island
Parkway and bridging the roadway across the freshwater marsh. An addi-
tional action could have been access from Range! ine Road along the State
Docks Railroad corridor, but because of the present plans to upgrade
this road to a divided highway with an above-grade crossing of the
railroad line, this action is not practical.
The alternative of using the Airco, Inc. access roadway is not feasible
due to various problems with the two industries using the same route
(i.e., a strike at one would close the other plant, the roadway would
have to be upgraded for heavier class service, liability, security
requirements, and ownership claims). In addition, Ideal Basic Indus-
tries has not been able to obtain permission from Airco, Inc., for use
of its roadway.
Alternative I. Access from Dauphin Island Parkway
The section of the Dauphin Island Parkway south of Island Road (Hamilton
Boulevard) could be utilized several different ways for access to the
E-44
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ABATEMENT MEASURES (PLANT SITE)
plant site. First, If permission could be obtained from the Alabama
State Docks Department for use of the road along their railroad spur,
access to the plant site could be provided anywhere along the northern
property line. Any of these routes would divide the marshland Into two
sections.
Second, access from Dauphin Island Parkway could be at a point south of
the North Fork Deer River and associated brackish marsh. This route
would cross the undeveloped greenbelt and would necessitate upgrading
the existing bridge over the North Fork Deer River.
The use of either of these corridors from Dauphin Island Parkway would
necessitate extensive roadway construction for the state-owned parkway
to handle the anticipated truck traffic.
Alternative II. Bridging of the Marsh
The entire freshwater marsh could be crossed by an approximately
165-meter (550-foot) long roadway bridge. This bridge would be within
the same corridor as the proposed action and does not involve the rail-
road structure. The additional cost for this extra bridging has been
estimated to be about $300,000.
Rationale for the Proposed Action
Access from the Daifphin Island Parkway and across the marsh would
involve greater disturbance than the proposed action and is therefore
undesirable. Access directly from the Dauphin Island Parkway (south of
the marsh) is feasible but would require the upgrading of the state-
owned bridge and roadway. An extensive redesigning of the facility
site would be required to utilize this access route.
The proposed action would fill in approximately 0.2 hectare (0.5 acre)
of the freshwater marsh but would bridge the North Fork Deer River so
that the water flow would not be disrupted. The alternative of bridging
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ABATEMENT MEASURES (PLANT SITE)
the entire freshwater marsh would effectively stop direct sunlight from
reaching the vegetation beneath the structure. This action would have
an impact upon the marsh; however, it would not be as great as the
proposed action.
The area to receive the fill is adjacent to the Airco roadway, which was
constructed with fill and several small culverts across the river and
marsh. The zone of influence of ancillary effects of the existing
roadway on the freshwater marsh (weedy vegetation and gradual silting)
would probably be extended by either the proposed access roadway or
Alternative II.
The proposed action, while not the best environmental alternative, is
considered to be acceptable. Based on the difference in impacts and
construction costs, the alternative of bridging the entire marsh would
not be as practical as the proposed action.
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NO ACTION (QUARRY SITE)
QUARRY SITE ALTERNATIVES
NO-ACTION ALTERNATIVE
FUTURE LAND USE
Whether or not the proposed quarrying operation Is conducted, the quarry
site area will be converted almost entirely to improved pasture by 1992.
Only land along the Alabama River and north of Thompson Mill (Marshall s)
Creek will remain in natural vegetation. Therefore, all of the
environmental changes linked to land clearing and cattle grazing will
still occur without the limestone quarry project.
Land use conditions in the area surrounding the quarry site are essen-
tially static, except for construction of the Parsons and Whittemore
Pulp Mill, 11 kilometers (7 miles) north of the site. Since the quarry
operation is not expected to have significant impacts on land use, land
value, or general amenity, the no-action alternative would resemble the
project alternative in terms of off-site conditions.
AIR QUALITY
Air quality in the vicinity of the quarry site will change slightly from
present levels due to the operation of the Parsons and Whittemore Pulp
Mill. An environmental assessment study for the proposed mill (Asso-
ciated Water and Air Resources Engineers, Inc., 1975) showed that air
emissions from the proposed mill would not exceed:
Sulfur Dioxide: Annual Average: 1 ug/m3
24-Hour: 8 ug/m3
3-Hour: 71 ug/m3
Total Suspended Participate Matter:
Annual Average: 4 ug/m3
24-Hour: 33 ug/m3
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NO ACTION (QUARRY SITE)
These maximum concentrations would occur within 2 kilometers (1.2 miles)
of the pulp mill. Since the quarry site is approximately 11 kilometers
(7 miles) from the mill, sulfur dioxide and TSP levels at the quarry
site will be much lower than those listed above. Therefore, 1992 sulfur
dioxide and TSP levels will probably not be significantly different from
existing baseline levels, provided that other major emission sources do
not locate in the area.
NOISE
Present sound levels at the quarry site are affected only by wildlife,
natural phenomena, and a small increase in barge traffic on the Alabama
River and in vehicular traffic on Stockton Road (Monroe County Road
No. 1). No significant changes from present conditions are expected in
the absence of the quarrying operation, except very localized noise
level increases due to livestock grazing and agricultural land
management.
WATER RESOURCES AND AQUATIC ECOLOGY
Much of the property belonging to Ideal Basic Industries has already
been timbered, and conversion to pasture is occurring at a rapid rate.
Based on the effects on Hollinger Creek, the changes in Thompson Mill
(Marshalls) Creek by 1992 will include: (1) elevated water temperatures
because of reduced forest canopy; (2) increases in specific conductiv-
ity, total dissolved 59!ids, and alkalinity as a result of higher rates
of soil leaching and surface erosion; and (3) higher ammonia and organic
nitrogen levels due to erosion and to cattle wastes. The worst effects
of erosion may be short-term in nature, but continuing degradation can
be expected as cattle loading rates increase. These changes will have
little effect on Randons Creek because only 3 percent of its watershed
lies within the quarry site. However, some water quality degradation is
expected due to expansion of the Frisco City urban area and conversion
of forest to agricultural land.
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NO ACTION (QUARRY SITE)
No change In the hydro logic regime of the Alabama River is expected
before 1992, since there are no planned navigation or flood control
projects. Some increased sediment loads to the Alabama River may result
from logging and land clearing in tributary watersheds, but these influ-
ences on the river should be negligible.
Silt deposition into the streams may bury present root, rubble, sand,
and gravel habitats and create soft bottoms and thus cause a major
change in the stream fauna. Such marked changes would require continual
heavy erosion and are probably not likely. Initial severe erosion
during and immediately following clearing could cause substantial mor-
tality, and community recovery could require a couple of years. Clear-
cutting trees along the stream banks will eliminate leaf-fall, an
important input to forest streams, and will expose the stream to direct
sunlight. These are major alterations and probably will lead to major
faunal changes. Heavy nutrient loading from cattle wastes and from any
fertilizers applied to the pastures would favor a restricted fauna of
pollution-tolerant species. Continual bottom disturbance by cattle
would reinforce this trend.
TERRESTRIAL ECOLOGY
With continued conversion of forest to pasture, there will be a reduc-
tion in the overall animal diversity of the site, especially of forest
and edge species; for example, the present decline of turkey and squir-
rel populations will continue. There will be, however, an increase in
grassland species, such as mice, meadowlarks, and grasshopper sparrows.
The attributes which will become more pronounced as the area is further
cleared include poor nutrient conservation, simplified food chains, low
diversity of both fauna and flora, and greater microclimate variation.
E-49
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NO ACIIUN I QUARRY SITE)
SOCIOECONOMIC CONDITIONS
In contrast to past decades, the. economy and population of Monroe County
are presently expanding. As discussed earlier in the description of
baseline environment, growth is expected to continue due to a variety of
factors. This development is expected to be well-balanced and largely
favorable in terms of labor force opportunities and overall community
impact.
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SITE LOCATION/DEVELOPMENT (QUARRY SITE)
SITE LOCATION AND DEVELOPMENT
ALTERNATIVE SITES
Ideal Basic Industries (1973) searched the Gulf Coast area for a source
which could supply 1.9 million metric tons (2.1 million tons) per year
(dry) of limestone suitable for cement manufacturing. Most potential
sites were rejected because the limestone was of unsuitable chemical
composition; mining would be difficult; the site could not be purchased;
or transportation costs would be excessive. The two best locations were
the Gail lard Tract and a site near Crystal River, Florida. Final choice
of the Gail lard Tract was primarily an economic decision based upon
proximity to the Theodore Industrial Park and barge access to the
tract.
The Gail lard quarry is also favorable in that:
1. Limestone is relatively close to the land surface;
2. Dredging is not required for construction of loading
facilities; and
3. Danger of flooding is much less than for most other sites
having water access.
ALTERNATIVE SOURCES OF CALCIUM CARBONATE
The principal ingredient of cement (about 80 percent) is a calcareous
substance such as limestone. The alternatives to limestone which have
been considered for the proposed project include oyster shells and
aragonite.
Oyster shells provide the calcium carbonate for the existing Ideal Basic
Industries cement plant in Mobile, but are not a feasible source for the
projected plant. The supply of shells is limited in Mobile Bay and the
new plant alone would require tripling the usage rate.
There are additional oyster shell reserves off the Louisiana coast, but
to dredge and transport these reserves to Mobile would require
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SITE LOCATION/DEVELOPMENT (QUARRY SITE)
additional costs. Also, the dredging of oyster shells has become a
subject of increasing environmental concern.
Aragonite is precipitated from sea water as a high purity granular lime-
stone sand. The only economically recoverable deposits known to exist
are those in the Bahamas. These deposits are geologically young, which
accounts for their high chemical product purity. They are being dredged
off Ocean Cay by Marcona Ocean Industries, a U.S.-owned corporation.
Aragonite tends to have a high chemical reactivity and would be attrac-
tive in terms of process operations. However, several disadvantages
outweigh this single advantage. First, the aragonite deposits are owned
by a foreign government, and it may be necessary to maintain stockpiles
larger than would be appropriate for a domestic source. Runoff from and
rehandling of these stockpiles could have adverse environmental effects.
Second, because the source is 1,300 nautical kilometers (800 miles) from
the plant, Ideal Basic Industries would be subject to increases in ocean
freight rates. This could significantly affect the profitability of the
proposed plant. Third, being marine deposits, aragonite materials
contain chlorides, and these must be removed prior to use in cement man-
ufacturing. The washing operation could generate a wastewater flow of
2 to 13 million liters (0.5 to 3.5 gallons) per day. This would make
large demands on local freshwater resources, and would affect existing
water quality in the receiving body of water.
Finally, purchase of the aragonite entails unacceptably high risks of
disruption of supply and of price fluctuations. For all the above rea-
sons, it was considered preferable to obtain limestone from a domestic
source under the control of the cement company.
The study of site locations and of alternative sources of calcium car-
bonate was conducted by Ideal Basic Industries. Although the study was
not performed specifically for this EIS, the selection of the quarry
site has been reviewed and found to be environmentally acceptable.
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PROCESS ALTERNATIVES (QUARRY SITE)
PROCESS ALTERNATIVES
The process alternatives for the quarry are somewhat restricted due to
the nature of the process—surface mining, only one raw material, no
major energy supplies other than purchased electricity, and the simple
deployment of conveyors, rock breakers, and barge-loading equipment.
The only process alternative relates to the use of a centrally-located
rock crusher.
Proposed Action. Movable Crusher
Front-end loaders will load the ripped material and transport it to a
portable breaker (crusher) in the quarrying area. The limestone will be
crushed in the breaker and transported by conveyor to the storage pile.
Alternative I. Centrally-Located Crusher
An alternative arrangement could be the placement of a permanent breaker
adjacent to the storage pile, serviced by a conveyor or by dump trucks
traveling from the quarrying area. This arrangement would eliminate the
need for a portable crusher and would also decrease the number of con-
veyors necessary. However, a centrally located crusher would increase
truck traffic on the site, as well as increasing fugitive dust levels.
Additional haul roads would also be required.
Rationale for Pro'posed Action
The arrangement planned by Ideal Basic Industries requires the least
amount of heavy equipment and is environmentally and economically
advantageous.
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ABATEMENT MEASURES (QUARRY SITE)
ABATEMENT MEASURES
AIR QUALITY
The proposed construction activities will generate smoke emissions from
burning of the land-clearing debris and fugitive dust from use of heavy
equipment and clearing operations. The alternatives to the burning
activities are discussed in the Solid Waste section.
The operation of the quarry and its conveyor systems will cause some
additional emissions of fugitive dust.
The dust from the construction and quarrying is uncontrollable except
for application of water on an area basis. Actually, the moisture
content of the soils and limestone is rather high and would naturally
reduce the emission level of dust. There are no practical alternative
actions that could control these emissions. However, the conveyor and
loading facilities could be enclosed and vented to a scrubber or
baghouse system.
Proposed Action. Dust Suppression System on Conveyors and Barge Loading
Facilities
The conveyor and barge-loading facilities will utilize a water spray
dust control; in addition, the barge-loading spout will have a tele-
scoping boot to reduce the dust generated. The water spray systems will
be used on an as-needed basis, since the material will be naturally
moist (approximately 22 percent moisture content).
Alternative I. Enclosing and Venting to a Higher-Efficiency Control
System
The dust-generating portions of the conveyor and loading systems, the
drop and transfer points, could be enclosed and vented to small scrub-
bers or baghouses.
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ABATEMENT MEASURES (QUARRY SITE)
Rationale for Proposed Action
Enclosing the drop and transfer points would require numerous control
devices throughout the quarry facility. While they would achieve a
higher degree of dust removal than water sprays, their costs would not
be warranted since the impact of the proposed system is already
considered to be low.
NOISE
The construction and operation of the quarry will cause an increase in
noise levels on-site. Due to the nature of the heavy equipment involved
and their functional tasks, there are no practical alternatives to the
proposed action that would reduce the noise generated.
WASTES FROM LAND CLEARING
Proposed Action. Burning and Chipping Land Clearing Wastes
It is proposed that, after clearing the 40-hectare (100-acre) construc-
tion site, all brush and branches and those trees not sold as timber be
burned or chipped for mulch. The use of an air-blower type pit burner
is expected to produce better combustion efficiency and less smoke than
ordinary open burning. The mulch would be used for erosion control and
revegetation of disturbed areas.
Alternative I. Landfill
All vegetative wastes that are planned to be burned or chipped could
(alternatively) be brought to the Monroe County Landfill for disposal;
however, this would require a round-trip distance of at least
80 kilometers (50 miles) per load.
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ABATEMENT MEASURES (QUARRY SITE)
Alternative II. On-site Disposal
Brush and trees could be buried or piled in areas not to be quarried,
thus eliminating all burning.
Rationale for Proposed Action
As discussed in Appendix C, Impacts, smoke emissions from burning land-
clearing wastes would have only a very short-term impact in the rural
area surrounding the site.
Alternative I would involve costly hauling of the trees and brush to the
landfill. Once there, the wastes would be buried and would thereby use
a portion of the available land.
The second alternative, by disturbing additional areas and creating
unstable surface contours, would render the land unsuitable for pas-
ture or other use until the wastes have decomposed and the land surface
has stabilized.
The proposed action was chosen because it is the most practical for the
construction contractor to accomplish, has only short-term impacts, and
does not put a stress on local landfill ing operations.
SOLID WASTE
Proposed Action. Disposal at an Approved Landfill
It is proposed that the solid wastes (except vegetation wastes) gener-
ated during both construction and operation be disposed at the Monroe
County Sanitary Landfill.
Alternative I. On-site Disposal
Because of the large size of the quarry tract, an on-site disposal area
could be found where re-excavation would not be a problem. Since the
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ABATEMENT MEASURES (QUARRY SITE)
wastes will not be toxic, their disposal does not present any ecolog-
ical problems.
Rationale for the Proposed Action
It is not efficient for Ideal Basic Industries to maintain a sanitary
landfill because commitment of heavy equipment and labor to the daily
covering required for a sanitary landfill would be more expensive than
off-site disposal of only 4.2 metric tons (4.5 tons) of solid wastes per
year.
PROCESS WASTEWATER/GENERAL STORMWATER RUNOFF—CONSTRUCTION AND
OPERATION
Proposed Action. Clarification Basins
The construction plan calls for at least three clarification basins to
contain stormwater runoff and to reduce the suspended solids concen-
trations prior to discharge to the Alabama River or to Thompson Mill
Creek.
Alternative I. Vegetation Buffers
The first alternative is the preservation or establishment of vegetative
buffers on the uplands and on downstream drainage courses. These buf-
fers would stabilize the soil and trap sediment. The advantages of this
alternative include: (1) low relative cost of development; (2) no opera-
tional requirements; (3) low maintenance requirements; and (4) capture
of sediment near its source. The disadvantages are: (1) decreased
ability to control sedimentation; and (2) decrease in usable land for
quarrying.
Alternative II. Quarry Pit Storage
The second alternative is the use of large quarry excavations as sedi-
ment basins. The advantages of this alternative include: (1) large
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ABATEMENT MEASURES (QUARRY SITE)
storage volumes; (2) little need to remove trapped sediment; and
(3) little construction required other than normal quarry excavations.
The disadvantage is the potential difficulty of drainage and/or the
pumpout requirements for discharging to a receiving body of water.
Rationale for Proposed Action
Vegetation buffers would not meet the stringent discharge control cri-
teria on a daily basis. Since the limestone deposits extend as deep as
30 meters (100 feet) below ground level, adequate vegetation buffers
would be difficult to establish and maintain on the subsurface soils.
The proposed clarification basins are designed to meet all discharge
requirements and can be used during both construction and operational
phases. The alternative of establishing pit storage is applicable only
to operations after 5 to 7 years of quarrying when adequate pit area
would be available. The use of quarry depressions for expanding the
water storage capacities is being studied by the design consultant.
Therefore, the use of the clarification basins is considered the most
practical solution to reduce the potential environmental impacts of
surface runoff from disturbed land areas on a continuous basis.
WATER USAGE AND SANITARY WASTES
Proposed Action
The potable water supply will be a deep well driven on the facility
site. The sanitary waste disposal system will be a septic tank and soil
absorption system to serve the 19 employees. Both systems must be
approved by the Monroe County Health Department. There are no practical
alternatives to the water supply system and sewage disposal system due
to the limited number of employees that would be served.
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ABATEMENT MEASURES (QUARRY SITE)
ECOLOGICAL SYSTEMS
The facility's construction and operation will affect about 80 percent
of the 1,633 hectares (4,035 acres) during its projected life of
50 years. The disturbed area will be reclaimed to pastureland after the
layer of limestone has been removed. Since this area is presently being
converted to pastureland, the significance of the quarrying activities
will be minimal. There are no practical alternative actions to the
proposed quarrying of the property other than the no-action alternative
described earlier.
RECLAMATION ALTERNATIVES
Proposed Action. Reclamation to Pastureland
Reclamation to improved pasture is specified in the lease agreements
between Ideal Basic Industries and Mr. McWilliams. Two potential
alternative uses of the land owned by Ideal Basic Industries would be:
(I) reclamation to timber land, and (2) development of part of the site
as an industrial area.
Alternative I. Reclamation to Timber!and
In upland areas, pine plantations could be established. They would
provide timber and also habitat for such game species as quail, rabbit,
and deer. Practices which could be employed to produce better forage
and increased growth of pines would include site preparation, thinning,
and winter burning. It has been suggested that livestock can graze
within a pine plantation if forage is provided, but this technique has
had limited success.
Alternative II. Industrial Park
The Gail lard tract is one of the most favorable industrial sites within
the Claiborne/Perdue Hill area because it has water access and lacks
flood hazards. This alternative might provide an attractive long-term
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ABATEMENT MEASURES (QUARRY SITE)
opportunity that is consistent with ongoing quarrying operations.
Monroe County might receive substantial economic benefits, without
significant impacts upon existing communities.
Rationale for Proposed Action
Reclamation to timberland might be preferable to pastureland in terms of
water quality and ecological conditions, but would involve a lower econ-
omic value and productivity of the land as a natural resource. Indus-
trialization of the area could have negative environmental impacts. The
decision for pastureland provides more flexibility in the long run since
timbering, agriculture, or some other land use could easily be estab-
lished at a later time on the gently rolling pastureland.
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