ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF ENFORCEMENT
REPORT ON
WASTE SOURCE INVESTIGATIONS
KINGSPORT, TENNESSEE
NATIONAL FIELD INVESTIGATION CENTERS
DENVER AND CINCINNATI
AND
REGION IV, ATLANTA. GEORGIA
APRIL 1973
W
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ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF ENFORCEMENT
REPORT ON
WASTE SOURCE INVESTIGATIONS
KINGSPORT, TENNESSEE
National Field Tnvcistip,ation Centers
Denver and Cincinnati
and
Region IV, Atlanta, Ccorgia
April 1973
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TABLE OF CONTENTS
Pape
LIST OF TABLES v
LIST OF FIGURES v
LIST OF APPENDICES vi
LIST OF APPENDICES TABLES vii
LIST OF APPENDICES FIGURES *
I. INTRODUCTION 1
4
A. BACKGROUND 3
B. 1972 WATER-QUALITY INVESTIGATIONS 2
II. SUMMARY AND CONCLUSIONS 5
A. STREAM SURVEY 5
r.. TENNESSEE EASTMAN COMTAEY 7
C. HOLS TON ARMY AMMUNITION PLANT
AREA A 8
D. HOLSTON ARMY AMMUNITION PLANT
AREA B 10
E. MEAD PAPERS 11
F. KINGSPORT MUNICIPAL WASTEWATER TREATMENT PLANT. ... 12
G. IIOLLTSTON MILLS 13
H. ASG INDUSTRIES, INC 14
I. PENN-DIXIE CEMENT CORPORATION 15
J. J. P. STEVENS 15
III. RECOMMENDATIONS 17
A. TENNESSEE EASTMAN COMPANY .* 17
B. HOLSTON ARMY AMMUNITION PLANT 18
C. MEAD PAPERS 20
D. KINGSPORT WASTEWATER TREATMENT PLANT 21
E. IIOLLTSTON MILLS 22
F. ASG INDUSTRIES, INC 22
G. PENN-WXIK CEMENT CORPORATION 23
II. GLNERAI 23
IV. STUDY AREA 25
A. GENERAL DESCRIPTION 25
B. ECONOMICS 25
C. HYDROLOGY 26
lii
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TABLE OF CONTENTS (Cont.)
Pa_pe_
V. APPLICABLE WATER QUALITY STANDARDS AND REGULATIONS. ... 27
A. WATER QUALITY STANDARDS 27
13. FEDERAL WATER POLLUTION CONTROL ACT
AMENDMENTS OF 1972 30
VI. STREAM SURVEY 33
A. 1969 FWOA SURVEY 33
B. 1972 EPA SURVEY 35
VII. WASTE SOURCE EVALUATION AND TREATMENT NEEDS 43
A. GENERAL 43
B. TENNESSEE EASTIIAN COMPANY 47
Waste-Source Evaluation 48
Treatment Needs 50
C. HOLSTON ARjTY AIIMUW1TIOK PLANT-AREA A 52
General 52
Waste-Source Evaluation 53
Treatricnt Needs 57
D. HOLSTON ARIIY AMMUNITION PLANT-AREA B 62
Waste-Source Evaluation 62
Treatment Meeds 68
E. MEAD PAPERS. A DIVISION OF MEAD CORPORATION 70
Waste-Source Evaluation 70
Treatment Needs 70
F. KINSPORT MUNICIPAL WASTEWATER TREATMENT PLANT .... 72
Waste-Source Evaluation 72
Treatment Needs 73
G. IIOLLISTON! MILLS, INCORPORATED 75
Waste-Source Evaluation 75
Treatment Needs 77
II. ASG INDUSTRIES, INC 78
Waste-Source Evaluation . . 78
Treatment Needs 79
I. PENN-DTXIE CEMENT CORPORATION 80
Waste-Source Evaluation 80
Treatment Needs . 81
J. J. P. STEVENS AND COMPANY, INC. ~ BORDEN PLANT ... 82
REFERENCES 83
iv
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LIST OF TABLES
Table No. Pag.e
V-l State of Tennessee Effluent Standards for Uaste
Discharges in the Kingsport Area 28
VI-1 Estimated Waste Load Limits Based on 1969 Survey. . 34
VI-2 Sumnary of Field Measurements and Selected Chemical
Data Stream Survey - Kingsport, Tennessee. ... 36
VI-3 Organic Analysis of Water Samples from Selected
Strean Locations - Kingsport, Tennessee 37
VI-4 Heavy Metals in Stream Sedinents
Kingsport, Tennessee 40
VI-5 Comparison of Nutrient Data, IIolston River
Kingsport, Tennessee 41
VII-1 Summary of Wastewater Discharges
1969 and 1972 Surveys - Kingsport, Tennessee . . 44
VI1-2 Wastewater Values - Sum of All Outfalls ...... 55
VII-3 Selected Water Quality Standards 60
VII-4 Selected Air Quality Standards Proposed by APSA . . 61
LIST OF FIGURES
Figure No.
IV-1 Study Area - Kingsport, Tennessee December 1972 . . Inside
back cover
v
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LIST OF APPENDICES
Ti tie Paee
A. GENERAL WATER DUALITY FOR THE DEFINITION AND A-l
CONTROL OF POLLUTION IN THE WATERS OF TENNESSEE
B. SAMPLING PROCEDURE B-l
C. SAMPLE STATIONS C-l
D. METHODS OF ANALYSIS AND SAMPLE PRESERVATION D-l
E. WASTE SOURCE EVALUATIONS E-l
I. ASG INDUSTRIES, INC. E-2
II. HOLLISTON MILLS E-13
III. J. P. STEVENS E-25
IV. KINGSPORT MUNICIPAL M.'TP E-29
V. MEAD PAPERS E-42
VI. PF.NN-DIXIE CEiIF.NT E-50
VII. TENNESSEE EASTMAN E-58
VIII. 1IOLSTON ARMY AMMUNITION PLANT-AREA A E-79
IX. HOLS TON AW/ AMMUNITION PLANT-AREA B E-119
F. CITY OF KINGSPORT, TENNESSEE - INDUSTRIAL F-l
WASTE ORDINANCE NO. 1539
G. BIOASSAY METHODS G-l
vi
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LIST OF APPENDICES TABLES
Table No. Title Page
E-l Effluent Discharges from ASG Industries Inc.,
Kinp,sport, Tennessee E-4
E-2 ASG Industries, Inc., Final Effluent Suspended
Solids, Kingsport, Tennessee E-5
E-3 Summary of Field Measurements and Chenical Data,
ASG Industries, Inc., Kingsport, Tennessee E-8
E-4 Summary of Field Measurements and Chemical Data,
Holliston Mills, Inc., Kingsport, Tennessee E-19
E-5 EPA Interim Effluent Limitations 1^- 20
E-6 Wastewater Discharged from Holliston Mills
Data from RAPP Application E-21
E-7 Summary of Field Measurements and Chemical Data,
J. P. Stevens and Company, Inc., Kingsport,
Tennessee E-27
E-8 Operation and Maintenance Procedures, Kingsport
Municipal Wastewater Treatment Plant E-32
E-9 Daily Plant Check List, Kingsport Municipal
Wastewater Treatment Plant E-34
E-10 Kingsport Municipal Wastewater Treatment Plant,
Frequency of Laboratory Analyses E-36
E-ll Plant Pcrfomance Data for High and Low Flow
Months, November 1971 - November 1972,
Kingsport Wastewater Treatment Plant E-38
E-12 Summary of Field Measurements and Chemical Data,
Mead Papers, Division of Mead Corporation,
Kingsport, Tennessee E-46
E-13 Data Submitted to the State of Tennessee
Department of Public Health by Penn-Dixie
Corporation L-53
E-14 Summary of Field Measurements and Chemical Data,
Penn-Dirde Cement Corporation, Kingsport,
Tennessee E-55
vn
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LIST OF APPENDICES TABLES (Cont.)
Table No. Title Page
E-15 Characteristics of Wastewater Discharged to the
South Fork of the Hols ton River Tennessee
Eastman Company, Kin?,sport, Tennessee Reported
in the Refuse Act Permit Program Application) E-60
E-16 Summary of Field Measurements and Chemical Data
Tennessee Eastman Conpany, Kingsport,
Tennessee, 4-9 December 1972 E-65
E-17 Summary of Field Measurements and Chemical Data,
Discharges to the South Fori: of the Ilolston
River Tennessee Eastman Company, Kinpsport,
Tennessee E-67
E-18 Organic Pollutants Identified, Tennessee Eastman
Company, Kingsport, Tennessee E-71
E-19 Summary of Field Measurements and Chemical Data,
Influent to Wastewater Treatment Facility,
Tennessee Eastman Company, Kingsport, Tennessee E-73
E-20 Summary of Field Measurements and Chemical Data,
Tennessee Eastman Company, Sanitary TIastes E-75
E-21 Outfall Characteristics from RAPP Application
Hols ton Army Ammunition Plant-Area A
Kingsport, Tennessee E-94
E-22 EPA Sampling Stations, 11AAP, Area A,
Kingsport, Tennessee E-96
E-23 Summary of Field Measurements and Chemical Data
Ilolston Army Ammunition Plant-Area A
Kingsport, Tennessee, 1-3 December 1972 E-99
E-24 Department of the Army, Ammunition Procurement &
Supply Agency - Proposed Guidelines E-110
E-25 Proposed Pollution-Abatement Schedule
IlAAr, Area A - Kingsport, Tennessee E-113
E-26 State of Tennessee Effluent Limitations for
IIAAP-Areas A and Y> E-116
E-27 Outfall Characteristics from 1JAPP Application
Hols ton Army Ammunition Plant-Area B
Kingsport, Tennessee E-127
viii
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LIST OF APPENDICES TABLES (Cont.)
Table No.
E-28
E-29
E-30
E-31
Title Page
Description of EPA Sampling Stations, HAAP,
Area B, Kingsport, Tennessee E-123
Summary of Field Measurements and Chemicnl Data
Hols ton Army Ammunition Plant-Area B
Kingsport, Tennessee, 13-15 December 1972 E-130
Oreanjc Pollutants Identified
Uolston Annv Ammunition Plant-Area B
December 1972 E-134
Proposed Pollution-Abatement Schedule
HAAP, Area B - Kingsport, Tennessee E-136
ix
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LIST OF APPENDICES FIGURES
Followc
Figure No. Page
E-l Plant F]ow Diagram - ASG Industries
Kingsport, Tennessee E-2
E-2 Wastewater Treatment Flow Diagram - ASG
Industries, Kingsport, Tennessee E-4
E-3 Wastewater Treatment System Flow Diagram -
llolliston Hills, Church Pill, Tennessee E-16
E-A Flow Diagram - Kingsport Municipal Wastewater
Treatment riant, Kingsport, Tennessee E-30
E-5 Flow Diagram - Head Papers ,
Kingsport, Tennessee E-44
E-6 Plant Layout - Penn-Dixie Cedent Corporation,
Kingsport, Tennessee E-50
E-7 Wastewater Treatment System Flow Diagram - Penn-Dixie
Cement Corporation, Kingsport, Tennessee E-52
E-8 Sampling Stations - Tennessee Fastran Company,
Kingsport, Tennessee E-58
E-9 Wastewater Treatment System Layout (Long Island
and Kit Bottom) Tennessee Eastman Company,
Kingsport, Tennessee E-62
E-10 Plant Layout - llolston Army Ammunition Plant -
Area A, kingyport, Tennessee E-84
E-ll Simplified Flowsheet - Area A, llolston Army
Ammunition riant E-84
E-12 Sampling Stations llolston Army Ammunition Plant -
Area L, King'-.port, Tennessee E-122
E-13 Schematic of Explosive Production Line - Area B,
Holston Army Ammunition riant E-122
x
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GLOSSARY OF TERMS
BOD
- Biochemical Oxygen Demand, 5-day
COD
- Chemical Oxygen Demand
TOC
- Total Organic Carbon
SS
- Suspended Solids
TKN
Total Kjeldahl Nitrogen
nh3-n
- Amnonia as Nitrogen
N03 + NO,-N
Total-P
Cr
Mn
Fe
Cu
Zn
Sn
11 g
Pb
RM
TL
m
WUT P
- Nitrate + Nitrite as Nitrogen
- Total Phosphorus
- Chromium
- Manganese
- Iron
- Copper
- Zinc
- Tin
- Mercury
- Lead
- River Mileage (e.g., 142.15/4.04) with first number
denoting distance from the mouth of the Hols ton River
to the confluence with a tributary upstream, and
second value indicating distance upstream of the mouth
of the tributary stream.
- Median Tolerance Li~.it, the concentration of toxicant
in water that causes a 30 ncrccnt mortality of the
test fish over a specified time period.
- Wastewater Treatment Plant
xi
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cfm - Flow rate Riven in cubic feet per minute
n 11 it n n it n
crs - second
gpm - " " " " gallons per minute
gpd - " " " " " " day
gpw - " " " " " " week
mgd - " " " " million gallons per dav
mg/1 - Concentration given in milligrams per liter
mg/kg - " " " " 11 la" lograms
Wg/1 - " " " micrograms per liter
pmhos/cm - Unit of specific conductance (mho—the inverse of the
standard unit of electrical resistance, the ohm) mea-
sured over o 1-centimetor distance, conventionally
at 25°C.
ppm - Concentration given m ports per million
xii
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1
I. INTRODUCTION
A. BACKGROUND
Wastes from municipal and industrial sources pollute the South Fork
of the Holston River as it flows through the City of Kingsport, Tennessee,
£
and the Holston River downstream from Kingsport. A study conducted by
the Federal Water Quality Administration, Department of the Interior,
Region IV, during June-July, 1969, reported that:—^
1. Wastewater discharges from the Tennessee Eastman Company (TEC);
Holston Army Ammunition Plant, Areas A and B (HAAP-A & B); Head
Papers, a division of Mead Corporation; Kingsport Wastewater
Treatment Plant; and Holliston Mills, Incorporated, contributed
approximately 137,500 lb/day of BOD and 22,000 lb/day of total
nitrogen to the Holston River system.
2. Cooling-water discharges from TEC and HAAP-A raised the ambient
water temperature of the South Fork of the Holston River by
3. Attached aquatic weeds (primarily Potamogeton pectinatus)
covered the bottom of the Holston River throughout the reach
of the 23 river miles studied. This resulted in a cyclical
variation of oxygen levels and caused violations of the
Tennessee Stream Standards for dissolved oxygen.
The Tennessee Water Quality Control Board subsequently established
effluent requirements that specified that those industries discharging
* The Holston River and the South and North Forks of the Holston River
are interstate streams.
about 12cC
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to the Hols ton River and its tributaries provide a minimum BOD removal
of 85 percent by April 1972. The 1969 report—^ concluded that the BOD
load discharged in the study reach must be reduced by 92 percent if
water quality conditions were to improve. It was further concluded
that the two largest dischargers, TEC and HAAP-B, must reduce the total
Kjeldahl nitrogen in the effluents by 92 percent. To date the 85-percent
BOD-removal goal has not been met.
However, with the passage of the Federal Water Pollution Control
Act Amroendments of 1972, previous State goals and implementation plans
will be reviewed to conform with the new Act. The State of Tennessee
is planning to hold a public hearing regarding the water pollution
problems in the Kingsport area, but no date has been set. Additionally,
the State has not requested interim authority from EPA to issue permits
under the 1972 Amendments.
B. 1972 WATER-QUALITY INVESTIGATIONS
The National Field Investigations Center-Denver (NFIC-D) was re-
quested by EPA Region IV, Atlanta, Georgia, to conduct waste-source
evaluations and a stream survey in the Kingsport, Tennessee, area —
Holston River Basin with the following objectives:
1. Determine the quality and quantity of waste pollutants dis-
charged to the Holston River and its tributaries so that ef-
fluent limitation can be established pursuant to the Federal
Water Pollution Control Act Amendments of 1972.
2. Ascertain the changes — as a result of waste discharges, in
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3
the water quality of the Holston River and its tributaries in
terms of specific pollutants, i.e., nitrogen, phosphorus, and
organic chemicals.
3. Evaluate present pollution control measures and determine what
additional control measures are necessary for the protection
and enhancement of receiving water quality.
The National Field Investigations Centers, Denver and Cincinnati,
conducted the investigations during the period 27 ^overabar through
15 December 1972.
The cooperation extended by the City of Kinggport, the industries,
and State and Federal agencies is gratefully acknowledged.
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II. SUMMARY AND CONCLUSIONS
A. STREAM SURVEY
Discharges to the South Fork of the Hols ton River and to the Hols ton
River, made during December 1972, contained average daily waste loads of
approximately 111,500 lb of BOD; 61,000 lb of TOC; 11,600 lb of total
Kjeldahl nitrogen (TKN); and 5,000 lb of nitrite + nitrate-nitrogen.
This includes measured loads from Tennessee Eastman Company (TEC), Holston
Array Ammunition Plant (HAAP) Areas A & B, ASG Industries, Penn-Dixie
Cement Corporation, Mead Papers, and Holliston Mills and the estimated
waste loads (based on operating records) from the Kingsport Wastewater
Treatment Plant. The discharges from TEC, HAAP Areas A & B and Mead
Papers accounted for more than 95 percent of the BOD load, 99 percent
of the TKN and 100 percent of the nitrite + nitrate nitrogen.
During the 1969 FWQA study, it was found that TEC, HAAP (Areas A
and B), Mead Papers, Kingsport Wastewater Treatment Plant, and Holliston
Mills discharged approximately 137,500 lb/day of BOD and 19,500 lb/day
of TKN (TEC and HAAP B contributed 99 percent of the latter). That study
concluded that in order to maintain a minimum dissolved oxygen concen-
tration of 3.0 mg/1 in the Holston River downstream of the confluence of
the North and South Forks, these waste loads must be reduced to no more
than approximately 14,000 lb of BOD and 1,950 lb of TKN to adequately
protect the receiving waters. In order to maintain a minimum DO concen-
tration of 5 mg/1, the official standard, the waste loads must be reduced
to 6,000 lb of BOD/day and 100 lb of TKN/day in the South Fork of the
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Holston River. The BOD and TKN loads discharged during December 1972
greatly exceed these recommended limits.
The hydrologic regimen of both the South Fork of the Ilolston River
and the Holston River are affected by releases from Fort Patrick Henry
Reservoir especially during off-peak power generating periods when
releases are reduced to a daily average of 750 cfs i.e., 3,000 cfs for
one hour and no releases for 3 hours. When this coincides with low
flows in the North Fork of the Holston (20 year, three day low flow is
46 cfs), the Holston River could be reduced to about 800 cfs. During
the July 1969 survey flows in the North and South Forks averaged 660 and
840 cfs, respectively. The North Fork and South Fork averaged approxi-
mately 880 and 3,130 cfs, respectively during the 1972 survey. The
Holston River at Church Hill Bridge (RM 131.5) averaged 4,100 cfs i.e.
the summation of the North and South Fork flows plus allowance for
minor inputs.
Heavy-rtietals analyses of water samples disclosed a significant
increase (more than 20 times — 0.03 to 0.69 mg/1) of manganese from
Station 54 (RM 142.15/5.6) upstream of TEC and HAAP Area A to Station
55 (RM 142.15/1.2) downstream from all discharges to the South Fork of
the Holston River. At Station 56 (RM 131.5 — downstream of HAAP Area B)
the manganese concentration ranged from 0.21 to 0.40 mg/1 which exceeds
the Public Health Service recommended limit (0.05 mg/1) for drinking
waters. The Holston River is classified suitable for domestic raw
water supply at Station 56. The standards established for this use
were violated (i.e. other pollutants shall not be added to the water
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7
in quantities that may be detrimental to public health or impair the
usefulness of the water as a source of domestic water supply.)
B. TENNESSEE EASTMAN COMPANY
The Tennessee Eastman Company discharged 343 mgd of cooling water
and process wastewater to the South Fork of the Holston River. The
total BOD and TKN loads p.yrp.i^rfsH 52,000 1h/Hav and 10,400 lb/day, re-
s —
spectively. The suspended-solids load averaged 106,000 lb/day over the
five-day survey. Flows from Hales Branch (Station 12) and the Long
Island lagoons (Station 17) contributed more than 49,000 lb BOD/day
while the lagoon effluent contained 100 percent of the TKN discharged.
The State of Tennessee has concluded that in order to protect water-
quality standards for a minimum DO concentration of 5.0 mg/1 in the
Holston River the raw water loads from TEC must be reduced to not more
than 3,350 lb BOD/day and 400 lb TKN/day. If a minimum DO concentration
of 3.0 mg/1 is to be maintained, the BOD and TKN loads in the effluent
must not exceed 6,000 lb/day and 1,600 lb/day, respectively.
A number of organic pollutants were identified in the TEC discharges.
The impact of these pollutants on aquatic life through chronic exposure
is presently unknown; however, compounds such as trichlorobenzene and
trichloraniline (both measured in the Long Island lagoon effluent) are
known to be quite toxic and undoubtedly contribute to the toxicity of
this discharge,.
Static bioassay studies disclosed that wastewaters from the Long
Island lagoons were toxic to fish. The 96-hr TL derived from the
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static bioassays with fathead minnows was with a 64-percent waste con-
centration, Other static bioassays using bluegills showed the 96-hr
TLm at a waste concentration of 36 percent. Based upon 1/20 of the
96-hr TL it was calculated that toxic concentrations in the wastewater
m
from the Long Island lagoons would have to be reduced by 95 percent in
order to protect aquatic life in the South Fork of the Holston River.
The discharge of toxic substances constitutes a violation of toxic Stan-
dards for Fish and Aquatic Life [Appendix A Item 3g—Toxic Substances].
Heavy-metals analyses revealed that 9,500 lb of manganese and
660 lb of zinc were discharged daily, the majority of which was con-
tained in the effluent of the Long Island lagoons. The manganese load
causes the violation of the Tennessee Water Quality Standards occurring
at Church Hill Bridge (Station 56),
C. HOLSTON ARM AMMUNITION PLANT-AREA A
1. The HAAP installation had virtually no treatment of industrial
process wastes and contaminated cooling waters. The total wastewaters,
including spent cooling waters, being discharged from the Holston Array
Ammunition Plant, Area A, into the South Fork of the Holston River was
A3.3 mgd. These wastewaters had average measured amounts of 20,300 lb/day
BOD; 19,100 lb/day COD; and 4,060 lb/day suspended solids. Due to the
complex nature of HAAP wastes and their potential effect upon analytical
tests, these results most likely represent minimum values.
2. The Main Outfall discharge (Station 2) was found to contain more
than 90 percent of the total BOD and COD loads being discharged from the
overall HAAP A complex. This discharge also represented about 75 percent
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9
of the total facilities wastewater flow. Effluents from the ASG Indus-
tries were discharged into the upper section of the HAAP Main Outfall,
amounting to approximately 3,600 lb/day of suspended solids in a waste
flow of 0.52 mgd. Many of these solids settled out in the open ditch
either before reaching or within the Main Outfall.
3. Bioassay studies conducted at HAAP, Area A, disclosed that waste-
water discharges at Stations 2 and 8 were highly toxic to aquatic life.
The coal-tar drainage (0.007 mgd) at Station 8 killed 50 percent of the
fathead minnow test species after 96 hr with a waste concentration of
only 0.17 percent. The Main Outfall (33.6 mgd) at Station 2 showed a
50 percent kill of test fish after 96 hr with a waste concentration
of 56.0 percent. These two waste discharges alone would require that
about 2,000 cfs be maintained in the South Fork and Holston Rivers to
ensure no long-term impact on aquatic life because of toxicity (based
upon 1/20 of the 96-hr TL ). This calculated dilution flow does not
include additional allowance for the many other potentially toxic waste
streams presently entering the Holston River, not only from the remaining
parts of HAAP A, but also HAAP B, Tennessee Eastman, and miscellaneous
sources. The concentrations of toxic materials in the Holston River
downstream from Kingsport, Tennessee, are approaching the levels that
are toxic to fish. These toxic discharges are in violation of the General
Water Quality Criteria for the Definition and Control of Pollution In the
Waters of Tennessee for Fish and Aquatic Life-subsection 3(g). If in-
cluded in the process waste stream for waste treatment purposes these two
waste streams may seriously interfere with the efficacy of the proposed
biological treatment.
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4. The Area A wastewater-treatment program relies exclusively upon
completion and adequate performance of the aerated lagoon (i.e., Phase II)
The full-scale lagoon is scheduled for operation by February 1976. In the
interim, process wastes will be discharged without treatment to the South
Fork of the Holston River, and projects completed prior to this data (e.g.
the tank-farm dike project and collection of boiler blowdown and steam-
plant wastes for treatment) will not be functional as all the wastes are
designed to ultimately flow to the lagoon.
5. Treatment performance criteria used for the design of the aerated
lagoon system are not expected to meet APSA Guidelines or Water Quality
Standards Requirements. The system, as described, is incompatible with
best practicable control technology. Design criteria were based upon
USAEHA derived waste loads which were found considerably lower than the
EPA 1972 survey loads. Consequently, expected treatment performance
may be greatly altered. Questions are also raised on the applicability
of biological treatment to the HAAP wastes. Modification of the criteria,
or even the concept itself, could be necessary.
6. A significant air pollution problem exists in Area A. Measures
are presently underway to alleviate some of these air pollution emissions.
D. HOLSTON ARMY AMMUNITION PLANT-AREA B
1. At Area B, the total discharge to the River was 84.4 mgd, con-
taining a net BOD of about 10,000 lb/day. The applicability ,of the BOD
test to some of these waste streams, which may contain nondegradable or
even toxic materials, is questionable.
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2. In the GPA survey, only about 100 lb of ammonia/day are dis-
charged in Che wastewater effluent. Other surveys showed up to almost
2,500 lb/day in the effluent streams. Almost 2,500 lb of the nitrate
and nitrite ion/day are discharged into the Holston River.
3. Waste treatment facilities designed by CERL and based on stan-
dards of the State of Tennessee were not designed in accordance with the
best practicable control technology currently available.
4. All solids removed in the water treatment facility and from
steam production are sent untreated to the river.
5. A significant air pollution problem exists in Area B. Measures
are presently underway to alleviate some of these air pollution emissions.
6. Static bioassay studies on Streams 29 and 30 after mixing but
before entering the river has a 96 hr TL^ value of 23 percent. The
combined flow was 16.72 mgd. A factor of 1/20 was used to obtain a
river flow that would dilute this so that there would be no long-term
impact on aquatic life. A bioassay on stream 31 (at 2.3 mgd) showed
a 96 hr TL of 23 percent. Similar calculations were performed on this
in
flow. The summation of the two bioassay calculations indicated that a
minimum flow of 2,600 cfs would have to be maintained in the river.
This figure does not include dilution water that would be necessary to
protect the aquatic life from discharges at Area A, Tennessee Eastman
Company, or other sources in the area.
E. MEAD PAPERS
Mead Papers, an integrated Kraft Mill, discharges approximately
17.5 mgd of process wastes containing 21,550 lb of BOD (39.9 lb/ton of
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12
product) 31,500 lb of suspended solids (68.5 lb/ton), and 450 lb of TKN
to the South Fork of the Holston River. The lagoon system under con-
struction was designed on the basis of meeting an effluent limit of
6,000 lb/day BOD. The present system might not meet requirements for
best practicable treatment currently available or water-quality standards
requirements. The 1969 study determined that in order to maintain a
minimum DO concentration of 3.0 mg/1 in the Holston River, the BOD load
must not exceed 2,000 lb/day (A.4 lb/ton of product). To meet the exis-
ting standard of 5.0 mg/1 DO, the BOD in the effluent should not exceed
1,100 lb/day (2.4 lb/ton).
F. KINGSPORT MUNICIPAL WASTEWATER TREATMENT PLANT
The ICingsport Wastewater Treatment Plant was not sampled because
of hydraulic overloading due to the combined sewer flow. The plant by-
passed raw sewage and storm water run-off to the South Fork of the Holston
River during the period 10 through 14 December 1972.
Plant records indicate that on an annual basis (November 1971 to
November 1972), the BOD and suspended solids are reduced by 70 percent
and 74 percent, respectively, during normal operating conditions. The
effluent contained an average of 57 rag/1 (3,130 lb/day) BOD and 36 mg/1
(2,190 lb/day) suspended solids, levels which do not meet the require-
ments for secondary treatment that have been proposed pursuant to the
1972 Amendments to the Federal Water Pollution Control Act. (EPA pro-
poses to limit BOD and SS in the effluent to a monthly average of
30 mg/1 and a weekly average of 45 mg/1, or 85 percent overall reduction,
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13
whichever produces better quality.) This level of treatment is beyond
the present capability of the plant. In addition, the 1969 survey rec-
commended that the effluent from the Kingsport Wastewater Treatment Plant
not exceed 900 lb/day BOD (92 percent removal) to ensure that a minimum
of 3.0 mg/1 of DO is maintained in the Holston River and in the South
Fork of the Holston River. To maintain the official standard of 5 mg/1
minimum DO, the effluent should not exceed 500 lb BOD/day (95.5 percent
removal).
In the interim until adequate facilities are constructed, some im-
provement in treatment could be realized by changing the method of recir-
culation to the trickling filter and by enforcement of the City Indus-
trial Waste Ordinance.
G. HOLLISTON MILLS
Hoiliston Mills discharges cooling water containing a BOD and sus-
pended solids load of 30 lb/day and 94 lb/day, respectively. The average
flow, 0.28 mgd, was considerably less than the 0.83 mgd reported by the
company. While the level here of BOD remained essentially the same as
in the raw intake water, increases in the concentrations from background
levels of suspended solids (19 mg/1 to AO mg/1), TKN (0.7 mg/1 to 1.4 mg/1),
total phosphorus (0.2 mg/1 to 1.2 mg/1), and sulfate (26.5 mg/1 to
66 mg/1) indicated that the water was being contaminated by process water.
Process wastewater is treated prior to discharge. The influent flow
to the wastewater lagoon averaged 0.7 mgd and the effluent flow averaged
0.6 mgd, thus demonstrating that excessive seepage from the lagoon was
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occurring. The suspended solids and sulfates in the polishing lagoon
influent were reduced by 20 percent and 41 percent, respectively.
However, all other pollutant concentrations Increased or remained
essentially the same in the lagoon before discharge. The treatment
system was not performing efficiently.
The effluent from the lagoon contained a total load of 1,940 lb
BOD/day, 200 lb suspended solids/day, and 221 lb sulfide/day. The
EPA interim Effluent Guidelines limit the discharges of BOD and sus-
pended solids to 700 lb/day each and sulfide to 7 lb/day. However,
I
the 1969 EWQA study concluded that in order to maintain a minimum DO
concentration of 3.0 mg/1 in the Holston River, the maximum BOD dis-
charge from Holliston Mills should not exceed 260 lb/day. To maintain
a minimum DO concentration of 5.0 mg/1, it is estimated that the maximum
BOD discharge shall not be greater than 150 lb/day.
H. ASG INDUSTRIES, INC.
ASG Industries, Inc. discharged untreated wastewater and cooling
water (1.2 mgd) and treated wastewater (0.52 mgd) to the South Fork of
the Holston River. The average daily loads from these two discharges
contained 4,060 lb suspended solids and 179 lb COD. The oil and grease
in the cooling water stream ranged from 4 to 7 mg/1 indicating con-
tamination. These loads are greatly in excess of those recommended in
the EPA interim Effluent Guidelines which, for a plant of this type,
limit the loads to 16.6 lb/day each of suspended solids and COD.
Additional treatment is necessary at ASG to meet the effluent
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15
guidelines for suspended solids and COD. All wastewaters need to be
segregated from uncontarainated cooling waters, and conservation and
water re-use must be practiced if the limits are to be met. Improved
coagulation methods will also aid in meeting the guidelines.
I. PENN-DIXIE CEMENT CORPORATION
The Penn-Dixie Cement Corporation discharged a total of 0.78 mgd
wastewater to the South Fork of the Holston River through two outfalls.
The wastewater contained a daily average load of 1,800 lb suspended
solids or more than 50 times the limit (35 lb/day for a plant of this
type) recommended in the EPA interim Effluent Guidelines. Ninety-six
percent of this loading came from a supposedly uncontaminated cooling-
water discharge for which no permit application had been filed.
To achieve effective pollution control, water re-use and conser-
vation must be practiced; the source of suspended solids in the cooling
water stream must be isolated and treated.
J. J. P. STEVENS
The J. P. Stevens-Borden Plant discharges all wastewater to the
Kingsport Municipal Wastewater Treatment Plant. However during the
survey wastewater was being diverted to the river because of a blocked
interceptor. This condition was subsequently corrected by city personnel.
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16
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17
III. RECOMMENDATIONS
To enhance and protect the quality of the Holston River and its
tributaries the following recommendations are made.
A. TENNESSEE EASTMAN COMPANY
1. To maintain a minimum concentration of 5.0 mg/1 DO in the
Holston River all process wastewater shall be immediately segregated
from the once through, non-contact cooling water. The total BOD and
TKN discharged in the process wastewaters shall not exceed 3,350 lb/day
and 400 lb/day, respectively. These loads are based on requirements
necessary to maintain a minimum concentration of 5.0 mg/1 DO in the
Holston River. The suspended solids concentration in the process waste-
water shall not exceed 30 mg/1 greater than background levels; the total
-— 1
concentration of heavy metals shall not exceed 1.0 mg/1; and the nitrite
+ nitrate nitrogen concentration shall not exceed 1.0 mg/1. The pH shall
be maintained within the range of 6.0 to 9.0 at all times. There shall
be no detectable discharge of potentially toxic organic wastes.
A suggested treatment system to meet these effluent limitations
could imcorporate:
a. Pretreatment measures to protect biological treatment process;
b. Activated sludge;
c. Deep-bed filtration; ^
d. Carbon adsorption;
" " f t
e. Denitrification; | > ^
2. Pretreatment regulations shall be established for the waste
discharged to the Kingsport WWTP requiring the removal of potentially
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18
toxic organic substances and other pollutants to levels that will
neither inhibit biological treatment processes nor pass through the
systems in concentrations or loads inconsistent with effluent limita-
tions that will be established pursuant to the Federal Water Pollution
Control Act Amendments of 1972.
3. All additional effluent requirements established by the State
of Tennessee shall be met.
4. A schedule and proposed method of treatment for achieving the
necessary pollution abatement shall be provided to EPA, Region IV, by
15 October 1973.
B. HOLSTON ARMY AMMUNITION PLANT
1. To meet water-quality standards in the Holston River and the
requirements of the National Pollution Discharge Elimination System the
following effluent limitations are recommended for the Holston Army
Ammunition Plant (Areas A & B) located in the vicinity of Kingsport,
Tennessee;
a. BOD not to exceed 2,400 lb/day
Area A-1,000 lb/day
Area B-1,400 lb/day
b. TKN not to exceed 100 lb/day
Area A-10 lb/day
Area B-90 lb/day
c. Heavy metals not to exceed 150 lb/day
Area A-30 lb/day
Area B-120 lb/day
d. Phenolics not to exceed 5 lb/day
Area A-l lb/day
Area B-4 lb/day
NOTE: Effluent limitations a through d refer to net additions to
raw intake water.
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19
e. No detectable discharge made of potentially toxic organic wastes
f. SS shall not exceed 30 rag/1 in process wastes and background in
cooling water. In the process waste, the SS limit shall bo
4,600 lb/day.
Area A-1,000 lb/day
Area B-3,600 lb/day
g. Nitrate and nitrite nitrogen shall not exceed 1 mg/1 in process
wastes and background in cooling water. In the process wastes
the nitrate-nitrite shall be limited to 150 lb/day.
Area A-30 lb/day
Area B-120 lb/day
2. The Army Munitions Command shall provide to the Environmental
Protection Agency, Region IV, by not later than 15 July 1973, a treafraent
system and schedule of abatement necessary to meet the effluent limita-
tions established in recommendation number one by 1 July 1977. A sug-
gested treatment system which could meet these limitations is:
a. Separation of process wastes and major uncontaminated cooling
water streams to the maximum extent feasible
b. Pretreatmeut measures to protect the biological treatment
process
c. Activated sludge
d. Deep-bed filtration
e. Carbon adsorption
f. Denitrification
3. Sludges, solids, and debris resulting from water treatment pro-
cess at both Areas A and B shall be dewatered and removed to approved
landfill with no discharge to receiving waters.
A. Wastes resulting from discharges in the tar-tank storage area
shall be completely contained and not discharged to receiving waters nor
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20
included in any process-waste streams that discharge to the waste treat-
ment system. There shall be no discharge of this coal tar waste to re-
ceiving waters.
5. For the tank-farm- and chemical-stcrage areas 11AAP shall develop
a strong spill prevention, containment, and countermeasure program as
soon as possible. Such a program and associated plan of action shall, as
a bare minimum, incorporate preventive maintenance and inspection; ade-
quate capacity diking or curbs shall be constructed around all tanks or
groups of tanks so as to prevent a) chemicals ]eaking or spilling from
the tanks and b) any storm water contaminated with chemicals from entering
a receiving watercourse. In no event shall spills, be allowed to enter
sanitary, process, or cooling-water sowers. Complete containment and
separate recovery or treatment of spills, leaks, and associated drainage
are recommended.
6. All additional effluent requirements established by the State of
Tennessee shall be met.
C. HEAD PAPERS
1. To maintain a minimum concentration of 5.0 mg/1 DO in the Hols ton
River the ROD in the effluent shall not exceed 1,100 lb/day. The sus-
pended solids shall not exceed 1,100 lb/day above background levels; the
pH shall be within the range of 6.0 to 9.0 at all times.
2. All additional effluent regulations established by the State of
Tennessee shall be met.
3. The aerated lagoon under construction shall receive all process
wastes. There shall be no discharge of wastes from the water-treatment
plant without adequate treatment.
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21
4. The effluent structure from the black liquor pond shall be
sealed, and all storm water diverted around the lagoon so that the
contents of the pond are not released.
5* A schedule and proposed method of treatment for achieving the
necessary pollution abatement shall be provided to EPA, Region IV, by
15 October 1973.
D, KINGSPORT WASTEWATER TREATMENT PLANT
City officials shall be formally advised that:
1. To maintain a minimum concentration of 5.0 mg/1 DO in the
Holston River, the BOD in the effluent shall not exceed 500 lb/day.
The suspended solids shall not exceed 500 lb/day. All additional ef-
fluent requirements established by the State of Tennessee shall be met.
2. The fecal-coliform bacterial density in the effluent shall not
exceed 200/100 ml as a monthly average and 400/100 ml as a weekly average.
3. The industrial waste ordinance for the city shall be modified
to meet the requirements for pretreatment when published in accordance
with the Federal Water Pollution Control Act Amendments of 1972.
A. Corrective measures shall be taken to preclude the by-passing
of untreated wastes from the plant or within the sewerage system due to
excessive combined sewer flows. A sewer maintenance program shall be
developed to routinely inspect, clean, and repair sewers and thus,
eliminate direct by-passing resulting from plugged lines, etc.
5. A schedule and proposed method of treatment for achieving the
necessary pollution abatement shall be provided EPA, Region IV, by
15 October 1973.
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E. ilOLLISTON MILLS
1. To maintain a minimum concentration of 5.0 mg/1 DO in the
Holston River, the BOD in the effluent shall not exceed 150 lb/day.
The suspended solids shall not exceed 150 lb/day above background
levels. Chromium and phenolics shall each not exceed 3.5 lb/day, and
sulfide shall not exceed 7.0 lb/day.
2. All additional effluent requirements established by the State
of Tennessee shall be met.
3. The cooling-water and process^wastewater streams shall be
segregated.
4. Holliston Mills, Inc., in its manufacturing processes, incor-
porate more in-plant control measures, re-use of cooling water, and
improved housekeeping in order to prevent solvents, sizing ap.ents,
dyes, pigments, plastics and other contaminants from entering the ¦
wastewater system.
5. A schedule and proposed method of treatment for achieving the
necessary pollution abatement shall be provided EPA, Region IV, by
15 October 1973.
F. ASG INDUSTRIES
1. To meet the EPA interim Effluent Guidelines, based on the best
practicable control technology currently available, the total wasteload
discharged shall not exceed the following limits:
Parameter lb/day
Suspended Solids 16.6
COD 16.6
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23
Hexane Extractables 2.1
(oil and grease)
Total Phosphorus 2.1
2, All additional effluent requirements established by the State
of Tennessee shall be met.
3. A schedule and proposed method of treatment for achieving the
necessary pollution abatement shall be provided EPA, Region IV, by
15 October 1973.
G. PENN-DIXIE CEMENT CORPORATION
1. To meet the EPA interim Effluent Guidelines, based on the best
practicable control technology currently available, the total COD and
suspended solids discharged shall each not exceed 35 lb/day. Additional
effluent requirements established by the State of Tennessee shall be met.
2. A schedule and proposed method of treatment for achieving the
necessary pollution abatement shall be provided EPA, Region IV, by
15 October 1973.
H. GENERAL
1. The permits issued to all waste dischargers in the Kingsport
area shall include requirements for a monitoring program of sufficient
detail to ensure compliance with the established effluent limitations
and protection of the receiving waters.
2. Effluent limits for parameters shall as color, fecal coliforms,
oil and grease, etc, shall be set where necessary in order to protect
the receiving-water quality.
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2U
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25
IV. STUDY AREA
A. GENERAL DESCRIPTION
The study area [Figure IV-1, inside back cover] lies within the
Holston River Basin in the rugged hill country of Northeastern Tennessee
and includes portions of Sullivan and Washington Counties. The Holston
River is formed by the confluence of the South and North Forks of the
Holston. River, at Kingsport.
Kingsport, Johnson City, and Bristol, major cities in eastern
Tennessee, form the "Tri-Cities" metropolitan area. Also, Bristol,
Virginia, is a major city in the Holston River Basin.
2/
Kingsport (population, 30,800- ) , located in Sullivan County, is
the only city that is within the study area. Kingsport is the most
industrialized of the three cities and provides jobs for more than
3/
34,000 people.— Since 1960, the city has grown at an annual rate that
exceeds 17 percent. The majority of the development has been along the
South Fork of the Holston River.
B. ECONOMICS
4/
A detailed study— of the economic growth in eastern Tennessee
and western Virginia reported that manufacturing is the major industry,
employing 73,200 persons. Chemicals and allied products, apparel, and
textile products are the leading industries. The pulp and paper indus-
try is projected as having the major growth potential. Employment in
the region is anticipated to increase from its present rate of 31 per
3 /
100 population to 36 per 100 population by the year 2020.—
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26
C. HYDROLOGY
The Tennessee Valley Authority (TVA) has constructed a series of
impoundments upstream of Kingsport on the South Fork of the Hols ton
River and its tributaries to control flooding and generate hydro-
electric power. The flow in the North Fork is unregulated. The
20 year, three-day low flow in the North Fork, recorded at Gate City,
Virginia, is 46 cfs, (or 58 cfs, for 7-day, 10-yr flow) and the mean
daily discharge is 851 cfs. The TVA is required to release water from
Fort Patrick Henry Dam to maintain a minimum daily flow of 450 cfs in
the South Fork of the Holston River, However, the Tennessee Eastman
Company requires a minimum daily stream flow of 750 cfs for process
and cooling water. The company purchases the additional water required
from the TVA.
* The Tennessee Water Quality Criteria are applied on the basis of two
definitions of minimum flow: (1) unregulated streams—3-day minimum,
20-year recurrence interval, and (2) regulated streams—instantaneous
minimum.
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27
V. APPLICABLE WATER QUALITY STANDARDS AND REGULATIONS
A. WATER QUALITY STANDARDS
The Hols ton River, an interstate stream, and the South Fork of the
Hols ton River are used for public water supply, industrial water supply,
recreation, hydroelectric power, agricultural purposes, and receipt of
treated wastes. Within the study area, all the rivers and streams investi-
gated, with the exception of Hales Branch (not classified) and North
Fork are classified as suitable for "Fish and Aquatic Life." In addi-
tion, the Hols ton River downstream (RM 131.5) from Kingsport is classi-
fied as "Domestic Raw Water Supply." [The Tennessee Water Quality
Criteria are contained in Appendix A.]
The criteria and standards require that all wastes in the Kingsport
area [Table V-l] will receive the best practicable treatment (secondary
or equivalent) or control according to the policy and procedure of the
Tennessee Water Quality Control Board. A degree of treatment greater
than secondary, when necessary to protect the water uses, will be re-
quired for selected sewage and waste discharges.
Specific standards applicable to this survey include:
1. Dissolved Oxygen—The dissolved oxygen shall be maintained
at 5.0 mg/1 except in limited sections of the stream receiving
A
treated effluent. In these limited sections, a minimum of
3.0 mg/1 dissolved oxygen shall be allowed. [These limited
sections are mixing zones which refer to that section of the
* The EPA has requested that Tennessee upgrade Water Quality Criteria for
these sections to 5.0 mg/1 DO and to establish a fecal colifora criteria
of 2,000/100 ml for water classified for fish and aquatic life.
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TABLE V-I
STATE OF TENNESSEE
EFFLUENT STANDARDS FOR WASTE DISCHARGES
IN THE KItiCSPORT AREA
Waste Load
Source
Parameter
lb/day
Tennessee Eastman Company
BOD
TKN
TK
NH.
75,000^
16,120^,
16,120^'.
10,780s-'-
N03
25,000^
6(£
60^
Mead Corporation
BOD
TKN
TK
NH,
0
ml
11,250®-'
16 CP,
180^-
KingEport WWTP
BOD
TKN
TK
NH,
NHj
20
Ho It ton Army
Ammunition Plant
BOD
TKN
23,4805/
io£
10f
Area A
TK
NH,
10^-
*°3
134,7 30s-'
16,350^'
Totals for South Fork
BOD
TKN
TN
NH,
10,900
"»3
Holston Army
BOD
32,220
Aasnunition Plant
TKN
3,045
Area B
TN
5,515
Nil
2,830
N03
2,460
Percent
Treatment
Effluent
Requirements
lb/day
95.54^
97.5
95.54*'
95.54^
95.54^
Totals
95.54—'
97.5
3.350
A00H/
3,310^' /
400 /
2,910^
1,100
500
133-'
1,050
e.ooo^
«37&'
2,133^
1.430^
76h/
620^-
76
556
&J Water Quality and Waste Treatment Requirements on the Upper llolston River, EPA,
Region IV, 1972, Table 4, Page 23.
b/ Calculated percentage of treatment required in the Kingsport Area to achieve 6,000
pounds total BOD disrliarKe. Based on raw waste loads from the EPA report of 1972.
cj Water Quality and WasLe Treatment Requirements on the Uoper Holston River, EPA,
Region IV, 1972; Appendix B, Waste Discnarges, Upper llolston River Nitrogenous
Mnteiial, Page B-2.
d/ Based on 1.0 tng/1 (A,000 lb/day) increase in the KO^ level in the llolston River
below all waste sources including Holston Army Ammunition Plant, Area B. This
Figure is based on maintaining a total phosphorus level of 0.1 mg/1 in the Holston
River below all waste sources. This rotio of ohosphoru3 to nitrogen is to be main-
tained below 1/10 in the river to attempt to control the aquatic veretation. Limits
for Eastman and Head vcre proportioned based on their present TN levels. Total TN
levels at present for all discharges was calculated to be 19,395 pounds per day.
e/ EPA, 1972 report, Appendix B, Waste Discharges, Upper Holston River. Effluent data.
_f/ Based on a plant flou of 10 rgd (6.2 mgd present and 3.8 rcgd expansion allowed) and
1.6 tng/1 NH^-N in the effluent,
jj/ "Treatment Levels Required for Kingspoit Waste Diicharpes," VA preliminary draft
report. Calculated based on a new BOD load in the Kingoporr. Area of 237,500 pounds
and a treatment requirement of 97.5 percent (see Figure 3, 760 cfs, 6 mg/1 DO) and
a TKN of 17,500 and a treatment of 97.5 percent.
_h/ Estimated based on 760 cubic feet per second stream flo^, maximum stream concentra-
tion of 0.5 based on the domestic raw water supply classification below Church Hill,
i/ Based on a treat le\cl the same as that of Eastman.
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29
flowing stream or impounded waters necessary for effluents
to become dispersed. The mixing zone necessary in each parti-
cular case shall be defined by the Tennessee Water Quality Control
Board.] The dissolved oxygen content shall be measured at mid-
depth in waters having a total depth of ten (10) feet or less
and at a depth of five (5) feet in waters having a total depth
of greater than ten (10) feet. Minimum dissolved oxygen content
of 6.0 mg/1 shall be maintained in recognized trout streams.
pH—The pH value shall lie within the range of 6.5 to 8.5 apd
shall not fluctuate more than 1.0 unit in this range over a
period of 24 hours.
Solids, Floating Materials and Deposits—There shall be no dis-
tinctly visible solids, scum, foam, oily slick, or the formation
of slimes, bottom deposits or sludge banks of such size or
character that may be detrimental to fish and aquatic life.
Turbidity or Color—There shall be no turbidity or color added
in such amounts or of such character that will materially
affect fish and aquatic life.
Temperature—The maximum water temperature change shall not
exceed 3°C relative to an upstream control point. The temper-
ature of the water shall not exceed 30.5°C and the maximum
rate of change shall not exceed 2°C per hour. The temperature
of recognized trout waters shall not exceed 20°C. There shall
be no abnormal temperature changes that may affect aquatic
life unless caused by natural conditions. The temperature
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30
of impoundments where stratification occurs will be measured
at a depth of 5 feet, or mid-depth whichever is less, and the
temperature in flowing streams shall be measured at raid-depth.
6. Taste or Odor—There shall be no substances added that will
impart unpalatable flavor to fish or result in noticeable
offensive odors in the vicinity of the water or otherwise
interfere with fish or aquatic life.
7. Toxic Substances—There shall be no substances added to the
waters that will produce toxic conditions that affect fish
or aquatic life.
8. Other Pollutants—Other pollutants shall not be added to the
waters that will be detrimental to fish or aquatic life.
B. FEDERAL WATER POLLUTION CONTROL ACT' AMENDMENTS OF 1972
Under the Federal Water Pollution Control Act Amendments of 1972
(FWPCAA), existing water quality standards for interstate waters are
preserved. In addition, the Act requires the preparation of water qua-
lity standards applicable to intrastate waters. The existing mechanism
for State establishment, Federal review and promulgation and review of
water quality standards is continued.
Hales Branch, a tributary to the South Fork of the Holston River,
falls within this intrastate category; water quality standards must
therefore be established.
The Act also provides that all point sources of pollution other
than publicly owned treatment works, which discharge directly into the
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31
Nation's waters are required to achieve, not later than July 1, 1977,
effluent limitations which shall require the application of the "best
practicable control technology currently available." The same point
sources must achieve effluent limitations which shall require the appli-
cation of the "best available technology economically achievable" by
July 1983. Point sources discharging into publicly owned treatment
works must comply with pretreatment standards as prescribed by the EPA.
EPA will also limit the discharge of pollutants determined to be toxic
and where appropriate may require an absolute prohibition of the dis-
charge of such toxic pollutants.
Publicly owned treatment works must meet effluent limitations by
July 1, 1977 which are based on "secondary treatment" as defined by EPA.
By July 1, 1983, public plants must meet "best practicable waste treat-
ment technology."
The established effluent limitations for each individual point
source will be applied as conditions of permits to be issued under the
National Pollutant Discharge Elimination System as established by the Act.
In cases where the prescribed effluent limitations will not achieve
a level of water quality consistent with water quality standards and
suitable for swimming and sustaining a balanced population of fish,
shellfish and wildlife, EPA may impose more stringent effluent limita-
tions as may be necessary to achieve that goal.
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32
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33
VI. STREAM SURVEY
A. 1969 EWQA SURVEY
An extensive stream survey conducted in July 1969 demonstrated that
waste discharges in the Kingsport, Tennessee, area seriously affected the
water quality of the South Fork of the Holston River and the Holston
River. At the time of that survey approximately 137,500 lb BOD were dis-
charged from the HAAP, Mead Papers, TEC, Holliston Mills and the Kingsport
Municipal Wastewater Treatment Plant. Discharges of total Kjeldahl
nitrogen, primarily from TEC and HAAP, amounted to almost 19,500 lb/day,
which theoretically represent an ultimate oxygen demand of about 84,000 lb.
Extensive sludge beds covered an estimated 25 percent of the bottom
area of the Holston River from the confluence of the North and South Forks
of the Holston River (RM 142.15) downstream for about 23 miles.
The 1969 study revealed that releases from Fort Patrick Henry Dam
had a marked affect upon the hydrological regimen of both the South Fork
of the Holston River and the Holston River, especially during off-peak,
power-generating periods when releases would be reduced to a daily average
of 750 cfs (3,000 cfs for one hr, no release for three hr). When this
coincides with low flows in the North Fork of the Holston River, the flow
in the Holston River could be reduced to about 800 cfs. Because releases
during these periods are made primarily from the hypolimnion of the res-
ervoir, the dissolved-oxygen concentrations are below the saturation level.
During the 1969 survey the flows in the South and North Forks of the
Holston River averaged 840 and 660 cfs, respectively.
The dissolved-oxygen levels fell below the established standards
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34
(5.0 mg/1) at stations within the reach, from RM 142.15/1.2 downstream
to RM 125.30.
Temperature in the South Fork of the Holston River increased from
averages of 15.5°C upstream of TEC discharges (RM 142.15/5.6) to greater
than 26.9°C downstream of the 1IAAP A discharges. This increase violated
the Tennessee Water Quality Standards for temperature which restricts
temperature changes to 3°C relative to an upstream control point. It
was concluded that cooling devices must be installed at TEC and HAAP A
to prohibit these increases.
Further, the results of the 1969 survey recommended that the BOD
discharged be reduced by 92 percent from the five sources mentioned
earlier. Moreover, the total Kjeldahl-nitrogen discharges from TEC and
HAAP waste sources "ere pIso to be reduced by 92 percent. The recommended
limits from each source, based on the 1969 survey results, are shown in
Table VI-1.
TABLE VI-1
ESTIMATED WASTE LOAD LIMITS BASED ON 1969 SURVEY
BOD lb/day
TKN lb/day
1,600
Tennessee Eastman Corp
6,000
2,000
900
Mead Papers
Kingsport WWTP
HAAP-Area A
1,900
HAAP-Area B
2,600
350
Holliston Mills, Inc
260
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35
B. 1972 EPA SURVEY
A limited scream survey was conducted during the period 4 through 7
December 1972 in order to ascertain the changes in receiving water quality
as a result of waste discharges. The four sampling stations [Figure IV-1]
selected were as follows:
Station Station
Number Description
53 North Fork of the Holston River at Ketherland Inn
Road (RM 142.15/0.2)
54 South Fork of the Holston River at Tennessee
Highway 93 Bridge (RM 142.15/5.6)
55 South Fork of the Holston River at Ridgefields
Bridge (RM 142.15/1.2)
56 Holston River at Church Hill Bridge (RM 131.5)
Samples collected at the stations were analyzed for the following
parameters: nitrogen series, total phosphorus, organic chemicals, and
heavy metals (Hg, Cu, Cr, Fe, Mh, Zn, Pb, and Sn). Because of the dif-
ferences in the climatic and hydrologic conditions, in 1972, from those
of the 1969 study period, dissolved oxygen and BOD analyses were not
performed. The samples from Stations 54 and 55 were also analyzed for
phenolic materials. At all locations samples were collected at the third
points near the surface. These grab samples were then composited on an
equal-volume basis. Each time a sample was collected field measurements
were made for pH conductivity and temperature [Table VI-2].
During the survey average daily flows in the Holston River were esti-
mated to be from 3,500 to 4,600 cfs [Table VI-3]. Releases from Fort
Patrick Henry Dam varied from zero to 7,500 cfs because of the power
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IjO
TABLE VI-2
SUMMARY OF FIELD MEASURE?IEVTS AND SELECTED CHEMICAL DATA
STREAM SURVEY
KINGSPORT, TENNESSEE
4-6 DECEfBSR 1972
Station Kuabcr 53 54 55 56
3/
Station Ce
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37
TABLE VI-3
ORGANIC ANALYSIS OF WATER SAMPLES
FROM SELECTED STREAM LOCATIONS
KINGSPORT, TENNESSEE
6 AND 13 DECEMBER 1972
Station
Number
Station Description
Water Analysis
53
North Fork of Hols ton River at
Netherland Inn Road
(RM 142.15/0.2)
None detected
54
55
56
South Fork of Holston River
at Tennessee Hwy 93 Bridge
(RM 142.15/5.6)
South Fork of Holston River at
Ridgefields Bridge
(RM 142.15/1.2)
Holston River at Churchill
Bridge (RM 131.5)
None detected
None detected
A chlorinated aromatic
compound tentatively
identified as a
chlorophenylbenzyl ether
T3~presentJ at about ~2 ppm.
There are other organic
compounds present in trace
amounts (less than 0.1 ppm).
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generation demands. This caused a wide range in the stages of the South
Fork of the Holston River. Stream samples were collected under varying
flow conditions.
Discharges to the South Fork of the Holston River made during
December 1972 had average daily waste loads of approximately 95,000 lb
of BOD; 54,000 lb TOC; 11S000 lb total Kjeldahl nitrogen; and 2,600 lb
of nitrate-nitrogen. These include measured loads from TEC; HAAP A & B;
ASG Industries, Penn-Dixie Cement Corporation; and Mead Papers; and the
estimated waste loads from the Kingsport Municipal Wastewater Treatment
Plant. Tennessee Eastman, HAAP, and Mead Papers contributed 95 percent
of these waste loads on a BOD basis. The waste loads from the Kingsport
Municipal Wastewater Treatment Plant were not measured. However, from
a review of operating records, the plant discharge to the South Fork of
the Holston River had an average BOD of 3,100 lb/day. The BOD and total
Kjeldahl nitrogen loads discharged greatly exceed the loads recommended
as a result of the 1969 survey [Table VI-l].
Discharges from HAAP 'B' and Holliston Mills contributed to the
Holston River a BOD of approximately 16,500 lb/day, 7,000 lb/day TOC,
1,000 lb/day total Kjeldahl nitrogen, and 2,400 lb/day nitrate-nitrogen,
the latter waste load discharged totally by HAAP B.
Heavy-metals analyses of water samples disclosed a significant
increase (more than 20 times) in manganese concentrations from the Sta-
tion-54 location to Station 55. The increase is attributed to the
Tennessee Eastman Company which was discharging wastewater containing
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39
about 9,500 lb/day of manganese. At Station 56 (RM 131.5) the concen-
trations of manganese ranged from 0.21 to 0.40 mg/1 well above the Public
Health Service Drinking Water standards recommended limit (0.05 mg/1).
(At Station 56 the Holston River is classified as a suitable public-
water supply for domestic use.) Violations of the standards for domestic
water supply occurred [Appendix A, Domestic Water Supply Item lK-other
Pollutants]. Manganese concentrations in the sediment were significant
at Stations 53 (844 mg/kg) and 54 (9,800 mg/kg) and increased by one
order of magnitude downstream from all waste sources in the Kingsport
area (Station 56). The sediments Table VI-4 also revealed exceedingly
high concentrations of iron (7,373 - 20,200 mg/kg) at all of the stations.
Water samples collected on 6 and 13 December 1972 for organic chem-
ical analysis disclosed that organic pollutants were present only at
Station 56, downstream from all waste discharges. A sediment sample
taken from the Holston River at Church Hill Bridge (RM 131.5) contained
aliphatic hydrocarbons, phenolics, fatty acid esters, and phthalates.
Di-rt-butyl phthalate was present in concentrations of 2 mg/kg, and the
concentration of an unidentified rz-alkane was 11 mg/kg. These materials
are not highly toxic, but the phthalates are suspected of producing
mutations in some species of fish.
A comparison of the 1969 and 1972 survey data (specifically, average
concentrations of total Kjeldahl nitrogen, NO^ + NO^-N, and Total P) is
available [Table VI-5]. Nutrients presently in the river are at levels
sufficient for the creation of water-quality problems such as those
observed during the 1969 survey.
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¦p-
o
TABLE VI—4
HEAVY KETALS IN STREAM SEDIMENTS
KINGSPORT, TENNESSEE
5-7 DECEMBER 1972
Station
Date
ms/kR of Dry Sanrole
Nirabf r
Station Description
Collected
Mercury
Conper
Cad-nium Iron
Manganese
Lead
Chromium
53
North Fork of Kolston
River at Netnerland Inn
Road (RM 142.15/0.2)
12/7
0.3
19.0
3.0
20,200
844
152
37
54
South Fork of liolston
River at Tennessee
Hvy 93 Bridge
(R.M 142.15/5.6)
12/5
<0.1
29.0
<1.0
9,800
330
29
22
56
Hols ton River at
Church Hill Bridge
(RM 131.5)
12/5^/
12/52/
6.6
6.9
93.0
94.0
2.0
2.0
7,373
8,100
2,136
2,080
30
30
56
55
12/6^
3.8
354
2.0
22,725
1,545
91
117
aj Sarcple taken on lfeft side of River.
bj Sample taken on right side of River.
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41
TABLE VI-5
COMPARISON OF NUTRIENT DATA
HOLSTON RIVER, KINGSPORT, TENNESSEE
Station
Number
Year
Concentration, mg/1
TK.N
N0?-N0^
Total-P
53
1969
0.39
1.01
0.03
1972
<0.5
0.4
0.11
54
1969
0.39
1.25
0.03
1972
<0.5
0.9
0.11
55
1969
3.02
0.86
0.27
1972
0.8
1.4
0.30
56
1969
2.17
0.89
0.07
1972
0.8
0.9
0.13
During the 1972 study the maximum temperature increase recorded
between stations 54 (RM 142.15/5.6) and 55 (RM 142.15/1.2) was 9°C.
For most of the study period, the increases recorded were 4°C or less
although the temperatures of the main waste discharges ranged from
18-25°C. For example, Hale's Branch which carries TEC cooling waters
(311 mgd average) varied from 22.5-25°C. As mentioned earlier flow
conditions were significantly different than those which occurred
during the 1969 study, thus the effects of the heated discharges was
diminished. However, the 1969 study conclusion stressing the need for
cooling devices at TEC and HAAP A is obviously still very valid. Vio-
lations of the stream temperature standards will continue to occur
until the temperature of the discharges is reduced.
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42
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43
VII. WASTE-SOURCE EVALUATION AND TREATMENT NEEDS
A. GENERAL
The major waste sources discharging to the South Fork of the
Holston River downstream from Fort Patrick Henry Dam (RM 142.15/8.2) and
the Holston River in the vicinity of Kingsport, Tennessee [Figure IV-1]
were evaluated during the period 28 November through 15 December 1972.
These investigations were made (1) to determine the quality and quan-
tity of wastes discharged to the Holston River and its tributaries,
(2) to provide information for establishing effluent limitations, and
(3) to evaluate present pollution control practices. The waste sources
evaluated included:
1. ASG Industries, Incorporated
2. Holston Army Ammunition Plant (HAAP)—Areas A and B
3. Holliston Mills, Incorporated
4. J. P. Stevens and Company, Incorporated
5. Kingsport Municipal Wastewater Treatment Plant
6. Mead Papers, a Division of Mead Corporation
7. Penn-Dixle Cement Corporation
8. Tennessee Eastman Company (TEC)
The measured waste loads from the industrial waste sources, together
with the estimated discharge from the Kingsport Municipal Wastewater Treat-
ment Plant, have been summarized [Table VII—1]; also included is a summary
of the waste loads found during the 1969 FWQA study of the Upper Holston
River Basin. From the latter study it was concluded that in order to
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4>
TABLE VII-1
SUMMARY OF WASTEWATER DISCHARGES
1969 AND 1972 SURVEYS
KINGSPORT, TENNESSEE
Waste Source
Receiving
Water
Number of
Outfalls
Sampled
Flow
m;;d
BOD
lbs/day
SS
lbs/day
TKN
lbs/day
NH3-N
lbs/day
no3+no2-n
lbs/day
a/
1969 FUQA Region IV Findings—'
ASG Industries, Inc.
HAAP-Area A
Area B
Holliston Mills
J.P. Stevens & Co., Inc.
Kingsport Municipal WWTP
Mead Papers
Penn-Dixie Cement Corp.
TEC
Total
SFHI&/
SFHR
hr!/
HR
SFHR
SFHR
SFHR
SFHR
SFHR
Not sampled
3 59.5 23,480 4,100 10 10 c/
7 103 32,220 4,840 3,045 2,810 2,460
1 0.38 3,200 89 30 cj c/
Not sampled
1 2.4 500 440 160 110 20
1 9 4 11,700 11,430 60 cj c/
Not sampled
3 256 69,300 7,780 16,120 10,780 c/
431 140,400 28,700 19,400 13,700 2,480
ASG Industries, Inc.
SFHR
2
1.70
NA—
4,100
NA
NA
NA
HAAP-Area A
SFHR
8
43.3
20,300
4,060
c /
c/
419
Area B
HR
9
73.6
14,600
26,800
600
106
2,352
Holliston Mills
HR
2
.890
1,970
294
39
14
c_/
J.P. Stevens & Co. Inc.
SFHR
1
1.20
620
46°
93
36
c/
Kingsport Municipal WWTP
SFHR
2
6.59 U
3,130l/
2,190±/
NA
NA
NA
Mead Papers
SFHR
2
17.5
21,600
31,500
451
164
14
Penn-Dixie Cement Corp.
SFHR
2
.770
NA
1,810
NA
NA
NA
TEC
SFHR
8
343
52,400
106,000
10,400
8,200
2,180
Total
489
114,600
177,200
11,600
8,520
4,950
a/ Water Quality and Waste Treatment Requirements on the Upper Holston River, Technical Study TS-03-71-208-07,
EPA Region IV, July 1972, Appendix B.
b/ This stands for South Fork of the Holston River,
c/ This load was not significantly greater than that of raw water,
d/ This stands for Holston River,
e/ NA stands for Not Analyzed.
f/ This value is average yearly summary of plant records.
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45
maintain a minimum concentration of 3.0 mg/1 DO in the Holston River, the
total pollution loads discharged should be limited to approximately
14,000 lb BOD/day and approximately 1,950 lb total Kjeldahl-nitrogen/day.
To maintain a minimum concentration of 5.0 mg/1 DO, the official standard,
the total pollution loads discharged to the South Fork of the Holston
River should be limited to approximately 6,000 lb BOD/day and 100 lb
TKN/day; the total load discharged to the Holston River from the Holston
Army Ammunition Plant, Area B, should be limited to approximately
1,400 lb BOD/day and 90 lb TKN/day. As discussed previously, the limits
of BOD and total Kjeldahl-nitrogen were recommended for these waste
sources [Table VI-1J.
The 1972 study disclosed that there had been some reduction in the
waste loads of BOD, total Kjeldahl-nitrogen, and ammonia, but that the
nitrate-nitrite-nitrogen and suspended solids loads had increased signi-
ficantly. During the survey, the combined waste loads from the Tennessee
Eastman Company, Mead Papers, and the Holston Army Ammunition Plant,
Areas A and B, amounted to 95 percent of the BOD (108,900 lb) and sus-
pended solids (168,400 lb), 99 percent of the total Kjeldahl-nitrogen,
(11,450 lb), and all of the nitrate-nitrite nitrogen (4,900 lb).
Subsequent to 1969 study, the State of Tennessee orally informed the
major industries in the Kingsport area, with the exception of HAAP that
a minimum BOD removal of 85 percent would be required. However, these
limitations were never established in writing, nor has any implementation
schedule ever been set up. Moreover, the 85-percent-removal requirement
would not be adequate to meet either the water-quality standards or the
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46
EPA interim Effluent Guidelines, whichever is the most limiting.
Regarding pollution control needs at IiAAP, the State deferred in-
forming the Department of the Army of the BOD limitations because HAAP
is a Federal facility. Therefore, pollution control is the responsibility
of the United States Government, pursuant to Executive Order 11507 (Pre-
vention, Control and Abatement of Air and Uater Pollution at Federal
Facilities; February 5, 1970). This order requires that:
1. Federal facilities conform to air- and water-quality standards
and related plans of implementation, including emission standards,
adopted pursuant to the Clean Air Act, as amended, and the Federal
Water Pollution Control Act, as amended, and more recently, the
1972 Amendments of the Federal Hater Pollution Control Act,
specifically sppi-io™ ^13.
2. Federal agencies will propose performance specifications em-
ploying the best techniques and methods available for the pro-
tection and enhancement of air and water quality, and
3. Federal agencies shall provide leadership in the Nationwide ef-
fort to protect and enhance the quality of the Nation's air and
water resources
* Pertinent sections of the Act that would seem to have full application
to Federal facilities and Army munitions manufacturing plants include
Sections 301 and 302 dealing with Best Practicable Control Technology
required by 1 July 197 7, the Best Available Technology required by
1 July 1983, which shall be directed to the National goal of eliminating
the discharge of all pollutants. Additionally, Sections 306 and 307,
respectively, deal with standards of performance to be established
through best available demonstrated control technology for new pol-
lution sources and with the establishment of toxic and pretreatment
effluent standards.
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47
From these requirements it is clear that Federal agencies are directed,
by Presidential Order and by Law, to ensure that adequate air- and water-
pollution control measures are in effect at all Federal facilities.
The treatment needs for the waste sources discussed on this section
were based on a) effluent limitations that are achievable by the instal-
lation of best practicable control technology and b) compliance with
applicable water-quality standards; the protection and enhancement of
of receiving water quality could require treatment beyond that considered
best practicable.
Effluent guidelines have been established for municipal wastes and
for most industrial categories of the kind evaluated, with the exception
of TEC and HAAP.
B. TENNESSEE EASTMAN COMPANY
The Tennessee Eastman Company, a division of the Eastman Kodak
Company, is one of the largest chemical manufacturers in the United
States and produces more than 275 different chemical products (14,500,000
lb/day) in three principal categories: plastics, fibers, and chemicals.
According to the Refuse Act Permit Program Application (RAPP), fi]ed
30 June 1971, the plant withdraws a total of 358 mgd from the South Fork
of the Uolston River and purchases 0.14 mgd from the City of Kingsport.
Approximately 10 percent of the intake water is treated. Water is used
for cooling purposes (336 mgd), boiler feed (3.7 mgd), process water
(16.8 mgd), and for other purposes (1.1 mgd). Sanitary wastes (0.35 mgd)
-------
48
are discharged to the municipal wastewater treatment plant, and 1.7 mgd
of water is lost through evaporation.
Waste-Source Evaluation
The waste discharged to the river was characterized during a five-day
period, 4 through 9 December 1972. The combined flow from the seven TEC
outfalls was approximately 343 mgd. The BOD discharged was greater than
52,000 lb/day, and the TKN and suspended solids loads averaged 10,400 lb/day
and 106,000 lb/day, respectively. The 1969 study reported the discharges
to contain 69,300 lb BOD/day; 16,100 lb TKN/day; and 7,800 lb suspended
solids/day; corresponding values reported in the RAPP application were
28,800 lb BOD; 13,000 lb TKN; and 86,400 lb suspended solids.
Several heavy metals are used as catalysts at the plant. Loads of
heavy metaJs discharged daily were approximately 9,500 lb manganese,
600 lb zinc, and 1,800 lb iron. Sediments taken from the river down-
stream had concentrations as high as 22,700 mg/kg for iron and 2,800 me,/kg
for manganese. The discharge of manganese is considered responsible for
the concentrations (0.21-0.40 mg/1), in the HoJston River at Church Hill
Bridge (Station 56), exceeding the U.S. Public Health Service recommended
drinking water standards (0.05 mg/1 Mn) and also resulting in violations
of the Tennessee standards for domestic rat? water supply [Appendix A-
ltem 1(K) other pollutants].
As previously discussed [Section VI], the heated discharges from
this industry combined with those from IIAAP A increased the temperature
of the Holston River — on one occasion by 9°C, but in most cases by 4°C
-------
49
or less. However, violations of the temperature standards for waters
classified suitable for fish and aquatic life occurred. High-flow condi-
tions during the survey tended to diminish the effects of the heated
discharges.
The treatment system located on Long Island (formed by a sluice in
the South Fork of the Holston River) that converts process wastes was
evaluated in order to determine the overall performance. The influent
flow averaged 10.4 mgd and contained more than 76,500 lb BOD and 50,600 lb
suspended solids. The effluent contained more than 35,100 lb BOD/day and
56,100 lb suspended solids/day. The treatment efficiencies of the faci-
lity were as follows:
Parameter % Removal
BOD 54
COD 65
SS 10 {increase)
NH.-N 14
Total P 49
Mn 260 (increase)
Wastes discharged from Station 14 (Outfall to the Sluice-Appendix C)
and Station 17 (Long Island Lagoon Effluent) contained complex mixtures
of organic compounds [Table E-18]. Among the compounds detected were
alkylated phenols, alkylane benzenes, phthalic acid esters, trichloro-
benzene (Station 17) and trichloroaniline (Station 17). Both the latter
are known to be toxic to aquatic life. Static bioassay studies were run
on five waste effluents from this plant (Stations 12, 14, 17, 22 and 23).
The waste from Stations 12, 14, 22, and 23 were not toxic to fathead
minnows in 100 percent concentrations for 96 hours. However, the studies
-------
50
showed that wastewaters from Station 17 were toxic to fish. The 96-hr
TL derived from the static bioassays with fathead minnows was with a
m
waste concentration of 64 percent. Other static bioassays using blue-
gills showed the 96-hr TL^ to be at a waste concentration of 36 percent.
Based upon 1/20 of the 96-hr TL it was calculated that toxic wastewater
m
from Station 17 would have to be diluted by maintaining approximately
800 cfs in the South Fork of the Holston River to protect aquatic life.
The discharge of these toxic wastes constitutes a violation of the water
quality standards for fish and aquatic life [Appendix A; item 3 (g)—Toxic
Substances].
Wastewater (Station 20) discharged to the Kingsport Municipal Waste-
water Treatment Plant contained organic compounds that could be toxic to
biological Lrc;aL..:c..'tL s>sLcnij or pass through 'die plant untreated [Table
E-18]. Compounds identified were m-chloroaniline, 2-ethyl-l-hexanol,
m- and p-xylene, ethoxyethyl acetate, and eight long-chained alkanes.
Treatment Needs
As discussed earlier, a waste-source evaluation and stream survey in
July 1969 reported that the Tennessee Eastman Company was discharging
approximately 69,300 lb BOD; 16,100 lb TKH; and 7,800 lb suspended solids
daily to the South Fork of the Holston River. The BOD and total Kjeldahl
nitrogen discharged comprised about 50 percent and 83 percent, respec-
tively, of the total BOD and TKN loads discharged.
The 92-percent reduction considered necessary in the 1969 survey
for the protection of receiving water quality required that TEC discharge
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51
no more than 6,000 lb BOD and 1,600 lb TKN/day. However, to maintain
a minimum concentration of 5.0 mg/1 DO in the Holston River, the BOD
and TKN discharged in the process wastewaters should not exceed
3,350 lb/day and 400 lb/day, respectively.
Effluent guidelines have not been established for this industry.
However, the following process waste effluent limits are considered
necessary to protect water quality:
1. BOD—3,350 lb/day;
2. TKN—400 lb/day;
3. Suspended Solids—30 mg/1 over background levels;
4. Total heavy-metals content (i.e. Zn, Mn, etc.) not exceed
1.0 mg/1; and
5. pH—6.0-9.0
In addition to these concentrations, levels of toxic substances must be
reduced to 1/20 of the 96-hr TL and, in now case, should the dilution
IQ
afforded by the receiving water be considered a substitute for treatment.
Moreover, to prohibit violations of the standards the temperature of the
heated discharges will need to be reduced. Cooling devices, concluded
as necessary in the 1969 report, should be installed.
The major sources of BOD were, from Hales Branch (Station 12),
14,000 lb/day and from the Long Island effluent (Station 17), 35,000 lb/day.
All of the TKN, 10,400 lb/day, was contributed from Station 17. The Long
Island lagoons receive 10.4 mgd of process wastes while Hales Branch re-
ceives 311 mgd of combined cooling water and process wastes.
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52
To meet the aforementioned limits and any additional effluent re-
quirements established by the State of Tennessee, the Tennessee Eastman
Company should procede immediately to separate all process waste and
non-contact cooling water streams. The best practicable treatment
technology currently available must be applied to the process wastes.
Recycling and re-use of water and good housekeeping procedures should
be incorporated in any proposed abatement plan. A schedule for achieving
the necessary pollution abatement should be provided EPA Region IV,
within the next six months. The control measures necessary should be
operational no later than 1 July 1975.
The permit issued to this industry should require a routine moni-
toring and sampling program of sufficient detail to ensure compliance
\;iih Vhe cfriucnu IIuiIlS "ana protection of receiving-water quality.
C. HOLSTONf ARMY AMMUNITION PLANT* - AREA A
General
Facilities of the Holston Army Ammunition Plant (HAAP), a Federal
installation, are in two separate locations, Areas A and B, in the vicinity
of Kingsport, Tennessee. HAAP is the property of the Department of Defense,
Department of the Army, but is operated and managed, under contractual
agreement, by the Holston Defense Corporation, a TEC subsidiary.
HAAP is the only munitions plant under the control the the Aimy Pro-
curement and Supply Agency (APSA) that manufactures RDX-HMX explosives.
They are admixed with TNT (TNT being received from sources outside the
* Much of the information on Area A and B concerning process operations,
waste sources, effluent criteria and proposed abatement plans has been
obtained from four military documents—References 5,6, 7 and 8.
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53
HAAP facilities) and various chemicals, desensitizing agents fillers,
etc., for primary use in manufacturing military explosives. Explosives
are also prepared for use by the National Aeronautics and Space Adminis-
tration. According to HAAP, its manufacturing capability includes about
50 RDX-HMX product variations of which Composition B is the most prominent.
(Composition B is an extremely powerful explosive, made up of RDX, TNT,
and wax.)
Applications under the 1899 Refuse Act Permit Program have previously
been filed with the U. S. Corps of Engineers for all waste discharges from
HAAP, Areas A and B.
Waste-Source Evaluation
Area A is situated within the corporate boundaries of the City of
Kingsport, occupies about 134 acres, and borders on the South Fork of the
Holston River [Figure IV-1], Area A can, for most purposes, be considered
the organic-acid manufacturing facility of HAAP. Major processes at HAAP
Area A, include the manufacture and refining of acetic anhydride and the
concentrating and refining of acetic acid (principally recovered from
Area B). In recent months Area A has been operating at between 40 and 50
percent of its total manufacturing capacity.
Water for cooling and process needs within Area A is diverted from
the South Fork of the Holston River, a short distance upstream of the
Tennessee Eastman Company waste outfalls. A portion of the river-water
flow is filtered and softened. Of this amount 0.8 mgd is used for boiler
feed and 0.7 mgd as process waters. Average water intake during the
-------
waste-source survey was estimated to be about 47 mgd. Of this amount
cooling-water use was estimated as 42 mgd. Process-water needs vary from
0.8 to 4.4 mgd. Area A also uses 0.2 mgd of city water for sanitary purposes
•k
Wastewaters From Acetic-Acid Concentrating and Refining — Cooling
waters plus spent process waters and sludges from this area are dis-
charged through the main outfall ditch (Station 2 ). These wastes are
reported to contain nitromethane methyl nitrate, acetic acid, n-propyl
acetic, nitric acid, and trace amounts of explosives.
Wastewaters From Acetic Anhydride Manufacturing — These waste flows
contain acetic anhydride, acetic acid, acetaldehyde, acetonitrite, methyl
acetaLe, methyl nitrate, ethanol, methanol, ethyl acetate, propanol, and
propyl acetate. The waste streams arc mixed with cooling waters needed
-"** ¦' .
jlll uunyui.'j.uc LucLHUi.ciCiiuij-iij, cii'id "Cuefi uxschcti'^tid Lo tJi<£ boudi i'ork of
the Holston River [Station 3].
Wastewaters From Production Gas Plant Are.i — These consist of
waters from the scrubbing units and coolinp and condenser water. Total
water usage and ensuing wastewater discharges from this area depends upon
the degree of recycling practiced. The Army reports that "excess cooling
and condenser waters amount to 0.17-0.10 mgd." Discharges from this
area are reflected on the results shown at Station 3 which also contained
acetic-anhydride manufacturing wastes and at Station 4 [Table E—23].
Wastewaters From Acetic-Anhydride Refinery Area — These include
cooling and condenser waters and process waters plus a portion of the
* Detailed information on the various processes and associated waste
sources can be found in the subsection "Process Operations and Waste
Sources" HAAP, Area A, [Appendix E],
** [Stations are described in Appendix C.]
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55
the sludges from the refining columns and the azeotropic distillation
columns (some concentrating of acetic acid is also carried on in this
area). These wastes are discharged to an industrial sewer, and their
presence is confirmed by the results obtained at Station 2.
Miscellaneous Wastes From Steam Generation Plant, Tar-Tank Area,
and Water Filter Plant — These contribute to the total waste load. Wastes
from the tar-tank area [Station 8] averaged 3,600 mg/1 phenols (range:
1,100-5,800 mg/1). Moreover, this waste discharge was found extremely
toxic in the bioassay tests to be discussed later.
Discussion — At the present time, all spent cooling waters, water-
treatment filter sludges, and industrial wastes from Area A are being
discharged with essentially no treatment to the South Fork of the Holston
River. During the survey the daily waste loads from Area A averaged
20,300 lb BOD; 4,060 lb suspended solids; and 19,100 lb COD [Table VII-2].
The average discharge was about 43 mgd. [Analytical results for those
parameters measured are contained in Table E-23.]
Comparison of the 1972 EPA study data with that collected by the
U. S. Army Environmental Hygiene Agency (USAEHA) and that contained in
the RAPP application are as follows:
TABLE VII-2
WASTEWATER VALUES - SUM OF ALL OUTFALLS
USAEHA
RAPP
1972 EPA
Flow (mgd)
BOD (lb/day)
COD (lb/day)
SS (lb/day)
37.6
9,360
13,200
6,060
40.3
9,920
25,500
68,000
43.3
20,300
19,100 (approx.)
4,060
* Production levels have remained fairly constant.
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56
Differences between the 1972 data and the previous USAEHA series of data
are critical because the latter figures were used to provide specific
engineering design criteria for the proposed biological treatment systems
(aerated lagoons). The USAEHA loadings for BOD and COD are about one-half
those of the 1972 EPA survey results. These differences could greatly
alter expected performance of the aeration basins.
Several of the waste discharges from Area A are heated. For example,
the temperature of the main outfall ditch (Station 2 — 33.6 mgd average)
discharge ranged from 18°-20°C. As mentioned previously, the heated dis-
charges from Area A and TEC effect a violation of the temperature standards
that prohibit no more than a 3°C temperature rise above background con-
ditions. The 1969 survey concluded that cooling devices were necessary
at bofh ind"stries.
Effluents from the main outfall (Station 2) and the coal-tar drain-
age (Station 8) at Area A were tested and found to be toxic to fish. The
waste concentrations for the 96-hr TL derived from static bioassays was
m
56 and 0.39 percent for Stations 2 and 8, respectively. Flow-through
bioassays produced a 48-hr TL of 25 percent waste concentration for
Station 2 and a 96-hr TL^ of 0.17 percent for Station 8. Based upon a
factor of 1/20 of the 96-hr TL , it was calculated that these two waste
m
discharges would require that about 2,000 cfs be maintained in the South
Fork of the Ilolston and Hol.ston Rivers to ensure no long-term damage to
aquatic life due to toxicity. The concentrations of toxic materials in
the Holston River imrediately downstream from Kingsport are approaching
levels that could be toxic to fish. The discharge of these toxic wastes
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57
into the river violates the Tennessee Water Quality Standards for Fish
and Aquatic Life (Subsection 3g.-Toxic substances).
To complete the evaluation of pollution sources in Area A it is
appropriate to itemize sources of air pollution derived from processes
already described in some detail.
Vent Gases Off Azeotropic Distillation Columns — At current pro-
duction rates these vent gases are reported to contain about 530 lb/day
of methyl nitrate, liberated in a mixture of nitromethane, methyl acetate,
propyl formate, propyl acetate, and methyl nitrate. The total solvent
vapors vented to the atmosphere approach 1,100 lb/day. Methyl nitrate is
especially toxic and has a high explosive-and-impact sensitivity hazard.
Gases From Acetic-Anhydride Area — Gases from this area contain
about 5,400 lb of hydrocarbons and 6,400 lb of carbon monoxide/day.
Vent Gases From Producer-Gas Manufacturing Area — Vent gases from
the producer gas contain particulate matter, sulfur oxides, and nitrogen
oxides.
Gases From Coal-Fired Steam Plant — Air pollutants from this plant
include 16,000 lb of particulates, 8,000 lb of sulfur oxides plus unknown
amounts of other materials.
Treatment Needs
The air- and water-pollution abatement schedules proposed by the
Munitions Command (MUC0M) for Area A have been outlined [Table E-25].
However, funds have not been appropriated beyond FY 73. Moreover,
there are a number of deficiencies in the abatement plan. For example,
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58
there is no schedule for the separation of uncontaminated cooling
waters from process waters; this is considered a necessary first step
in achieving effective water pollution control in Area A. Additional
information is required in order to determine the step-by-step abate-
ment activity and the implementation schedules to be undertaken at
HAAP. Abatement items have not been adequately described in the schedule
so that their relationship to the other projects can be determined. Some
abatement projects, such as the construction for controlling and routing
tank-farm waste spills to the aerated lagoon, will be completed several
years in advance of the latter system which is to be carried out in 1976.
During the survey the pilot-plant aerated lagoon (4.5 mgd) was under
•k
construction. Several aspects of the proposed biological systems warrant
attention. The wre designed using vastc loads measured during
a study by the USAE1IA. The waste loads, found by USAEHA, as discussed
earlier, were considerably lower than those found in 1972; thus, the
expected performance of the aerated lagoons could be greatly altered.
Moreover, the system is incompatible with best practicable control
technology.
Another aspect deals with the types and amounts of wastes to be
treated and the effect of these wastes on biological treatment efficiency.
Through increased recycling, re-use, and recovery of process flows plus
the segregation of uncontaminated cooling waters, total process wastewaters
at Area A could be reduced to 1 mgd or less. Available data indicate that
* It should be noted that this pilot aeration lagoon was scheduled for
completion in December 19 72 but had not been completed as of early
March 1973.
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59
these process effluents per se are extremely strong in COD, complex
organlcs, toxicity, and possibly, heavy metals. Based on this data and
similar experiences, the implied risk of using biological treatment is
high. These wasLes are judged to be more adaptable to physical chemical
treatment than biological treatment as presently planned.
The 1969 study of the Hols ton River concluded that the BOD load
from Area A must be reduced to about 1,900 lb [Table VII-1]. This is
more than a 90-percent reduction from the BOD load discharged during the
1972 survey.
To data EPA interim Effluent Guidelines have not been developed for
this industry. However, APSA has developed Air and Water Quality Standards
[Tables VII-3 and VII-4] for munitions manufacturing plants. These
criteria are judged to be controlling for waste-abatement practices at
Army munitions facilities, such as HAAP, and, relative to the BOD, SS,
ammonia, and nitrate levels established, these criteria appear consistent
with those levels obtainable with the use of the best practicable control
technology currently available. The total heavy metals concentration of
5.0 mg/1 allowed by the APSA Guidelines is considered excessive when com-
pared with the total metal standards established in the effluent guide-
lines for other industries (i.e., 1.0 mg/1).
Information contained in the Army reports of a waste survey implies
that spills, leaks, and errant discharges are relatively common in the
tank-farm and materials-storaae areas. A program for the prevention and
containment of strong waste spills is necessary. Such a program and
associated contingency plan would require preventative maintenance and
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60
TABLE VII-3
a/
SELECTED WATER QUALITY STANDARDS-
Pollutant
>b/
Effluent
Standard
—EES
3-30
c/
15
15.0
20.0
30.0
10
6.0-K.5
500
25
Boundary^-
Standard
Color (Color Units)—
Maximum Temperature (°F)
Oil (ppm)
Biological Oxygen Demand (ppm)
Chemical Oxygen Demand (ppm)
Total Organic Carbon (ppm)
Phenols (ppb)
pH (standard units)
Solids, Dissolved (ppm)
Solids, Suspended (ppm)
Bacteria-monthly averape
(No./lOO ml)-% of samples
(Coliform count)
TNT and Nitrobodles (ppm) 0.5
Ammonia (ppm) 0.1
Nitrate; (ppm) 5.0
Phosphate (ppm) 0.5
Total Heavy Metals—'^ 5.0
a_/ Standards arc as prepared by APSA. It is assumed that effluent standards
refer to the process wastewater streams after treatment whereas boundary
conditions refer to all waters discharged, i.e., cooling water included.
[A complete set of these standards is contained in Table E-24, Appendix E.]
hj Color units are based on platinum-coba]I standard.
c/ State water ambient temperature shall not be increased by more than 5°F,
with the hourly temnerature change of the State water not to exceed 1°F.
d/ This total includes cadmium, chromium, copper, lead, mercury, nickel,
zinc, etc, which have individual limits Table E-24, Appendix E].
3-30
90
no visible oil
on water surface
2.0
2.0
3.0
10
6.0-8.5
200
25
(5000)-20
(2000)-5
0.3
0.01
0.5
0.05
5.0
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61
TABLE VII-A
SELECTED AIR QUALITY STANDARDS
PROPOSED BY APSA
Design and Operating Standards (Proposed)
b/
Pollutant
Ammonia
Carbon Monoxide
Hydrocarbons
Lead
Nitrogen Oxides—'
Oxidants
Ozone
Particulates
Particulates, Incinerator
Sulfur Dioxide, Power Plant
Sulfur Dioxide, Acid Plant
Boundary
Standard
(ppm)
0.15
0.15
0.20
0.5 »ir/113 -
0.10^
0.04
0.03
80 ns/ir3
80 Mg/II
0.04—^
0.0
,3 a/
Stack
Emission
Standard
(ppm)
100
200
200
200 mg/M~
450 mg/M"^
500
200
a./ This is a maximum value for any 24-hr sample period.
hj Nitrogen oxides include NO + NO^.
c./ Average value for measurable limits over a one-hr period is not to be
exceeded more than 1.0 percent of the time over a three-month period,
d/ Maximum value is not over one percent of the time in a 24-hr sample
period.
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62
inspection procedures, adequate diking, or curbs around tank-storage
areas, in order to prevent spills and surface runoff from reaching the
water course. Tn no event should spills be allowed to enter sanitary,
process or cooling-water sewers. Complete containment, recovery or
treatment of spills, etc., is necessary at Area A.
Waste discharges from the tar-tank area must be eliminated. In
addition, toxic substances in the remaining discharp.es must be reduced
to at least 1/20 of the 96-hr TL in order to protect fish and aquatic
m
life. In no case should the dilution afforded by the receiving stream
be considered a substitute for treatment.
To abate its air-pollution problems at Area A, the Army is proposing
control and treatment for the venc gases from the acetic-anhydride manu-
facturing ar.d relitiing processes and from the producer gas area. Control
measures for NO and SO arc presently being studied.
X X
D. HOLSTQM ARMY AMMUNITION PLANT* - Area B
Waste-Source Evaluation
Area 3 is located on 6,370 acres immediately downstream from the
confluence of the North and South Forks of the Holston River [Figure IV-1]
and approximately six miles west of the City of Kingsport and Area A. The
major processes at Area B include nitric-acid and amnonium-nitrate produc-
tion; the preparation, manufacturing, and packaging of various explosives;
and the recovery of waste acetic acid for shipment to Area A. (Areas A
and B are interconnected by a railroad spur and by a series of stainless
A Much of the information concerning process operations, waste sources,
effluent criteria, and proposed abatement plan's has been obtained
from two Army documents.
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63
steel pipelines, laid parallel to the tracks. The lines serve to convey
raw materials and intermediate products between the two HAAP manufacturing
facilities.)
A
Area-B records indicate that approximately 84.4 mgd of water is
pumped from the Holston River through intake screens at two pumping sta-
tions. About 14.5 mgd of this is intended for use as process water, and,
therefore, is treated by flocculation, sedimentation, and filtration. Of
this filtered water, approximately 0.75 mgd is de-ionized for use as boiler-
feed water. During the survey the total of all wastewaters discharged to
the river was 84.6 mgd. A natural stream entering the plant grounds
(Arnotts Branch) contributed 11.4 mgd so that the net waste flow was
approximately 73 mgd.
Wastewaters Associated With Production And Concentration Of Nitric
Acid — The wastes from the production process contain ammonia, nitric
acid, nitrite ion, and a small amount of oil from the compressors employed
in the ammonia-oxidation process. These wastes together with cooling
waters are discharged without treatment via the main outfall ditch to the
Holston River (Station 33). Wastewaters from the concentrating process
are essentially all cooling waters. These also go to the main outfall ditch.
During the survey the waste discharge from this ditch averaged 53 mgd and
contained average loads of 2,400 lb BOD; 20,500 lb SS; and 1,920 lb
N02 + N03-N [Table E-29].
* These have been calculated from pump-rating curves.
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64
Wastewaters From Production, Purification, And Packaging of Explo-
sives — At Area B the manufacture of the explosive compounds is carried
out in a series of buildings where glacial acetic acid and acetic anhydride
are received from Area A and nitric acid and the ammonium nitrate-nitric
acid solution is received from elsewhere in Area B. Other materials (out-
side purchases) for use in the process enter the complex here, too. These
other materials include hexamine (hexamethylene tetramine), wax, TNT
(trinitrotoluene), lacquer, and several desensitizing agents.
The hexamines are dissolved in glacial aretic acid, and the solution
is then mixed with a nitric acid-ammonium nitrate solution to yield crude
RDX and HMX. Contaminated waste streams from these operations arc routed
through a catch basin and then to the industrial sewer. The waste flows
include cooling water, condensate, seal water, and floor and equipment
wash-down water, as well as possibly containing RDX, HMX, acetic acid,
hexamine, and other organics. These flows were monitored at Stations 28,
29, 31, and 33.
Following this process, the crude RDX and HMX slurry is subjected to
a filtering and washing process. From this operation the wastewaters
containing explosives, acetic and nitric acids, and other components of
the mixture pass through baffled catch basins before entering the indus-
trial sewer. There is also good evidence of the quality and quantity of
these wastes from the data ohtained from sampling at Stations 28, 29,
31, and 33.
The washed explosive slurry is then sent through a recryslallization
process. Depending upon the crystal configuration desired, the solvent
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65
to be used varies between cyclohexane, acetone, and toluene. The waste
stream containing solvents, explosives, and lacquers passes through
baffled catch basins before entering the sewers. Samples were collected
at Stations 28, 29, 30, 31, and 32.
Subsequent to the process just described, the explosive slurry is
subjected to a grinding process and is then dewatered. Ground, dewatered
explosives (wet cake) are then sent to the compounding process. The
wastewaters consisting of explosives, solvents, condensate, acetic acid,
settling tank overflow, and wash water were included in the flows passing
Stations 28, 29, and 31.
Compounding of the explosives involves mixing RDX or HMX with melted
TNT to yield Composition B. This material is heated, wax is added, and
the mixture is cooled. After the compounding process, the explosives are
passed through a packing process. Dust from this operation is exhausted
from the buildings and scrubbed with water. The scrubber water, floor
and equipment wash down, wastewater from the compounding process (con-
sisting of explosives including TNT) are also included in wasteflows at
Stations 28, 29, and 31.
a
Wastewaters from the two water filtration plants — These include
wastes from cleaning the intake screens, backwashing the filters, and de-
sludging the sedimentation basins. The quality was measured at Station 25.
Sanitary wastes — This wastewater, including domestic wastes from
several homes in the immediate vicinity, receives secondary treatment con-
sisting of primary sedimentation, trickling filtration, secondary clari-
fication, and chlorination. The effluent (Station 26) was of good quality.
* Only one water treatment plant was operational during the survey.
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66
Discussion — During the survey the total BOD discharged from Area B
i;
averaged 14,750 (net, 10,000 lb ) lb/day; the average total Kjeldahl-
nitrogen and NO^ + NO^-N measured approximately 600 and 2,500 lb/day,
respectively. When compared with the discharge measured during the 1969
survey [Table VII-1] loads of the BOD and TKN are significantly less; the
nitrite + nitrate load is similar. The complex nature of the Area-B
wastes and the possible effluents upon analytical procedures probably
accounts for the low BOD.
Complex organic analyses were performed on a mixed sample (composited
over a 24-hr period using equal aliquots) from Stations 28 and 29, with a
combined flow of 4.24 mgd. These waste discharges came from the explosive
manufacturing area [Appendix C]. Using the same procedure, a mixed sample
r ' "*
vas also collected frorc Stationo 31 and 33 and analyzed for complex
organics. These stations had a combined flow of 55.3 mgd and contain
process wastes from the production, purification, and packaging of explo-
sives. [The organic chemicals isolated are listed in Table E-30.] The
quantities of TNT and cyclohexanone discharged from Area B represent a
serious hazard to aquatic life in the llolston River. The cyclohexanone
and TNT in the discharges from Stations 28 and 29 ranged from 15.3 to
76.9 lb and 9.1 to 46 lb/day, respectively. The amount of cyclohexanone
from Stations 31 and 33 ranged between 54 lb to 1,240 lb/day. These
quantities are likely to result in adverse effects of a chronic nature
through continuous exposure of aquatic life.
* The BOD load in the two intake water streams has been subtracted from
the gross loads.
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67
Static bioassay studies on streams 28 and 30 after mixing but prior
to entering the river yielded a 96-hr TL with a waste concentration of
m
23 percent; the 72-hr TL from a flow-through bioassay was 13 percent.
m
In addition, the effluent from Station 31 was tested and found to
be toxic to fish. A flow-through bioassay indicated that the 96-hr TL^
occurred in a waste concentration of 23 percent. Based upon 1/20 of the
96-hr TL^, a river flow of approximately 2,600 cfs would be required to
adequately dilute toxic materials contained in Area B wastewaters
(Stations 29, 30, and 31) to protect stream life in the Holston River.
Moreover, these discharges of toxic substances constitute violations of
the Tennessee Standards on toxicity for waters classified suitable for
Fish and Aquatic Life.
To complete the evaluation of waste sources in Area B it is appro-
priate to itemize sources of air pollution derived from processes already
described in some detail.
-Nitric-Acid Production And Concentration — The nitric-acid producers,
at full capacity, release about 17,000 lb of NO^/day to the atmosphere.
The level of in the general area is greater than 5 ppm, the maximum
level recommended for personnel. The nitric-acid concentrators, at full
production, contribute about 5,200 lb of NO^/day.
Open Burning Of Trash — About 13 tons of refuse and explosive wastes
are burned each day by open-burning techniques. It is estimated that this
operation adds 1,410 lb of contaminants to the atmosphere each day.
Steam Production — The six coal-fired and the three natural-gas or
oil-fired boilers release each day about 28,000 lb of particulates and
11,000 lb of sulfur oxides to the atmosphere.
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68
Treatment Needs
The proposed air- and water-pollution abatement schedule for Area B
has been documented [Table E-31]. As noted for the abatement projects
scheduled for Area A, there have been no funds appropriated beyond FY 1973.
(The same deficiencies noted in the Area-A abatement plans also exist in
the Area B plans.)
The reservations expressed for the proposed biological systems at
Area A apply to the proposed Area-B systems. CERL has conducted a few
treatability studies on the Area-B wastes and has found that, after the
organisms became acclimated, the wastes were treatable by biological
processes. However, because of the numerous organic and toxic chemicals
present it is questionable whether a biomass could be kept viable and,
if Lt does survive, wheLher complex organic materials, such as RDX, HMX,
TNT, and cyclohexanone, will be degraded.
If biological processes are employed for treating process streams,
the biological system should serve only as first-stage treatment. Should
a biological process not be applicable, the first stage could consist of
chemical coagulation followed by flocculation and sedimentation. Either
kind of first stage should be designed to produce an effluent with a
suspended-solids concentration of approximately 30 to 40 mg/1. A second
stage possibly consisting of carbon adsorption or oxidation with ozone
will be necessary to order to remove the complex organics, many of which
are toxic.
Nitrogen (TKN and NO^ + ^0^) removal wil] be necessary at Area B.
If the aforementioned two-stage system is employed, the nitrogen in the
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69
effluent should be present primarily in the nitrate state and could be
removed using, for example, biological denitrification.
The proposed industrial waste lagoons (aerated) were designed (by
CERL) using State of Tennessee Standards (effluent limits - 450 mg/1 of
BOD and 180 mg/1 of suspended solids). Because treatment beyond that
presently proposed will be necessary at both Areas A and B the APSA
standards should be employed (with the exception of the heavy metals
standard which should be reduced from 5.0 mg/1 to 1.0 mg/1) as the basis
for design. Toxicity levels in discharges will need to be reduced to
1/20 of the 96-hr TL . and in no case can dilution afforded bv the
m J
receiving water be considered in place of treatment.
Plans for pollution abatement at the water-treatment facility call
for land disposal of material removed from the intake screens, continuous
sedimentation of backwash water with solids going to thickeners, sand-bed
drying and ultimate disposal at a landfill. The sedimentation basins
will be converted to continuous sludge removal; the sludge will be
thickened, dried in sand beds, and disposed of at a landfill. This pro-
posed control measure is considered adequate.
To abate air-pollution problems HAAP plans to reduce KO^ emissions
from the nitric-acid producers and concentrators by the use of molecular
sieves. They should reduce the stack emission from 3,,000 ppm down to
50 ppm. The NO adsorbed will be recovered as dilute nitric acid. Con-
x
sideration is being given to the use of electrostatic precipitators or
wet scrubbers for the removal of particulate matter from the boiler-
building stack gas.
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70
E. MEAD PAPERS, A DIVISION OF MEAD CORPORATION
Waste-Source Evaluation
Head Papers, an integrated Kraft mill, manufactures 250 tons/day of
pulp by the hot-soda process; an additional 240 tons/day of pulp is im-
*
ported. The pulps are combined with fillers to produce about 540 tons/day
of paper. Approximately 17 mgd of the wastewater is treated in a 150-ft
dia. clarifier (Station 41) before being combined with about 1.5 mgd of
untreated wastes and water-treatment-plant wastes. The combined wastes
are discharged to the South Fork, of the llolston River (RM 142.15/2.5).
A RAPP application has been filed for this discharge.
The combined daily wasteload discharged contained 21,550 lb BOD
(148 ng/1) , 31,500 lb suspended solids (216 tng/1) , and 451 lb total
Kjeldahl-nitrogen (3.3 m
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71
primary clarifler effluent was under construction at the time of the 1972
survey. The company also plans to install a defoaming process and con-
struct a submerged diffuser across the river to provide for better waste-
water diffusion. The State of Tennessee orally informed the company the
the waste load must be reduced to 6,000 lb/day maximum (13 lb/ton of
product). However, the State has not established an implementation date
or put the requirement in writing. Mead officials indicated that, if the
aerated lagoon performs as anticipated, the effluent will meet the
6,000 lb BOD/day requirement.
EPA Interim Effluent Guidelines have been established for the pulp
and paper industry based on best practicable control technology. These
effluent limitations require that the BOD and suspended solids not exceed
*
9 lb /ton of product each (28 mg/1 of each at present flow of 11 mgd).
However, these limits are not stringent enough for this plant. The 1969
study determined that in order to maintain a minimum concentration of
3.0 mg/1 DO in the Holston River and to protect and enhance the receiving
waters the BOD load not exceed 2,000 lb/day (4.4 lb/ton of product).
However, to maintain a minimum concentration of 5.0 mg/1 DO, the BOD in
the effluent should not exceed 1,100 lb/day (2.4 lb/ton). To reduce the
BOD to this level would require the installation of additional treatment
facilities.
* The limit for Kraft pulping and manufacturing of bleached grades was
used for half the production, and the limit for manufacturing "fine"
paper from purchased pulp for the other half of production was used
in the calculation of this value.
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72
The permit issued for this plant should include the following ef-
fluent limits:
1. BOD - 1,100 lb/day
2. Suspended Solids - 1,100 lb/day
3. pH - between 6.0 and S.O (not to be outside this range at any time)
Limits for color, toxic materials, fecal coliforms, oil and grease,
ammonia, heavy metals, and foam should be set, as necessary, to protect
the receiving-water quality [Appendix E - Mead Papers]. In addition, both
a monitoring and sampling program of sufficient detail to ensure compli-
ance with these effluent limits and the protection of receiving-water
quality should be required on the permit.
F. KINGSPORT MUNICIPAL WASTEWATER TREATMENT PLANT
Waste-Source Evaluation
The Kingsport Wastewater Treatment Plant is a single-stage, high-
rate trickling-filter facility. The plant (6.5 mgd capacity) was not
sampled during the survey because of hydraulic overloading due to infil-
tration from wet-weather conditions; the plant was by-passing raw sewage
£
and storm water to the South Fork of the Hols ton River. The by-passing
commenced about 0700 hr 10 December and continued until about 1300 hr
14 December. The City does not have plans to eliminate these combined
sewers or to provide disinfection of the by-passed water.
A summary of plant records for the period of November 1971 through
November 1972 for waste removals at the WWTP indicates that:
* The City has combined sewers. By-passinp occurs at the WWTP when flows
exceed 13 mgd. Sewer overflows also occur within the sewerage system
when the capacity of individual sewers and lift stations is exceeded.
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73
1. influent BOD was reduced by about 70 percent; and
2. influent suspended solids (SS) were reduced by 74 percent.
The average effluent BOD and SS levels were 57 mg/1 (3,130 lb/day)
and 36 mg/1 (2,190 lb/day), respectively, which does not meet the require-
ments for secondary treatment that have been proposed pursuant to the
*
Federal Water Pollution Control Act Amendments of 1972.
Plant operational problems have occurred from influent wastewaters
received from several industries connected to the city sewer, in parti-
cular the Tennessee Eastman Company and Slip-Not Belt Company. Plant
personnel reported toxic materials and highly colored wastewaters from
the Slip-Not Belt Company. Together with large quantities of suspended
and floating solids from TEC they were responsible for operational prob-
lems. The digesters became inoperative in late 1971 and presently do not
function properly. The cause of this malfunction has not been positively
identified. During the 1972 survey various organic compounds [Table E—18]
were identified in the TEC sanitary wastewaters that are discharged to the
Kingsport Wastewater Treatment Plant. These organic compounds could be
toxic to biological treatment systems at the plant or pass through untreated.
Treatment Needs
The City is currently not enforcing its Industrial Waste Ordinance
* EPA is currently proposing to limit BOD and SS, in the effluent, to a
monthly average of 30 mg/1 and to a weekly average of 45 mg/1, or
85-percent overall reduction, whichever produces better quality ef-
fluent. In addition, the effluent should contain no more than 400
fecal coliform bacteria/100 ml on a weekly average nor more than
200/100 ml on a monthly average.
-------
No. 1539 [Appendix P] that requires pretreatment of high organic and sus-
pended solids waste (>300 mg/1 BOD, >350 mg/1 SS). The ordinance also
requires toxic substances (iron, copper, lead, zinc, etc.) to be limited
in quantity so that the total contribution will not cause interference
in normal plant operations. Enforcement of this ordinance would help
reduce the present waste loads into the plant.
Changing the method of operation so that the wastewater is recircu-
lated to the trickling filters before clarification rather than recircu-
lation to the trickling filters after clarification would also iinproye
treatment efficiency. However, even though improvement in the treatment
could be obtained by following the latter and the enforcement of the
ordinance, the plant as it presently exists cannot meet the proposed F.rA
interim Effluent Cui_dclir.es. Moreover, Lhe 1969 FtJQA report concluded
that the BOD load from this plant was not to exceed 900 lb/day in order
to maintain a minimum concentration of 3.0 ng/1 DO in the Hols ton River
and to protect receiving-water quality. To maintain the official stan-
dard of 5.0 mg/1 minimum DO, the effluent should not exceed 500 lb BOD/day.
At the present design flow (6.5 mgd) this would require an effluent BO])
which is more stringent than the proposed guidelines. In addition the
suspended solids load should be no greater than 500 lb/day; the ef-
fluent fecal-coliform concentrations should be in accordance with the
prepared EPA limitations.
Corrective measures must be taken to preclude the by-passing of
untreated wastes from the plant or from within the sewerage system due
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75
to excessive combined flows. Moreover, on one occasion during the survey,
by-passing from an interceptor line (i.e.. the interceptor line collecting
wastes from the J. P. Stevens plant and a residential area) occurred. To
prevent this, a sewer maintenance program has to be developed so that
sewer inspections, cleaning, and repairs are carried out routinely.
G. HOLLISTON MILLS, INCORPORATED
Waste-Source Evaluation
Holliston Mills produces about 250,000 yd (460 tons/day) of finished
products consisting primarily of binding cloth which is divided into two
general classes: starch (cornstarch) filled book cloth (about 20 percent)
and plastic-covered book cloth (about 80 percent). The latter can include
plastic on cloth; plastic on paper; and a combination of cloth and paper.
There are two wastewater discharges to the Holston River from
Holliston Mills: the untreated cooling water (Station 45, RM 128.9/0.70)
and the treated process wastes (Station 46, KM 129.2) [Appendix E-2„
Figure E-3]. A RAPP application has been filed for both discharges.
The wastewater-treatment system, completed in July 1972, is a co-
operative research and development project partially funded by an EPA
grant. The system includes pH control, screening, primary and secondary
clarification, trickling filtration, and lagooning. There are three
lagoons. One pond (1/2 acre) receives sludge from the primary clarifier
and then overflows to a large polishing pond (two acres). Another pond
(1/2 acre) receives the secondary clarifier effluent that also overflows
* The finished product weighs from six to nine oz per running yd.
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76
to the large pond [Figure E-3]. Company officials indicated that the
ponds are full of solids, thus affecting the treatment capability.
An in-plant survey was conducted from 6 through 8 December 1972.
The wastewaters discharged from the larger lagoon contained average daily
loads of approximately 1,940 lb of BOD (380 mg/1); 3,600 lb of COD
(703 mg/1); and 200 lb of suspended solids (39 mg/]). The concentrations
of sulfide in the effluent ranged from 40 to 50 mg/1. The loads of BOD
and COD in the lagoon effluent were higher than those in the influent
[Table E-4J.
Adequate treatment was not being provided during the survey. The
suspended solids and sulfide were reduced. However, the loads of 130D and
COD in the effluent were consistently higher than those in the influent.
The influent of the lagoon system averaged 0.7 mgd, whereas the effluent
was averaging 0.6 mgd, an indication that excessive seepage was taking
place. The cooling-water discharge contained average daily I»0D and
suspended solids loads of 30 lb/day and 90 lb/day, respectively. The
flow averaged about 0.3 mgd-considerably less than the 0.8 mgd reported
by the company. Uhile the BOD levels renamed the same as those of the
A
raw intake water, the average concentrations of suspended solids increased
from 19 mg/1 to 40 mg/1; TIQ increased from 0.7 rag/1 to 1.4 mg/1; total
phosphorus increased from 0.2 mg/1 to 1.2 mg/1; and sulfate increased
from 27 mg/1 to 66 mg/1, all indications thai the cooling water was being
contaminated.
" [For comparison between the discharges of raw intake water and of
cooling water, refer to Table E-4, Appendix E.]
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77
Treatment Needs
The EPA interim Effluent Guidelines recommend the following limita-
tions on the discharge from a plant of this kinds:
lb/day (present
Parameter lb/day/1,000 lb product plant capacity)
BOD 6 700
SS 6 700
Chromium 0.03 3.5
Phenolics 0.03 3.5
Sulfides 0.06 7.0
Currently the BOD load discharged exceeded the guidelines by almost three
times (1,970 lb/day). The recommended sulfide load was exceeded by more
than, in order to maintain a minimum DO concentration in the Holston River,
30 times (220 lb/day). In addition the 1969 TVQA survey, concluded that,
in order to maintain a minimum DO concentration in the Holston River, the
maximum BOD load not exceed 260 lb/day, substantially less than suggested
in the guidelines. To maintain a minimum DO concentration of 5.0 mg/1,
it is estimated that the maximum BOD discharge should not be greater than
150 lb/day.
To obtain this lower limit will require at least a 92 percent re-
duction of the BCD load discharged during the survey. Effluent limits
that this mill must meet are as follows:
1. BOD 150 lb/day or 1.4 lb/1,000 lb of product
2. Suspended Solids 150 lb/day or 1.4 lb/l,000 lb of product
(above background levels)
3. Chromium 3.5 lb/day or 0.03 lb/1,000 lb of product
4. Phenolics 3.5 lb/day or 0.03 lb/1,000 lb of product
5. Sulfides 7.0 lb/day or 0.06 lb/1,000 lb of product
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These limits can only be met by segregating cooling water and pro-
cess water and the installation of additional treatment that must employ,
as a minimum, best practicable control technology. A routine monitoring
and sampling program will be necessary to ensure compliance with these
effluent limits.
In order to improve the treatment afforded by the present system
the company will have to clean out the lagoons. The lagoons will have
to also be sealed to prevent excessive seepage.
H. ASG INDUSTRIES, INC.
Waste-Source Evaluation
ASG Industries produces 198 tons/day of rolled glass, polished wire
glass and miscellaneous flat glass including tempered and laminated glass.
There are two discharges to the South Fork of the llolston River. A RAPP
Application has been filed for both discharges.
The cooling-water discharge (Station 39, RM 142.15/4.35) receives
surface run-off and cooling and rinse water from a glass-washing operation.
and flows directly to the river. The other discharge (Station 37,
RM 142.15/4.04) contains wastewater from the grinding and polishing
operation, specialty coating operation, and washer rinse-water, all of
which is treated. The treatment system basically consists of a thickener
"A
(alum coagulation ) with thickened sludge dewatered by vacuum filtration.
At the time of the initial plant visit (10 November 1972) the effluent
* Alum is dumped in the center of the clarifier. No attempt is made to
mix it with the wastewater nor to allow time for the floe to settle.
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79
had a deep red color and appeared to have a high concentration of sus-
pended solids. This effluent joins a milky white stream of rinse water
from other washers and flows into an open ditch located on the Hols ton
Army Ammunition Plant (Area A). It mixes with Area-A wastewaters before
being discharged into the South Fork for both discharges.
EPA personnel performed jar tests on the influent stream to the
clarificr. They revealed chat the suspended solids could be reduced to
approximately 20 nig/I by the addition of an anionic polymer and ferric
sulfate and by maintaining the pH at 7.0. During the survey the clari-
I
fier effluent averaged 843 rag/I of suspended so]ids. The discharge
(0.52 mgd) had a COD load of 179 lb/day and contad nod 3,600 lb/day of
suspended solids and had a pll ranging from 6.5 to 10.9, The cooling
water flow was 1.2 mgd and contained 460 lb of suspended solids; the
oil and grease ranged from 4 to 7 mg/1.
Treatment Needs
According to EPA interim Effluent Guidelines for the Cement, Lime,
Gypsum, Asbestos and F3at-Glass Industries (21 September 1972) a typical
process- and cooling-water stream for a plant of this type would be
approximately 0.1 mgd. Effluent limitations for the total plant dis-
charge are as follows:
lb/],000 Tons lb/day (This Actual Load (lb/day)
Parameter Finished Product Size Plant) Discharged During Survey
Suspended Solids S4 16.6 4,060
COD 84 16.6 ]79
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80
The guidelines also stipulate that no more than 4.2 lb of hexane
extractables (oil and grease) and total phosphorus be generated for each
1,000 tons of glass produced. During the survey ASG discharged more than
200 times the recommended limit of suspended solids and 10 times the COD
limit. The oil and grease detected in Station 39 should not be present
in an uncontaminated cooling-watcr stream.
To achieve effective pollution control at ASG the cooling- and
waste-water streams should be segregated, with the latter being routed
to the treatment system. Conservation and re-use of waters within the
I
plant are other steps that can be taken to reduce treatment costs.
By employing the best practicable control technology currently
available, ASG should meet the proposed effluent limitations by 1 July
1974. A monitoring and sampling program is necessary Lo ensui-e com-
pliance with the effluent limits and protection of the receiving waters.
I. PENN-DIXIE CEf-IKis'T CORPORATION
Waste-Source Evaluation
The Penn-Dixie plant produces an average of 900 tons/day of cement.
There are two waste streams that discharge to the South Fork of the
Holston River: the untreated cooling-water stream (Station 47, RM 142.15/
2.6) and the process-waste stream from the air-solids waste treatment
system (Station 48, RM 142.15/2.7). A RAPP application has been fi]ed
for the latter discharge only.
The treatment system is employed to remove soluble alkalies from the
stack dust before the dust is recirculated back to the kiln. Briefly, the
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81
dust from the kiln stack precipitator is slurried with water and then
thickened in a settler from which the sludge is returned to the kiln. The
overflow is carbonated, to reduce the pH, and clarified; the clarifier
sludge is then returned to the thickener while the overf]ow is recarbon-
ated and discharged to the river [Figure E-7].
Penn-Dixie discharged a total flow of 0.73 mgd containing 1,800 lb
of suspended solids/day (362 lb/],000 bbl). Ninty-slx percent of this
suspended-solids loading is contained in the cooling-uater discharges
(0.49 ragd).
Treatment Heeds
The EPA interim Effluent Guidelines recommend the following limita-
tions for a cement plant:
lbs/day lb/day
Parameter 1,000 bbl produced (plant this kind)
Suspended Solids 7 35
COD 7 35
The process-waste stream contained almost twice this recommended
suspended-solids load; the uncontaninated cooling \Tater stream contained
50 times this amount.
In addition, data from the RAPP application and the State of Tennessee
Appendix K, indicate that the solids concentration in the process-waste
stream normally exceeds the. levels found at the time of the survey. The
guidelines also estimate that a plant of this kind would have a waste
flow of 0.14 mgd (27,000 gal/1,000-bbl production), roughly one sixth the
flow presently being discharged by Penn-Dixie.
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82
In accordance with the best applicable control technology currently
available the guidelines are based upon minimum water usage, its time of
contact with leachable substances, and upon the elimination of frequent
and unnecessary spillage, overflows, and inefficient washing methods.
To achieve effective pollution control Penn-Di::ie must conserve and
re-use wastewater within the plant and isolate and treat the source of
suspended solids in the cooling-water stream. A monitoring and sampling
program, of sufficient detail to ensure that the effluent limits are met
and that recciving-watcr quality is protected, should be a requirement
of the permit.
J • J. P- STEVENS AND COUP ANY. INC.—BOPkDKN PLANT
The Borden Plant converts approximately 54,000 lb/day of baled cot-
ton to greigc (untreated condition, just as it comes from the loom) -
cotton fabric by cording, spinning, and weaving. A RAPP application was
not filed because all wastewater flows are sent to the municipal sewer
system. However, dye studies, conducted 1 December 1972, indicated that
the Borden Plant wastewater was being discharged to the South Fork of the
Iiolston River (Station 121 142.15/4.31). Inspection of the sewer line
revealed that trash and debris had blocked the interceptor line, located
on Lincoln Street, where the J. P. Stevens wastes enter the municipal
sewer. This condition was corrected 6 December 1972. The characteristics
indicated that the flow contained domestic wastes.
To prevent the occurrence of by-passing wjthin the sewerage system
it has been recommended that the City develop a routing sewer maintenance
program [Appendix E, Section E],
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83
REFERENCES
1. Water Quality and Waste Treatment Requirements on the Upper Holston
River, Kingsport, Tennessee to Cherokee Reservoir - Technical Study
TS-03-71-208-07. Surveillance and Analysis Division, Region IV,
Environmental Protection Agency. Athens, Georgia. July 1972.
2. U. S. Census of Population: 1970. U. S. Bureau of the Census, U.S.
Department of Commerce, Washington, D.C. 1970
3. "Kingsport Marks 50th Anniversary with Progress Report," Tennessee
Totin and City, XVIII, No. 6; 14-15. Tennessee Municipal League.
Nashville, Tennessee. January 1968.
4. Preliminary Report on Economic Projections for Selected Geographic
Areas. Vol. 1, March 1968. United States Water Resource Council.
Washington, D.C.
5. Comprehensive Technical Evaluation Study-Hols ton Army Arrmwiition
Plant3 Kingsport, Tennessee. Department of Defense, Department
of the Army, Construction Engineering Research Laboratory.
Champaign, Illinois. July 1972.
6. btilitary Explosives. Department of the Army Technical Manual
TM9-1300-214 and Department of the Air Force Technical Order
TO 11A-1-34. Department of Defense. November 1967.
7. W. Heidelbergcr. Holston Army Ammunition Playit Pollution and
Abatement Plans Technical Report 4286. Process Automation and
Pollution Abatement Division, Manufacturing Technology Directorate,
Picatinny Arsenal, Department of Defense. Dover, New Jersey.
November 1971.
8. Water Quality Engineering Special Study No. 24-021-71/72,
Industrial Wastewater-Holston Army Ammunition Plant-Kingsport>
Tennessee. 19 March-?,8 June, 1971. Department of the Army,
U. S. Army Environmental Hygiene Agency, Edgewood Arsenal,
Department of Defense. Aberdeen Proving Ground, Maryland.
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APPENDIX A
GENERAL WATER QUALITY CRITERIA
FOR THE DEFINITION AND CONTROL OF POLLUTION
IN THE WATERS OF TENNESSEE
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A-l
GENERAL water quality criteria for the definition and control of
POLLUTION i;< THE WATERS OF TENuESSLE
Adopted on Hay 26, 1967
Anended on November 17, 1967, May 22, 1970, October 26, 1971, and
December 14, 1971
Tennessee Water Quality Control Board
The Water Quality Control Act of 1971, Chapter 164 Public Acts of 1971 as
tended by Chapter 385, makes it the duty of the Water Quality Control Board
to study and investigate all problems concerned with the pollution of the
waters of the State and with its prevention, aoatement, and control and to
establish such standards of quality for any waters of the State in relation
to their reasonable and necessary use as the Eoard shall deem to De in the
public interest and establish general policies relating to existing or pro-
posed future pollution as the Board shall deem necessary to accomplish the
purpose of the Control Act. The following general considerations and
criteria are officially adopted by the Board as a guide in determining
the permissible conditions of waters with respect to pollution and the
preventive or corrective measures required to control pollution in various
waters or in different sections of the same waters.
GENERAL CONSIDERATIONS
1. Waters have many uses which in the public interest are reasonable and
necessary. Such uses include: sources of water supply for do.nestic
and industrial purposes; propagation and maintenance of fish and othei
desirable aquatic life; recreational boating and fishing; the final
disposal of municipal sewage and industrial waste following adequate
treatment; stock watering and irrigation; navigation; generation of
power; and the enjoyment of scenic and esthetic qualities of the water
2. The rigid application of uniform water quality is not desirable or
reasonable because of the varying uses of such waters. The assimilati
capacity of a stream for sewage and waste varies depending upon variou
factors including tne following: volume of flow, depth of channel, th
presence of falls or rapids, rate of flow, temperature, natural
characteristics, and the nature of the stream. Also the relative
importance assigned to each use in 11 differ for different waters and
sections of waters throughout the stream.
3. To permit reasonable and necessary uses of the waters of the State,
existing pollution should be corrected as rapidly as practical and
future pollution controlled by treatment plants or other measures.
There is an economical balance between the cost of se./age and waste
treatrunt and the benefits received. Within permissible limits,
the dilution factor and the assimilative capacity of surface w?ter
should be utilized. Waste recovery, control of rates and dispers'on
of wdste into the streams, and control of rates and characteristics
of flow of waters in the stream where adequate, will be considered to
be a iireans of correction.
* lullyT^ro~t-cT6fr3une 2, 1972, by the Environmental Protection Agency.
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A-2
A. r:-.'3^o, i*1~,jst",';:l wastes, or other wastes, as defined in The '..'ater
Quality Control Act of 1971, Chapter 164 Public Acts of 1971, as
emended by Chapter 386, shall not be discharged into or adjacent to
streams or other surface waters in such quantity and of such character
or under such conditions of discharge in relation to the receiving
waters as will result in visual or olfactory nuisances, undue inter-
ference to other reasonable and necessary uses of the water, or
„ appreciable damage to the natural processes of self-purification.
In relation to the various qualities and the specific uses of tne
receiving waters, no sewage, industrial wastes, or other wastes dis-
charged shall be responsible for conditions that fail to meet the
criteria of water quality outlined below. Bypassing or accidental
spills will not be tolerated.
The criteria of water quality outlined below are considered as guides
in applying the water quality objectives in order to insure reasonable
and necessary uses of the waters of the State. In order to protect
the public health and maintain the water suitaole for other reasonable
and necessary uses; to provide for future development; to allow proper
sharing of available water resources; and to meet the needs of parti-
cular situations, additional criteria will be set.
CRITERIA OF WATER CONDITIONS
1. Domestic Raw Water Supply
(a) Dissolved Oxygen - There shall always be sufficient dissolved
oxygen present to prevent odors of decomposition and other
offensive conditions.
(b) pH - The pH value shall lie within the range of 6.0 to 9.0 and
shall not fluctuate more than 1.0 unit in this range over a period
of 24 hours.
(c) Hardness or Mineral Compounds - There shall'be no substances added
to the waters that will increase the hardness or mineral content
of the waters to such an extent to appreciaoly impair the useful-
ness of the water as a source of domestic water supply.
(d) Total Dissolved Solids - The total dissolved solids shall at no
time exceed 500 rng/1.
(e) Solids, Floating Materials and Deposits - There shall be no
distinctly visible solids, scum, foam, oily sleek, or the formation
of slimes, bottom deposits or sludge banks of such size or character
as may impair the usefulness of the water as a source of domestic
v/ater supply.
(f) Turbidity or Color - There shall be no turbiihty or color added in
amounts or characteristics that can not be reduced to acceptable
concentrations by conventional v/ater treatment processes.
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A-3
not exceed 3C° relative to an upstream control point. Tne
temperature of the water shall not exceed 30.5°C and the mcxirvum
rate of change shall not exceed 2C° per hour. The temperature of
impoundments wnere stratification occurs will be measured at a
depth of 5 feet, or mid-depth whichever is less, and the tempera-
ture in flowing streams snail be measured at mid-depth.
(h) Microbiological Colifcrm - Coliform group shall not exceed 10,000
per 100 ml. as a monthly average value (either ilPN or MF count);
nor exceed this number in more than 20 per cent of the samples
examined during any month; nor exceed 20,000 per 100 ml. in rr^ore
than five per cent of such samples. These values may be exceeded
provided the orgamsns arc known to be of nonfecal origin [no
di sease producing bacteria or other objectionable organisms shall
be added to surface waters which will result in the contamination
of said waters to such an extent as to render the water unsuitable
as sources of domestic water supply after conventional water treat-
ment.
(i) Taste or Odor - There shall be no substances added which will result
in taste or odor that prevent the production of potable water by
conventional water treatment processes.
U) Toxic Substances - There shall be no toxic substances added to the
waters thai will produce toxic conditions that materially affect
man or animals or impair the safety of a conventionally treated
water supply.
(k) Other Pollutants - Other pollutants shall not be added to the water
in quantities that may be detrimental to public health or impair
the usefulness of the water as a source of domestic water supply.
2. Industrial Water Supply.
(a) Dissolved Oxygen - There shall always be sufficient dissolved oxygen
present to prevent odors of decomposition and other offensive condi-
tions.
(b) pH - The pH value shall lie within the range of G.O to 9.0 and shall
not fluctuate more than 1.0 unit in this range over a period of 24
hours.
-(c)- Hardness cr Mineral Compounds - There shall be no substances added
to the waters that will increase the hardness or mineral content
of the waters to such an extent as to appreciably impair the useful-
ness of the water as a source of industrial water supply.
(d) Total Dissolved Solids - The total dissolved solids shall at no
time exceed 500 mg/1,
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A-4
(e) Solids, Floating Materials"and Deposits - There shall be no
c^'sti^fiy ">c""ble so"id:, :cun, fear., oily sleek, or tne for-
mation of slimes, bottom deposits or sludge banks of such size
or character as may impair the usefulness of the water as a
source of industrial water supply.
(f) Turbidity or Color - There shall be no turbidity or color added in
amounts or characteristics that can not be reduced to acceptable
concentrations by conventional water treatment processes.
(g) Temiierature - The maximum water temperature change shall not exceed
3C° relative to ar> uostreem control point. The temperature of the
water shall not exceed 30.5°C and the maximum rate of change shall
not exceed 2C° per hour. The temperature of impoundments wnere
stratification occurs will be measured at a depth of 5 feet, or
mid-depth whichever is less, and the temperature in flowing streams
shall be measured at mid-depth.
(h) Taste or Odor - There shall be no substances added that will result
in taste or odor tnat would prevent the use of the water for indus-
trial processing.
(i) Toxic Substances - There shall be no substances added to the waters
that m3y produce toxic conditions that will adversely affect the water
for industrial processing.
(j) Other Pollutants - Other pollutants shall not be added to the waters
in quantities that may adversely affect the water for industrial
processing.
3. Fish and Aquatic Life.
(a) Dissolved Oxygen - The dissolved oxygen shall be maintained at 5.0
mg/1 except in limited sections of the stream receiving treated ef-
fluents. In these limited sections, a minimum of 3.0 mg/1 dissolved
oxygen shall be allowed. The dissolved oxygen content shall be
measured at mid-depth in waters havinq a total depth of ten (10)
feet or less and at a depth of five (b) feet in waters having a
total depth of greater than ten (10) feet. A minimum dissolved
oxygen content of 6.0 mg/1 shall be maintained in recognized
trout streams.
(b) pH - The pH value shall lie within the range of 6.5 to 8.5 and
shall not fluctuate more than 1.0 unit in tins range over a
period of 24 hours,
Cc) Solids, Floating Materials and Deposits - There shall be no
distinctly visible solids, scum, focm, oily sleek, or the for-
mation of slimes, bottom deposits or sludge banks of such size
or character that may be detrimental to fish and aquatic life.
(d) Turbidity or Color - There shall be no turbidity or color added in
such amounts or of such character that will materially affect fish
and aquatic life.
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A-5
(e) Temperature - The maximum water temperature change shall rot
exceed 3C° relative to an upstream control point. The ttnir.G^c-
ture of the water shall not exceed 30.5°C and the maximum ra*e of
change shall not exceed 2C° per hour. Tne temperature of recognized
trout waters shall not exceed 2G°C. There shall be no abnormal
temperature changes that may affect aquatic life unless caused by
natural conditions. The temperature of impoundments where strati-
fication occurs will be measured at a depth of 5 feet, or mid-depth
whichever is less, and the temperature in flowing streams shall be '
measured at mid-depth.
(f) Taste or Odor - There shall be no substances added that will impart
unpalatable flavor to fish or result in noticeable offensive odors
in the vicinity of the water or otherwise interfere with fisn or
aquatic life.
(g) Toxic Substances - There shall be no substances added to the waters
that will produce toxic conditions that affect fish or aquatic life.
(h) Other Pollutants - Other pollutants shall not be added to the waters
that will be detrimental to fish or aquatic life.
A. Recreation.
(a) Dissolved Oxygen - There shall always be sufficient dissolved
oxygen present to prevent odors of decomposition and other offen-
sive conch liujis.
(b) pH - The pH value shall lie within the range of 6.0 to 9.0 and
shall not fluctuate more than 1.0 unit in this range over a period
of 24 hours.
(c) Solids, Floating Materials and Deposits - There shall be no
distinctly visible solids, scum, foam, oily sleek, or the forma-
tion of slimes, bottc.n deposits or sludge banks of such size or
character that may be detrimental to recreation.
(d) Turbidity or Color - There shall be no turbidity or color added in
such amounts or character that will result in an objectionable ap-
pearance to the water.
(c) Temperature - The maximum water temperature change shall not
exceed 3C° relative to an upstream control point. The tempera-
ture of the water shall not exceed 30.5°C and the maximum rate of
change shall not exceed 2C° per hour. The temperature of imoound-
ments where stratification occurs will be measured at a depth of
5 feet, or mid-depth whichever is less, and the temperature in
flowing streams shall be measured at mid-depth.
(f) Microbiological Coliform - The fecal colifom group shall not
exceed 5,0C0 per 100 ml. as a monthly average value nor oceed
this number in more than 20 per cent of the samples examined djring
any month nor exceed 20,000 per 100 nil. in more thsn five por cent
of such samples. In those waters that arc physically suitable and
available to the public for water-contact recreation the fecal
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coHform concentration shall not exceed 1 ,000 per 100 n.l. t-*
eny two consecutive samples collected during tne irontns of '.'zy
through September, '.,'ater areas near outfalls of dorcstic severe
treatme.it plants are not considered suitable for water-contact
recreation.
(s) Taste or Odor - There shall be no substances added that will
result in objectionable taste or odor.
(Ii) Toxic Substances - There shall be no substances added to the water
that will produce toxic conditions tnat affect man or animal.
(i) Other Pollutants - Other pollutants shall not be added to the water
in quantities which may have d detrimental effect on recreation.
Irrigation
(a) Dissolved Oxygen - There shall always be sufficient dissolved
oxygen present to prevent odors of decomposition and other
offensive conditions.
(b) pH - The pH value shall lie within the range of 6.0 to 9.0 and
shall not fluctuate more than 1.0 unit in this range over a period
of 24 hours.
(c) Hardness or Mineral Compounds - There shall be no substances added
to the water that will increase the mineral content to such an extent
as to impair its use for irrigation.
(d) Solids, Floating Materials and Deposits - There shall be no distinct-
ly visible solids, scum, foam, oily sleek, or the formation of slimes,
bottom deposits or sludge banks of such size or character as may
impair the usefulness of the water for irrigation purposes.
(e) Temperature - The temperature of the water'shall not be raised or
lowered to such an extent as to interfere with its use for irriga-
tion purposes.
(f) Toxic Substances - There shall be no substances added to water that
will produce toxic conditions that will affect the water for irriga-
tion.
(g) Other Pollutants - Other pollutants shall not be added to the water
in quantities which may be detrimental to the waters used for irri-
gation.
Livestock Watering and Wildlife
(a) Di ssolved Oxygen - There shall always be sufficient dissolved
oxygen present to prevent odors of decomposition and other
offensive conditions.
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A-7
(b) The pH value shall lie within the ranee of 6.0 to 9 0 and
she"*! rot '""vctL'atr r"'~e t'i£- 1 ? t, V -.s :\=:i$s ever e period
of 24 hours.
(c) Hardness or Mineral Compounds - There shall be no substances added
to water that will increase the mineral convent to such an c-/tent
as to impair its use for livestock watering and wildlife.
(d) Solids, Floating Materials and Deposits - There shall be no distinct-
ly visible solids, scum, foam, oily sleek, or the formation of slurbs,
bottom deposits or sludge banks of such size or character as to inter-
fere with livestock watering and wildlife.
(e) Temperature - The temperature of the water shall not be raised or
lowered to such an extent as to interfere with its use for live-
stock watering and wildlife.
(f) Toxic Substances - There shall be no substances added to wat-( that
will produce toxic conditions that will affect the water for live-
stock watering ana wildlife.
(g) Other Pollutants - Other pollutants shall not be added to the water
in quantities which may be detrimental tc the water for livestock
watering and wildlife.
7. Navigation
(d) Dissolved Oxygen - There shall always be sufficient dissolved oxygen
present to prevent odors of decomposition and other offensive condi-
tions.
(b) Hardness or Mineral Compounds - There shall £>e do substances added
to the water that will increase the mineral content to sucli an
extent as to impair its use for navigation.
(c) Solids, Floating Materials and Deposits - There shall be no distinct-
ly visible solids, scum, foam, oily sleek, or the toraatioj) of slices,
bottom deposits or sludge banks of such size or character as to inter-
fere with navigation.
(d} Temperature - The temperature of the water shall not be raised or
lowered to such an extent as to interfere with its use for naviga-
tion purposes.
(e) Toxic Substances - There shall be no substances added to water that
will produce toxic conditions that will affect the water for naviga-
tion.
(f) Other Pollutants - Other pollutants shall not be added to the water
in quantities which may be detrimental to the waters used fo~ navi-
gation.
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A-8
criteria should not be construed as Dermittino the degradation of hierer
' i';ter when such con be Drevcnied by reasonable ooHution control n jjsurc-s.
'rabove.- coiioitions are recognizee as applying to waters affectec by the discnarge
l'~sewage and/or industrial waste or other waste and not resulting fron natural
causes.
prnillTlOf.'S
1. Conventional Water Treatment - Conventional water treatment as referred
to in the criteria denotes coagulation, sedimentation, filtration and
chlon nation.
2. Mixing Zone - Mixing zone refers to that section of flowing stream or
impounded waters necessary for effluents to become dispersed.
The mixing zone necessary in each particular case shall be defined by
the Tennessee i.'ater Quality Control Board.
INTERPRETATION OF CRITERIA
1. Interpretations of the above criteria shall conform to any rules and re-
gulations or policies adopted by the Water Quality Control Board.
2. Insofar as practicable, the effect of treated sewage or waste discharges
on the receiving waters shall be considered after they are mixed with the
waters and beyond a reasonable zone of immediate effect upon the quali-
ties of the waters. The extent to which this is practicable depends upon
local conditions and the proximity and nature of other uses of the waters.
3. The technical and economical feasibility of waste treatment, recovery, or
adjustment of the method of discharge to provide correction shall be con-
sidered in determining the tune to be allowed for the development of
practicable methods and for the specified correction.
4. The criteria set forth shall be applied on the basis of the following
stream flows: unregulated streams - stream flow's equal to or exceeding
the 3-day rmmilium, 20-year recurrence interval; regulated streams -
instantaneous mi in mum flow.
5. In general, deviations fron nonnal water conditions may be undesirable,
but the rate and extent of the deviations sliould be considered in inter-
preting the above criteria.
6. The criteria and standards proude that all discharges of sewage, indus-
trial waste, and other wastes will receive the best practicable treatment
(secondary or the equivalent) or control according to the policy and pro-
cedure of the Tennessee Water Quality Control Beard. A degree of treat-
ment greater than secondary when necessary to protect the water uses will
be required for selected sewage and waste discharges.
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T:I,KESSEE ANTIDEGRADATION STATEMENT
A-9
1. The Standards end Plan adopted are designed to provide for the pro-
tection of existing water quality and/or the upgrading or "ennancc-
ment" of water quality in all waters within Tennessee. It is recog-
nised that some waters may have existing quality better than
established standards.
2. The Criteria and Standards shall not be construed as permitting the
degradation of these higher quality waters wnen such can be preverr.ed
by reasonable pollution control measures. In this regard, existing
high quality water will be maintained unless and until it is affirma-
tively demonstrated to the Tennessee Water Quality Control Board tnat
a change is justifiable as a result of necessary social and economic
development.
3. All discharges of sewage, industrial waste, or other waste shall
receive the best practicable treatment (secondary or the equivalent)
or control according to the policy and procedure of the Tennessee
Water Quality Control Board. A degree of treatment greater than
secondary when necessary to protect the water uses will be required
for selected sewage and waste discharges.
4. In implementing the provisions of the above as they relate to inter-
state streams, the Tennessee Water Quality Control Board will cooperate
with the appropriate Federal Agency in order to assist in carrying out
responsibilities under the Federal Water Pollution Control Act, as
amended.
December 17, 1971
-------
A-10
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-------
A -11
Holston Array Ammunition Plant "A"
I. The following parameters show limitations which apply to net contri-
bution of all wastewater discharges. Each discharge point requires
a separate Permit by the State of Tennessee. A Permit will state
that the limitation for each of the following parameters will apply
for the particular discharge, either singularly or in combination
with all other discharges.
1. The total five (5) day, 20°C biochemical oxygen demand contrib-
uted by all discharges from the Holston Army Ammunition
Plant/Kolston Defense Corporation Area "A", as measured by the
combined differences in each intake and each discharge, must not
exceed 1,050 pounds per day.
2. The total contribution of total kjeldahl nitrogen of all discharges
from the Holston Army Ammunition Plant/Holston Defense Corporation
Area "A", as measured by the combined differences in each intake
and each discharge, must not exceed 10 pounds per day.
3. The total contribution of total nitrogen of all discharges from
the Holston Army Ammunition Plant/llolston Defense Corporation
Area "A", as measured by the combined differences in each intake
and each discharge, must not exceed JO pounds per day.
4. The total contribution of ammonia nitrogen, as N, of all discharges
from the Holston Army Anmunition Plant/Holston Defense Corporation
Area "A", as measured by the combined differences in each intake
and each discharge, must not exceed 10 pounds per day.
5. The total contribution of nitrates plus nitrites of all discharges
from the Holston Army Ammunition Plant/llolston Defense Corporation
Area "A" as measured by the combined differences in each intake
and each discharge, must not exceed 10 pounds per day.
6. The total contribution of phosphorus, as P, of all discharges
from the Holston Army Anmunition Plant/Holston Defense Corporation
Area "A", as measured by the combined differences in each intake
and each discharge, must not exceed 172 poun.ds per day.
7. The total contribution of total dissolved solids of all discharges
from the Holston Army Ammunition Plant/Holston Defense Corporation
Area "A", as measured by the combined differences in each intake
and each discharge, must not exceed 100.000 pounds per day.
8. The total contribution of phenols of all discharges from the
Holston Army Ammunition Plant/Holston Defense Corporation Area
"A", as measured by the combined differences in each intake and
each discharge, must not exceed 10 pounds per day.
-------
A-12
15. There shall be no objectionable color change in the receiving
stream resulting from the wastewater discharge.
16. This discharge must not cause a water temperature change in
the South Fork Kolston River or llolston River of more than 3°C
relative to an upstream control point. Also, the discharge
must be such that the water temperature of the South Fork llolston
River or llolston River does not exceed 30.5°C (except as a result
of natural causes) and the discharge must be such that the maxi-
mum rate of temperature change in the South Fork llolston River or
Holston River does not exceed 2°C per hour (except as a result of
of natural causes).
llolston Army Ammunition Plant "B"
X. The following parameters show limitations which apply to net contri-
bution of all wastewater discharges. Each discharge point requires
a separate Permit by the State of Tennessee. A Permit will state
that the limitation for each of the following parameters will apply
for the particular discharge, either singularly or in combination
with all other discharges.
1. The total five (5) day, 20°C biochemical oxvgen demand contributed
by all discharges from the Holston Army Ammunition Plant/llolston
Defense Corporation Area "B", as measured by the combined differ-
ences in each intake and each discharge, must not exceed 1,430
pounds per day.
2. The total contribution of total kjeldahl nitrogen of all dis-
charges from the Holston Army Ammunition Plant/llolston Defense
Corporation Area "B", as measured by the combined differences
in each intake and each discharge, must not exceed 76 pounds per day
3. The total contribution of total nitrogen of all discharges from
the llolston Army Ammunition Plant/llolston Defense Corporation Area
"B", as measured by the combined differences in each intake and
each discharge, must not exceed 620 pounds per day.
4. The total contribution of ammonia nitrogen, as N, of all dis-
charges from the Holston Army Ammunition Plant/Holston Defense
Corporation Area "B", as measured by the combined differences in
each intake and each discharge, must not exceed 76 pounds per day.
5. The total contribution of nitrates plus nitrites of all discharges
from the Holston Army Ammunition Plant/Holston Defense Corpor-
ation Area MB" as measured by the combined differences in each
intake and each discharge, must not exceed 556 pounds per day.
-------
A-13
The following parameters show limitations in concentration which
apply to each and every discharge point.
1. The daily average concentration of suspended solids in the
wastewater mu3t not exceed 40 mg/1.
2. The instantaneous maximum concentration of suspended solids
in the wastewater must not exceed 50 mg/1.
3. The daily average concentration of total chromium in the waste-
water discharge must not exceed 0.05 mg/1.
4. The instantaneous maximum concentration of total chromium in
the wastewater discharge must not exceed 0.075 mg/1.
5. The daily average concentration of copper in the wastewater
discharge must not exceed 0.02 mg/1.
6. The instantaneous maximum concentration of copper in the
wastewater discharge must not exceed 0.03 mg/1.
7. The daily average concentration of mercury in the wastewater
discharge must not exceed 0.005 mg/1.
8. The instantaneous maximum concentration of mercury in the
wastewater discharge must not exceed 0.0075 mg/1.
9. The daily average concentration of lead in the wastewater
discharge must not exceed 0.05 mg/1.
10. The instantaneous maximum concentration of lead in the waste-
water discharge must not exceed 0.075 mg/1.
11. The dissolved oxygen concentration in the final effluent must
be greater than 5.0 mg/1.
12. The concentration of settleable solids in the wastewater dis-
charge must not exceed 0.5 ml/1 as measured by the standard
one-hour Imhoff cone test.
13. The pH of the wastewater discharge must not be less than 6.0
nor greater than 9.0.
14. The wastewater must contain no distinctly visible floating scum,
oil, or other floating matter.
-------
6. The total contribution of phosphorus, as P, of all discharges
from the Holston Army Ammunition Plant/llolston Defense Corpor-
ation Area "B", as measured by the combined differences in each
intake and each discharge must not exceed 213 pounds per day.
7. The total contribution of total dissolved solids of all dis-
charges from the Holston Army Ammunition Plant/Holston Defense
Corporation Area "B", as measured by the combined differences in
each intake and each discharge, must not exceed 500,000 pounds
per day,
8. The total contribution of phenols of all discharges from the
Holston Army Ammunition Plant/llolston Defense Corporation Area
"B", as measured by the combined differences in each intake and
each discharge, must not exceed 10 pounds per day.
I
The following parameters show limitations in concentrations which
apply to each and every discharge point.
1. The daily average concentration of suspended solids in the
wastewater must not exceed 40 mg/1.
2. The instantaneous maximum concentration of suspended solids
in the wastewater must not exceed 50 mg/1.
3. The daily average concentration of total chromium in the waste-
water discharge must not exceed 0.05 mg/1.
4. The instantaneous maximum concentration of total chromium in
the wastewater discharge must not exceed 0.075 mg/1.
5. The daily average concentration of copper in the wastewater
discharge must not exceed 0.02 mg/1.
6. The instantaneous maximum concentration of copper in the
the wastewater discharge must not exceed 0.03 mg/1.
7. The daily average concentration of mercury in the wastewater
discharge must not exceed 0.005 mg/1.
8. The instantaneous maximum concentration of mercury in the
wastewater discharge must not exceed 0.0075 mg/1.
9. The daily average concentration of lead in the wastewater dis-
charge must not exceed 0.05 mg/1.
-------
A-15
10. The instantaneous maximum concentration of lead in the waste-
water discharge must not exceed 0.075 mg/1.
11. The dissolved oxygen concentration in the final effluent must
be greater than 5.0 mg/1.
12. The concentration of settleable solids in the wastewater dis-
charge must not exceed 0.5 ml/1 as measured by the standard
one-hour Imhoff cone test.
13. The pH of the wastewater discharge must not be less than 6.0
nor greater than 9.0.
14. The wastewater must contain no distinctly visible floating scum,
oil, or other floating matter.
15. There shall be no objectionable clolor change in the receiving
stream resulting from the wastewater discharge.
16. This discharge must not cause a water temperature change in
the Holston River of more than 3°C relative to an upstream
control point. Also, the discharge must be such that the water
temperature of the Holston River does not exceed 30.5°C (except
as a result of natural causes) and the discharge must be such
that the rntc of temperature change in the Holston River
docs not exceed 2°C per hour (except as a result of natural causes).
According to our records, the referenced discharges will not at this time
meet the above standards. It will, therefore, be necessary that addi-
tional treatment facilities or other alterations resulting in substantial
wastewater characterization changes are in order.
As we discussed in the neeting, the Holston Army Ammunition Plants arc
not making formal application for a wastewater discharge Permit due to
certain policy regulations promulgated by the Department of Army. For
this reason and since it is necessary for the Division to hold an en-
forceable document outlining an implementation schedule for pollution
abatement, the Division will recommend that a Commissioner's Order be
issued. This Commissioner's Order will contain the effluent criteria as
outlined above and an implementation schedule which is to be provided to
this Division by the Holston Army Ammunition Plant on or before May A, 1973.
As we discussed, the schedule should represent a rapid approach to the
solution of this problem and should include dates for:
1. Submittal of an engineering report;
2. Submittal of final plans aid specifications;
3. Initiation of construction;
4. Completion of construction;
5. Treatment facilities to be in satisfactory operation; and
6. Any additional interim dates as deemed by 1LAAP.
-------
A-16
Upon receipt of this schedule, it will be reviewed by engineers of this
Division. At that time, any revisions deemed necessary by this Division
will be made.
Within two weeks of the date of receipt of this schedule, pursuant to
TCA Section 70-331 (a) made applicable to you by 33 USC 1323, this
Division will recommend to the Commissioner of the Department of Public
Health that an Order be issued as early as possible.
-------
A-17
STATE OF TENNESSEE STANDARDS
TENNESSEE EASTMAN COMPANY
I. The following parameters show limitations which apply to net contri-
bution of all wastewater discharges. Each discharge point requires
a separate Permit by the State of Tennessee. A Permit will state
that the limitation for each of the following parameters will apply
for the particular discharge, either singularly or in combination
with all other discharges.
1. The total five (5) day, 20°C biochemical oxygen demand contri-
buted by all discharges from the Tennessee Eastman Company,
as measured by the combined differences in each intake and each
discharge, must not exceed 3,350 pounds per day.
2. The total contribution of total kjeldahl nitrogen of all dis-
charges from Tennessee Eastman Company, as measured by the com-
bined differences in each intake and each discharge, must not
exceed 400 pounds per day.
3. The total contribution of total nitrogen of all discharges from
Tennessee Eastman Company, as measured by the combined differ-
ences in each intake and each discharge, must not exceed 3,310
pounds per day.
4. The total contribution of ammonia nitrogen, as N, of all dis-
charges from Tennessee Eastman Company, as measured by the
combined differences in each intake and each discharge, must
not exceed 400 pounds.
5. The total contribution of nitrates plus nitrites of all discharges
from Tennessee Eastman Company, as measured by the combined dif-
ferences in each intake and each discharge, must not exceed
2,910 pounds.
6. The total contribution of phosphorus, as P, of all discharges
from Tennessee Eastman Company, as measured by the combined
differences in each intake and each discharge, must not exceed
213 pounds per day.
7. The total contribution of total dissolved solids, of all dis-
charges from Tennessee Eastman Company, as measured by the
combined differences in each intake and each discharge, must not
exceed 1,200,000 pounds per day.
-------
8. The total contribution of zinc of all discharges from
Tennessee Eastman Company, as measured by the combined dif-
ferences in each intake and each discharge, must not exceed
250 pounds per day.
9. The total contribution of phenols of all discharges from
Tennessee Eastman Company, as measured by the combined dif-
ferences in each intake and each discharge must not exceed
100 pounds per day.
10. The total contribution of iron, as Fe, of all discharges from
Tennessee Eastman Company, as measured by the combined dif-
ferences in each intake and each discharge must not exceed
1,000 pounds per day.
The following parameters show limitations in concentrations which
apply to each and every discharge point.
1. The daily average concentration of suspended solids in the
wastewater must not exceed 40 mg/1.
2. The instantaneous maximum concentration of suspended solids
in the wastewater must not exceed 50 mg/1.
3. The daily average concentration of total chromium in the
wastewater discharge must not exceed 0.05 mg/1.
4. The instantaneous maximum concentration of total chromium
in the wastewater discharge nust not exceed 0.075 mg/1.
5. The daily average concentration of copper in the wastewater
discharge must not exceed 0.02 mg/1.
6. The instantaneous maximum concentration of copper in the
wastewater discharge must not exceed 0.03 mg/1.
7. The daily average concentration of mercury in the wastewater
discharge must not exceed 0.005 mg/1.
8. The instantaneous maximum concentration of mercury in the
wastewater discharge must not exceed 0.0075 mg/1.
9. The daily average concentration of lead in the wastewater
discharge must not exceed 0.05 mg/1.
-------
A-19
10. The instantaneous maximum concentration of lead in the waste-
water discharge must not exceed 0.075 mg/1.
11. The dissolved oxygen concentration in the final effluent must
be greater than 5.0 mg/1.
12. The concentration of settleable solids in the wastewater dis-
charge must not exceed 0.5 ml/1 as measured by the standard
one-hour Imhoff cone test.
13. The pH of the wastewater discharge must not be less than 6.0
nor greater than 9.0.
14. The wastewater must contain no distinctly visible floating scum,
oil or other floating matter.
15. There shall be no objectionable color change in the receiving
stream resulting from the wastewater discharge.
16. This discharge must not cause a water temperature change in
the South Fork Ilolston River or llclston River of more than
3°C relative to an upstream control point. Also, the discharge
must be such that the water temperature of the South Fork Ilolston
River or Holston River does not exceed 30.5°C (except as a result
of natural causes) and the discharge must be such that the maxi-
mum rate of temperature change in the South Fork Holston River
or Holston River does not exceed 2°C per hour (except as a re-
sult of natural causes).
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A-20
STATE OF TENNESSEE STANDARDS
CITY OF KINGSPORT
SEWAGE TREATMENT PLANT
1. The concentration of settleable solids in the wastewater discharge
must not exceed 0.1 ml/1 as measured by the standard one-hour Imhoff
cone test.
2. The pH of the wastewater discharge must not be less than 6.0 nor
greater than 9.0.
3. The wastewater must contain no distinctly visible floating scum,
oil, or other floating matter.
4. The daily average five (5) day, 20°C biochemical oxygen demand
concentration in the wastewater discharge must not exceed 10 mg/1.
5. The instantaneous maximum five (5) day, 20°C biochemical oxygen
demand concentration in the wastewater discharge must not exceed
15 rag/1.
6. The total five (5) day, 20°C biochemical oxygen demand concentration
in the wastewater discharge must not exceed 500 pounds per day.
7. The daily average concentration of suspended solids in the waste-
water mu9t not exceed 15 mg/1.
8. The instantaneous maximum concentration of suspended solids in the
wastewater must not exceed 20 mg/1.
9. The total suspended solids in the wastewater discharge must not
exceed 1,250 pounds per day.
10. The daily average concentration of total kjeldahl nitrogen in the
wastewater discharge must not exceed 1.6 mg/1.
11. The instantaneous maximum concentration of total kjeldahl in the
wastewater discharge must not exceed 2.4 mg/1.
12. The total amount of total kjeldahl nitrogen in the wastewater dis-
charge must not exceed 133 pounds per day.
-------
A-21
13. The daily average concentration of total nitrogen in the waste-
water discharge must not exceed 1.8 mg/1.
14. The instantaneous maximum concentration of total nitrogen in the
wastewater discharge must not exceed 2.7 rag/1.
15. The total amount of total nitrogen in the wastewater discharge
must not exceed 150 pounds per day.
16. The daily average concentration of ammonia nitrogen in the waste-
water discharge must not exceed 1.6 mg/1 as N.
17. The instantaneous maximum concentration of ammonia nitrogen in
the wastewater discharge must not exceed 2.4 mg/1 as N.
18. The total amount of ammonia nitrogen in the vastewater discharge
must not exceed 133 pounds per day as N.
19. The daily average concentration of nitrates plus nitrites in the
wastewater discharge must not exceed 1.8 ir.g/1.
20. The instantaneous maximum concentration of nitrates plus nitrites
in the wastewater discharge must not exceed 2.7 mg/1.
23 « The total "rcunt of nitrates plus rJLtriLus ir. thi v.istevaLer dis-
charge must not exceed 150 pounds per day.
22. The daily average concentration of phosphorus as P in the waste-
water discharge must not exceed 1.0 mg/1.
23. The instantaneous maximum concentration of phosphorus as P in the
wastewater discharge must not exceed 1.5 mg/1.
24. The total amount of phosphorus as P in the wastewater discharge
must not exceed 85 pounds per day.
25. The wastewater discharge must have a chlorine residual between the
limits of 0.2 mg/1 and 1,0 mg/1, and must be disinfected to the
extent that viable coliform organisms are effectively eliminated.
26. The dissolved oxygen concentration in the final effluent must be
greater than 5.0 mg/1.
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STATE OF TENNESSEE STANDARDS
MEAD CORPORATION
The following parameters show limitations which apply to net
contributions of all wastewater discharges. Each discharge point
requires a separate Pernit by the State of Tennessee. A Permit
will state that the limitation for each of the following parameters
will apply for the particular discharge, either singularly or in
combination with all other discharges.
1. The total five (5) day, 20°C biochemical oxygen demand contri-
buted by all discharges from Mead Corporation, as measured
by the combined differences in each intake and each discharge,
must not exceed 1,100 pounds per day.
(¦
2. The total contribution of total kjeldahl nitrogen of all dis-
charges front Mead Corporation, as measured by the combined
differences in each intake and each discharge, must not exceed
60 pounds per day.
3. The total contribution of total nitrogen of all discharges from
Mead Corporation, as measured by the combined differences in each
intake and each discharge, must not exceed 60 pounds per day.
4. The total contribution of ammonia nitrogen, as N, of all dis-
charges from Mead Corporation, as measured by the combined
differences in each intake and each discharge, must not exceed
60 pounds per day.
5. The total contribution of nitrates plus nitrites of all discharges
from Mead Corporation, as measured by the combined differences in
each intake and each discharge, must not exceed 60 pounds per day.
6. The total contribution of phosphorus, as P, of all discharges
from Mead Corporation, as measured by the combined differences
in each intake and each discharge, must not exceed 85 pounds
per day.
7. The total contribution of total dissolved solids, of all dis-
charges from Mead Corporation, as measured by the combined dif-
ferences in each intake and each discharge, must not exceed
200,000 pounds per day.
8. The total contribution of phenols of all discharges from Mead
Corporation, as measured by the combined differences in each
intake and each discharge, must not exceed 50 pounds per day.
-------
A-23
II. The following parameters show limitations in concentrations which
apply to each and every discharge point:
1. The daily average concentration of suspended solids in the
wastewater must not exceed AO mg/1.
2. The instantaneous maximum concentration of suspended solids
in the wastewater must not exceed 50 mg/1.
3. The daily average concentration of total chromium in the waste-
water discharge must not exceed 0.05 ng/1.
4. The instantaneous maximum concentration of total chromium in
the wastewater discharge must not exceed 0.075 mg/1.
5. The daily average concentration of copper in the wastewater
discharge must not exceed 0.02 mg/1.
6. The instantaneous maximum concentration of copper in the waste-
water discharge must not exceed 0.03 mg/1.
7. The daily average concentration of mercury in the wastewater
discharge must not exceed 0.005 mg/1.
8„ Th° inrtsntcrecuc mr.nimuir. concentration of mercury in the waste-
water discharge must not exceed 0.0075 mg/1.
9. The daily average concentration of lead in the wastewater dis-
charge must not exceed 0.05 raj/l.
10. The instantaneous maximum concentration of lead in the waste-
water discharge must not exceed 0.075 mg/1.
11. The dissolved oxygen concentration in the final effluent must
be greater than 5.0 mg/1.
12. The concentration of settleable solids in the wastewater dis-
charge must not exceed 0.5 ml/1 as measured by the standard
one-hour Imhoff cone test.
13. The pH of the wastewater discharge must not be less than 6.0
nor greater than 9.0.
14. The wastewater must contain no distinctly visible floating scum,
oil, or other floating matter.
-------
A-24
15. There shall be no objectionable color change in the receiving
stream resulting from this wastewater discharge.
16. This discharge must not cause a water temperature change in
the South Fork llolston River or Ilolston River of more than
3°C relative to an upstream control point. Also, the discharge
must be such that the water temperature of the South Fork Holston
River or Ilolston River does not exceed 30.5°C (except as a result
of natural causes) and the discharge must be such that the maxi-
mum rate of temperature change in the South Fork Ilolston River
or Holston River does not exceed 2°C per hour (except as a result
of natural causes).
-------
APPENDIX B
SAMPLTMf: PftOrFJVIlTCTC
-------
B-l
SAMPLING PROCEDURE
Fifty-six sampling locations were established for the waste
source and stream survey. These locations included direct dis-
charges from seven industries to the Ilolston River and its tribu-
taries, in-plant waste streams at Ilolston Mills, ASG Industries and
Tennessee Eastman Company, and four stations in the Ilolston River.
The majority of the industrial waste samples were collected
hourly by using automatic samplers and composited on an equal vol-
ume basis at the end of each 24-hour period. Where automatic samplers
could not be used, samples were collected manually every two hours and
composited on an equal volume basis.
Temperature, pH and conductivity were determined periodically.
Samples were analyzed for solids, COD, TOC, nutrients, sulfates, or-
ganics, fluorides, metals and alkalinity. Grab samples for phenolic
and oil and grease analyses were composited over a 4-6 hour period.
Samples for BOD, solids, phenolics, sulfide, color, alkalinity
and oil and grease extractions were analyzed in the EPA mobile lab-
oratory. COD, TOC, nutrients, sulfates, and fluoride analyses were
performed at the NFIC laboratory in Cincinnati, Ohio. Organic samples
were analyzed at the NFIC laboratories in Denver and Cincinnati.
Sediment samples were collected at stream stations 10-53, 54, and
-56, using a Pheleger core sampler. These samples were immediately
-------
packed with dry ice and shipped to the NFIC laboratory in Cincinnati
for analyses.
Flow measurements were obtained from company records and flow
meters, if available. Uhere necessary, EPA personnel installed
flow measuring devices and recording equipment, or, if this was
not possible, instantaneous flow measurements were taken using a
Marsh-McBirney flow meter.
-------
APPENDIX c
SAiIPLh STATIONS
-------
Stat
Numb
1
2
3
4
6
7
8
9
10
11
12
:igna
SAMPLE STATIONS
Industry
HAAP "A"
HAAP "A"
1IAA? "A"
HAAP "A"
HAAP "A"
HAAP "A"
HAAP "A"
HAAP "A"
HAAP "A"
hAAP "A"
TEC
River Mileage
142.15/4.04
142.15/4.04
142.15/4.30
142.15/4.30
142.15/4.25
142.15/4.24
142.15/4.20
142.15/4.19
142.15/4.10
142.15/4.OS
142.15/A.50
Location and Type of Sampling
Unnamed Creek, upstream of HAAP outfall discharges
(grab)
A
Main outfall stream (013) at chain-link fence
near river bank (composite)
Process waste outfall (001) at nanhole S, prior to
discharge (composite)
Process waste and cooling water outfall (001) at
manhole 7, prior to discharge (composite)
Zeolite regeneration wastes and backwash (005) inside
filter plant (grab depending on operation schedule)
Process ijaste outfall (006) at outfall to river
(composite)
Leached wastes from tar-tank area (003) at discharge
point near river bank (composite)
Stean-plant effluent and floor drainage (009) at
manhole steam plant (composite)
Steam-plant and puir.p-house discharges (012) at
sluice pit outfall (composite)
Raw water intake at filter plant (grab)
Hales Brar-ch (001) effluent at TEC Sampler in
Building 106 (composite) n
I
is Refuse Act Permit Application discharge identification number.
-------
SArEPLF, stations
Figure Station
'Number Number Indus try River Mileage
E-8 13 TEC
E-8 14 TEC 142.15/5.55/4.30
E-8 15 TEC 142.15/5.80
E-8 16 TEC
E-9 17 TEC 142.15/3.50
E-9 18 TEC
E-S 19 TEC 142.15/4.50
E-8 20 TEC
E-8 21 TEC 142.15/4.80
E-8 22 TEC 142.15/5.20
E-8 23 TEC 142.15/5.30
(Cont.)
Location and Type of Sampling
Process waste to aerated lagoon at Building 250
lift station (composite)
Process waste (004) to sluice outfall at manhole
behind Building 245-11 (composite)
Incinerator ash scrubber water at outfall (008) to
South Fork of the Hols ton River (composite)
Process wste to Kit Bottom at TEC sampler, outside
Building 122 lift station (composite)
Aerated lagoon effluent (002) to South Fork of the
Lolston River, at Long Island (composite)
Process waste to aerated lagoon, at Long Island
lift station (composite)
Long Island storm drainage overflow (003), at
open ditch adjacent to Long Island lift station
(composite)
Sanitary wastes pumped to the Kingsport Municipal
Wastewater Treatment Plant at parshall flune
behind Building 208 (composite)
Raw water intake at Building 63 (composite)
13th Street sewer outfall (005), at Riverside Drive
manhole (composite)
14th Street sewer outfall (006) , at Riverside Drive
manhole (connosite)
-------
SAMPLE STATIONS (Cent.)
Figure Station
Number Number Indus try River Mileage
E-8 24 TEC 142.15/5.70
E-12 25 HAAP "B" 141.60
E-12 26 HAAP "B" 140.70
E-12 27 HAAP "B" 140.30
E-12 28 HAAP "B" 139.70
E-12 29 HAAP "B" 139.60
E-12 30 HAAP "B" 139.60
E-12 31 HAAP "B" 139.20
E-12 32 HAAP "B" 139.20
E-12 33 HAAP "B" 137.90
Location and Type of Samples
Raw water intake at Building 269 (grab)
Filter-plant backwash (001) at manhole adjacent to
perimeter road (composite)
Wastewater-treatment plant effluent (002), at
clarifier overflow prior to chlorination (composite)
Surface water drainage (003) from production lines
9 and 10, at open ditch adjacent to perimeter
road (grab)
Process wastes at sewer outfall (004), adjacent to
perimeter road (composite)
Process wastes and cooling water at outfall (005),
adjacent to perimeter road (composite)
Cooling and surface waters from production lines 6
and 7 at sewer outfall (005) , adjacent to perimeter
road (composite)
Process wastes from production lines 3, 4, and 5 at
sewer outfall (007) , adjacent to perimter road
(composite)
Cooling water from production lines 3, 4, and 5
at sewer outfall (007), adjacent to perimeter road
(composite)
Main outfall ditch (008) at HAAP effluent water
quality monitor station (composite)
-------
Figure Station
Number isurrber Indus try
E-12 34 HAAP "3"
E-12 35 hAAP "D"
E-12 30 LiAAP :,C"
E-2 37 ASG Industries
E-2 38 ASG Industries
39 ASC Industries
40 J. P. Stevens
E-5 41 Ilead Papers
E-5 42 Kead Papers
E-5 43 lead Papers
E-3 44 Uolliston V-ills
E-3 45 Holliston Mills
SAKPLE STATIONS
River ?'ilea?.e
141.10
137.9/0.S
142.15/13j.0
142.15/4.04
142.15/4.35
142.15/4.31
142.15/2.4 0
142.15/2.40
142.15/2.50
129.04
128.9/0.70
0
1
(Cont.)
Location and Type of Samples
Raw water intake at Building 201 punphouse (composite)
Arnott Branch, upstream of nitric acid production
area (grab)
Raw water intake at Building 209 pump'nouse (composite)
ASG effluent (002) at ASG/HAAP "A" boundary fence
Influent to clarifier at settling pit (composite)
ASG cooling water effluent (001) at manhole inside
HAAP Area "A" (composite)
Outfall pipe 20 ft upstream of HAAP "A" (001) outfall
(composite) . Flo;/ at narhole adjacent to ASG guard shack
CJarifier effluent before it mixes with the water plant
by-pass discharge (composite)
V'ater-treatment plant backwash and overflow at parshall
flune (composite)
Raw water intake at pumphouse on South Fork of the
hols tor. River (composite)
Raw water intake at water treatment unit (composite)
Cooling-water discharge (002), at effluent weir
(composi te~
-------
SAIIPLE STATIONS (Cont.)
Figure Station
Kurr.ber Number Industry
River Nil ease
E-3
E-3
E-6
E-6
E-6
46
52
47
4S
49
Holliston Mills 129.2
Holliston Hills
Penn Dixie
Penn Dixie
Penn Dixie
142.15/2.60
142.15/2.60
142.15/2.62
Location and Type of Samples
Discharge (001) to Ilolston River, at lagoon effluent
v;eir (composite)
'-Jastewater-treatment-facility effluent to lagoon,
at parshall flume (composite)
Cooling-uater effluent at discharge point to open
ditch on Penn-Dixie property (conposite)
Process-vaste and cooling-water effluent, at (001)
discharge point to open ditch on Penn-Dixie property
(composite)
Raw water supply at South Fork of the Holston River
intake structure (composite)
STREAII SURVEY
IV-1
IV-1
IV-1
53
54
55
142.15/0.20
142.15/5.6
142.15/1.2
North Fork of the Holston River, at Net'nerland Inn
Road Bridge
South Fork of the Holston River, at Tennessee Hwy 99
Bridge (Rli 5.6)
South Fork of the Holston River, at Ridgefields
Bridge (RM 1.2)
IV-1
56
131.5
Holston River, at Church Hill Bridge (RM 131.5)
0
1
-------
APPENDIX D
METHODS OF ANALYSIS AND SAMPLE PRESKRVAT)ON
-------
D-l
METHODS OF ANALYSIS AND SAMPLE PRESERVATION
Analyses for COD, sulfate, sulfide, phenolics, and BOD and DO
were conducted according to standard methods (using the azide modifi-
*
cation of the Winkler technique).
All other laboratory analyses and field measurements vere carried
¦kt't
out in accordance with accepted sLandard techniques.
Samples collected in the field were preserved as follows:
Sample for Analysis of-
Sulfate
F1 uoridc
BOD
So] ids
Sulf Ldo
Organics
Alkalinity
Sediment
NutrienLs
COD
TOC
Metals
Oil & Grease
Phenolics
Preservative
None
ICG
Dry ice
1 nil conc. ll,,S0./l
/ H
2 ml conc
2 ml conc )1„S0./1
I 4
1 nm CuSO. + 1 nil conc !I„P0,/1
A 3 4
* M. J. Tarus, A. E. Greenberr.r D. Hoak, and M. C. Rnnd, Standard
Methods for the Fxarri-nation of Ucd-er and Wastewater} 1Jrh Edition,
American Public Health Association. Nev York, New York. 1971.
** Methods for Chemical Analysis of Mover and bastes^ Environmental
Protection Agency, National Environmental Research Center, Analytical
Quality Control Laboratory. Cincinnati, Ohio. July 1971.
*** Ice was packed around sample containers to lower tcir.peraLurc and
retard bacteriological degradation.
-------
APPENDIX E
WASTE SOURCE EVALUATIONS
-------
E-l
INTRODUCTION
This appendix summarizes information concerning industrial waste
sources investigated in the Kin^sport, Tennessee, vicinity.
Each industry was requested to grant permission to allow EPA personnel
to sample waste sources and make flow measurements on company property.
All industries were cooperative and granted permission to EPA personnel.
The format employed in preparation of the individual evaluation
reports was not identical in all cases but generally resembled the following
outline:
A. General — includes background information and contacts;
B. Waste Sources and Treatment — includes types of processes,
sources of pollution, and waste treatment practices;
C. Plant Evaluations and Findings — includes information on
evaluation procedure, data from chemical analyses, field
measurements, and observations.
D. Summary and Conclusions
E. Recommendations
-------
E-2
E-I. ASG INDUSTRIES, INCORPORATED
KINGSPORT, TENNESSEE
A. GENERAL
ASG Industries employs about 700 people and operates continuously.
The company produces 198 tons/day of rolled glass, polished wire glass,
and miscellaneous flat glass including tempered and laminated glass
[Plant flow diagram Figure E-l]. Raw materials arc sand (61 tons),
soda ash (19 tons), limestone (15 tons), dolomite (6 tons), and
various amounts of recycled glass. Other additives, such as saltcake,
feldspar, aluminum hydrate, titanium oxide, carbon, sodium silicate
fluoride, selenium and cobalt, are employed in order to obtain specific
properties in the glass. Arsenic is used about two months out of the
year; hydrofluoric acid is used for etching about one day/month.
The raw materials are melted in four gas-fired furnaces". The
glass passes out of the oven through large rollers and onto a conveyor
belt which continuously moves through more water-cooled rollers. The
glass is annealed and might be sent to the warehouse or be processed
further. Generally, the glass is ground, using a sand and water slurry,
then washed, and polished with rouge (ferric oxide). The glass can also
be tempered or laminated, according to the demands for specific properties.
On 10 November 1972, EPA and Tennessee State personnel visited
the plant. R. W. Smith, R. 0. Bivens, and J. C. McDavid of ASG
Industries provided information on plant processes.
B. WASTE SOURCES AND TREATMENT
Water (approximately 0.9/1 mgd) is purchased from the Tennessee
-------
SETTLING PIT AND THICKENER
01)2 AFTER THICKENER
001 Of — PASSED TO RIVE
CONTINUOUS
FURNACE
CQKTIUUOU
BATCH HOUSE
RAW MATERIALS
FIHAl
PROCESSING
WASHER
AUTOCLAVE
WASHER
| CAUSTIC
'j MACH /WASHER
WAREHOUSE
WASHER
WAREHOUSE
com
COHVE
NOTE WATER SOURCE IS RIUR WATER THAT HAS BEEH CHEHilUlU CLARIFIED AND FILTERED
Figure E-1. Plant Flow Diagram-AS6 industries
Kingsport, Tennessee
-------
E-3
Eastman Company and is treated by alum coagulation, sedimentation, and
filtration. One-half mgd is used for cooling water, 0.4 mgd for process
water, and 0.04 mgd for boiler feed. City water (0.01 mgd) is employed
for sanitary purposes.
The company has filed RAPP Applications for two discharges [Table
A
E-l]. Outfall 001 (Station 39) contains suiface run-off, coolinp water
and river water from a glass-washing operation. This wastewater is dis-
charged directly to the South Fork of the Holston River without treatment.
The other discharge (002 - Station 37) , consisting of wastewater
from the grinding-and-polishing operation and specialty coating operation,
and some rinse water fron washers are treated. This wastewater enters
a thickener tanlc [Figure E—2] through a central cylindrical section.
The effluent is discharged via a peripheral weir. At 0.57 mgd, the
surface overflow rate is 1,800 gpd/sq ft. About one pound of alum per
2,500 gal. of water (48 mg/1) is added in the center section, but no
attempt is made to mix this alum with the wastewater. With no rapid
mix or floc-culation of the clarifier feed, it is probable that the alum
is not being used effectively for coagulation. Sludge renoved from the
clari-fier is vacuum filtered; the filtrate is returned to the thickener
and the filter cake is hauled to a landfill for disposal.
The clarifier discharges into a ditch where the effluent joins
a milky white rinse water from other washers. The combined flows dis-
charge to the South Fork of the Holston River via an open ditch passing
* This is the conpany designated discharge number in Refuse Act Termit
Application. The discharge point is located on the property of the
liolston Army Ammunition Plant.
-------
PI
I
TABLE E-l
EFFLUENT DISCHARGES FROM - ASG INDUSTRIES, INC.—'f
KINGSPORT, TENNESSEE
EPA Total Volatile Suspended Oil &
Discharge Stn. Flow Solids Solids Solids TOC BOD TKN NO^-N Grease Phenolics
Number No. mgd nig/1 mg/1 nig/1 mg/1 mg/1 mg/1 mg/1 mg/1 mg/1
001 39 0.37 296 59 140 11.2 4 0.84 0.8 0.004
002 37 0.57 2,170 90 b / 11 2 0 1.6 0.02 22.5
a/ This data is from RAPP Application.
b/ The average suspended solids content of 002, in 1970, was 1,400 mg/1. Two 24-hr composite samples taken
on 2 and 3 June 1971 averaged 1,948 mg/1 suspended solids.
-------
5 p s i Air in
Return Line
D laphragm
y Pump
Valve
Cli
Wastewater
F i 11 r at e
Receiver
Streams
E-1
F i It r ate
Pump
V a c u u m
Pump
"\7
Filter Cake to Landfill
r-Q
Overflow
O 57 MGD Settled
Edge
Fro
Settling Pit
Pu
and Glass
Washing
Operation (Sec Figure E-1 )
Eff lu
Fork
Ho Istor River
A SAMPLING STATIONS
Figure E-2. Wastewater Treatment Flow Diagram - ASG Industries
King sport, " cnnessee
-------
E-5
through the property of the Holston Army Ammunition Plant (Station 37).
At the time of the plant visit (10 November 1972) this stream had a deep
red color, lliph concentrations of phenolic materials have been reported
in this discharge [Table E—1]. Company officials indicated that the only
source of pheriolics was a floor-washing compound which they have
discontinued usina. Recent company data showed a phenolic content of
0.016 mg/1.
Samples of the clarifier influent and effluent and of the filtrate
are collected daily, and data on pH, suspended and settleable solids
are submitted to the State of Tennessee Stream Pollution Control
Division. The average monthly suspended solids data submitted by ASC.
Industries to the State of Tennessee Stream Pollution Control Division
are as follows.
TABLE E-2
ASG INDUSTRIES, INCORPORATED
FINAL r.FFLUENT-SUSPLNDED SOLIDS
KING5P0RT, TEUULSSEE
Suspended Solids
I
v—\
;=3
"jq
s-/
Month (1972)
Avg.
Max
Min
May
840
4,455
Tr
June
596
2,350
180
July
506
2,430
210
August
1,239
8,545
125
September
478
2,145
40
October
437
4,970
0
The wastewater from the plass-etchinoperation (hydrofluoric acid)
is, according to company officials, percolated over a limestone bed
before it joins other waste streams. However, this action is evidently
a/ Water sampled is final effluent, or Station 37 on EPA 1972 survey.
-------
E-6
not sufficient to neutralize the acid. On 9 and 10 June 1971, during
the etching operation, process effluent samples collected by Tennessee
Stream Pollution Control Division personnel indicated a pH of 3.2 and
an acidity of 550 rap/1.
The State, in 1968, recommended additional treatment for the
process stream, just mentioned, or replacement of the present system
with a lime or caustic neutralization system. Two years later, company
officials notified the State that the additional investment for neutral-
ization equipment was not justified because the demand for acid-trerf:.cd
glass is decreasing and that acid treatment would probably not be nec-
essary after 1975. At the time of the survey neutralization on lime-
stone was still being used.
Storm water is discharged through a sewer line owned by the
J. P. Stevens Company to which ASG has an easement. Sanitary wastes
are sent to the Kingsport municipal Wastewater Treatment Plant.
C. DISCUSSION OF STUDY FINDINGS
This industry was sampled at three locations for three consecutive
days from 30 November to 3 December 1972. The three sampling points
were: the clarifier influent (Station 3S); the effluent (after it
joined a washwater stream) at the point where it entered the property
of the Holston Army Ammunition Plant (Station 37); and the cooling-water
discharge in a manhole on HAAP property (Station 39). Using SF.PXO auto-
matic samplers, EPA personnel collected samples and composited them
on an equal-volume basis at the end of each 24-hr period.
-------
E-7
The cooling-water discharge (1.2 ragd) contained 460 lb/day suspended
solids and had an oil-and-grcase concentration ranging from 4-7 mg/1.
Samples of the clarificr influent (Station 38) taken during the survey
[Table E-3] had an average, suspended-solids concentration of 15,700 mg/1
while the level in the effluent waste stream was 843 mg/1 or 3,600 lb/day.
The influent contained 1S5 mg/1 of iron, and the effluent averaged
6.1 mg/1 (26 lb/day). The nil on this discharge ranged from 6.5-10.9;
the COD load averaged 179 lb/dav.
Jar tests wore performed on the influent wastewater to the clarifier
in order to determine solids-removal efficiency. The test involved the
use of two anionic polymers, a cationic polymer, and ferric sulfate and
alum as coagulants. The suspended-solids concentration of the influent
sample was 9,200 mg/1. The most effective coagulant for improving
suspended-solids removal was ferric sulfate at a dosage rate of 100 mg/1.
As a result, the suspended solids in the supernatant was reduced to
21 mg/1. Reducing the pll to 7.0, before the addition of ferric sulfate,
further improved the suspended-solids removal efficiency (14 mg/1 in the
supernantant). Alum was less effective than ferric sulfate. The
optimum dosage was 100 mg/1, leaving 58 ntg/1 suspended solids in the
supernatant and resulting in floe that was s^all and settled slowly.
A dosage of 0.5 mg/1 anionic polymer (A 23, Dow Chemical Co.) used
with either 100 mg/1 ferric sulfate or alun doubled the settling rate
and improved the removal of suspended solids even further. After only
five minutes, the concentratLons of suspended solids were 33 mg/1 with
ferric sulfate and 40 mg/1 with alum. With employment of these chemicals,
-------
w
I
00
TABLE E-3
SUMMARY OF FIELD MEASUREMENTS AND CHEMICAL DATA
ASC INDUSTRIES, INC.
KIXCSPORT, TENNESSEE
1-3 DECEMBER 1972
Station Number 37 33 . 39
1 a /
Station Description—
Effluent
Influent to
Clarifier
Cooling Water
(RM 142
.15/4.01)
(RM 142
.15/4.01)
b/
Para-neter—
Ranr.e
Average
Ranse
Average
Ran Re
Average
Flow (ngd)
0.47-0.55
0.52
0.50
0.94-1.47
1.21
pH (standard
units)
6.5-10.9
7.3-8.4
7.4-8.5
Temperature (
°C)
15.0-20.0
17.0-21.0
22.0-25.0
Conductivity
(vmhos/cm)
250-725
250-300
240-260
COD
40-42
41
TOC
10£?
Total Solids
879-1,370
1,123
228-434
312
Suspended Solids
599-1,050
843
13,200-17,000
15,700
25-66
47
Suspended Solids (lb/day)
3,600
66,000
460
Oil and Crease
N.D.—^
4-7
6
Phenols
<0.01-0.08
0.03
Copper
0.02-0.10
0.C5
Chromium
<0.01-0.03
0.02
N.D.
Iron
1.12-10.0
6.1
170-200
185
Manganese
0.24-0.30
0.27
Antimony
N.D.
Cobalt
N.D.
Floridc
0.76-0.94
0.83
a! See Appendix C. for Station Description.
W All values reported as rag7l, except where otherwise specified.
c/ This is based on one value,
d/ N.D. - None Detected.
-------
E-9
it is highly desirable to rapid-mix immediately following chemical addi-
tion and slow-mix for formation of a scttleable floe. Dumping coagulants
into the clarifier, as presently practiced at ASG, precludes adequate
mixing and prevents efficient coagulation.
According to the EPA interim Effluent Guidelines for the Cement,
Lime, Cypsum, and Asbestos and Flat-Glass Industries (dated 21 September
1972), a typical process and cooling-water stream for a plant of this
type would be about 0.1 mgd. Effluent limitations for the total plant
discharge are as follows:
lb/1,000 tons 3b/day Actual Load (lb/day)
Parameter glass produced (This Size Plant) Discharged Durinp Survey
Suspended 84 16.6 4,060
Solids
COD 84 16.6 179
The guidelines also recommend that no more than 4.2 lb each of hexane
extractables and total phosphorus be discharged, per 1,000 tons of glass.
The average suspended-solids load discharged during the survey
was more than 200 times the recommended limit; the COD was about 10
times the proposed load. Oil and grease was detected in the cooling-
water stream in a quantity greater than the guideline limitations. This
material should not be present in an uncontaminated cooling-water discharge.
The suspended solids in the cooling-water stream alone exceeded the
guideline limitations. The company should first segregate the washer
rinse \^ater from the cooling-water stream, then recirculate the cooling
water (after treatment, if it proves necessary).
The loads and flow rates proposed in these guidelines are based
-------
E-10
on the best practicable control technology currently available. They
employ maximum practical recirculation and re-use of cooling waters,
sedimentation, neutralization, and other control methods derived from
demonstration projects, pilot plants, and actual industrial use.
The guidelines propose that a 24-hr composite sample be collected
for COD, suspended solids, total phosphorus and hexane extractables
(oil and grease) every two weeks and that the flow be monitored con-
tinuously. It shall be considered a violation of the waste discharge
permit if the average analyses over any 20 working days exceeds the t
limitations or if any single composite sample exceeds these limits by
more than 50 percent. Four violations in any one single year will re-
quire an action memorandum from the Regional Administrator containing
recommendations on what action is to be taken. Any single violation of
the permit is grounds for its revocation. Implementation of this moni-
toring program is considered necessary to ensure adequate pollution
control and should be a requirement of the permit issued to this industry.
D. SUMMARY AND CONCLUSIONS
1. Jar tests performed on the influent wastewater to the ASG clari-
fier revealed that suspended-solids removal could be improved by the
addition of an anionic polymer and ferric sulfate and by maintaining the
ptl at 7.0. The present method of adding alun into the clnrifier feed
without proper mixing is not conducive to effective coagulation.
2. ASG Industries, Inc., discharged untreated wastewater and cooling
water (1.2 mgd) and treated wastewater (0.52 mgd) to the South Fork of
-------
E-ll
the Holston River. The average daily loads from these two discharges
contained A,060 lb of suspended solids and 179 lb of COD. The oil and
grease in the cooling-uater stream ranged from 4 to 7 mg/1 indicating
contamination. These loads are greatly in excess of those recommended
in the EPA interim Effluent Guidelines which, for a plant of this kind,
limit the loads to J 6.6 lb/day each of suspended solids and COD.
3. Additional treatment is necessary at ASG to meet the effluent
guidelines for suspended solids and COD. All wastewater^ need to be
segregated from uncontaminated cooling waters and conservation and \;iter
re-use must be practiced if the limits are to be met. Improved coagu-
lation methods will also aid in meeting the guidelines.
A. In the past (1968) ASG Industries has been advised by the
State to neutralise their process uaste stream with lime or caustic
when the glass-etching process is in operation. The company advised
the State in 19 70 that the additional investment involved was not
justified. No further action has been taken.
E. RECOMMENDATIONS
It is recommended that:
1. To meet the EPA interim Effluent Guidelines, based on the best
practicable control technology currently available, the total uasteload
discharged shall not exceed the following limits:
Parameter lb /day
Suspended Solids 16.6
COD 16.6
Hexane Extractables 2.1
(oil £< grease)
Total Phosphorus 2.1
-------
E-12
2. All additional effluent
of Tennessee shall be met.
3. A schedule and proposed
necessary pollution abatement be
1973.
requirements established by the State
method of treatment for achieving the
provided EPA, Region IV, by 15 October
-------
E-13
E-II. HOLLISTON MILLS, INCORPORATED
KINGSPORT, TENNESSEE
A. GENERAL
This mill, located about 12 miles west of Kingsport, is included
under the broad classification of textile manufacturing (SIC 22).
The major products of this plant are divided into two general
classes: starch (cornstarch)-filled book cloth (about 20 percent) and
plastic-covered bookcloth (approx. 80 percent), which can include
plastic on cloth; plastic on paper; and a combination of cloth and
paper. In addition to bookcloth other finished products are shade
cloth and various auto materials.
The finished product is manufactured at a rate of 250,000 yd/day.
The average weight of the starch r.loth is abcv.t ccven oz/yd vhcreas
plastic-coated products will average approximately eight oz/yd of which
an estimated 20 to 25 percent is plastic. The Holliston Mills plant
at Kingsport employs 550 people and operates 16 hr/day five days a week.
The normal process operations consist of subjecting cotton greige
goods to:
1. Starch Department Operations
a) Enzyme desizing with the cloth being held approximately
24 hr prior to enzyme removal
b) Washing with some washwater return back to desizing
c) Caustic scouring (four percent caustic solution for removal
of gums, oils, waxes, and final enzyme destruction)
d) Two-stage washing (supposedly with washwater return to
caustic scour)
e) Hypochlorite bleaching
-------
E-14
f) Neutralization of the hypochlorite solution by means of
bisulfite or equivalent.
g) Washing
h) Interim cloth storage
i) Water saturation of the cloth in continuously overflowing vats
j) Application of aqueous dyes and/or pigments to the cloth
(dyeing may also be combined with the sizing operations,
Step 11)
k) Sizing
2. Plastic Department Operations
a) Goods transferred from the starch department undergo the
addition of various plasticizers onto the polyvinyl-acetate-
starch filled cloth and papers
b) Auxiliary operations include pigment addition, differential
setting followed by further pigment addition giving an
over-printing or embossing effect
•k
A RAPP application was filed with the U.S. Army Corps of Engineers
on 25 June 1971. It lists one cooling-water outfall and one process outfall.
EPA and State of Tennessee personnel made a plant inspection on 10
November 1972. Ken Young, chief chemist, provided information and assis-
tance. An in-plant survey was conducted from 6 through 8 December 1972.
B. WASTE SOURCES AND TREATMENT
Water (approx. 1 mgd) is pumped from the Hols ton River and treated
with alum and a polymer (for coagulation/clarification), followed by
sand filtration. Of this volume of water, 0.83 mgd is used for cooling
* The Federal Water Pollution Control Act Amendments of 1972 stipulate
that the Refuse Act Permit application be processed through the
National Pollution Discharge Elimination System (NPDES).
-------
E-15
water, 0.12 mgd for boiler feed, and 0.05 for process water. An addi-
tional 0.01 mgd is purchased from a privately o\med company in Church
llill, Tennessee, and is employed for sanitary purposes.
Holliston Mills, Inc., has two discharpes (Stations 45 and 46).
All liquid wastes originate from the starch department operations. (The
company reported that the Dlastic department plant has been sealed off
from the sewer.) The starch plant wastes, together with plant sanitary
sewage and some cooling waters, arc collected and passed through biological
treatment works [Figure E—3] before being discharged (Station 46). The
waste-treatment processes consist of pll control, screening, primary and
secondary clarification, trickling filtration, and lagooning. The WWTP
was not fully operational until September 1972.
The wastewater enters the treatment works through a concrete channel
equipped with pH control and flow measurement. The flow is lifted by a
screw conveyor and falls vertically through a bar screen before entering
the primary clarifier where a pll of 6 to 8 is maintained. At the time of
the initial EPA visit, globules of starch were evident on the water surface
of the clarifier. Sludge from the primary clarifier proceeds to the
No. 1 half-acre lagoon and then to a two-acre lagoon. Overflow from the
latter passes directly to the river.
The primary effluent is cascaded down a large polyvinyl-chloride-
packed tower serving as a biological trickling filter. A portion of the
trickling-filter effluent is recirculated to the filter inlet; the re-
mainder goes to a secondary clarifier. Secondary sludge is returned to
the primary clarifier. Overflow from the secondary clarifier flows to
-------
E-16
the No. 2 half-acre lagoon that also discharges to the two-acre lagoon.
These lagoons (Nos. 1 and 2 and the two-acre lagoon) were intended
to serve as polishing ponds. However, the company reports that the
ponds are so badly loaded with solids that the waste concentration
actually increases between the points of pond inflow and outflow. The
company reported that the influent BOD to its WWTP averages 600 mg/1;
250 uig/1 leaves the secondary clarifier and the final effluent averages
400 mg/1.
Since 1968 the Holliston waste-treatment system has been the subject
of a research and development study partially funded by an EPA grant. The
system was completed in July 1972, but not considered fully operational
until September 1972. The last phase of the R&D project will be di-
rected to an evaluation of the overall treatment system. In addition,
the company is considering the installation of an enzyme digester to
convert primary sludge starches into sugars that would then be recycled
back to the primary clarifier. After three months of operation, only
minimum biological growth was observed on the trickling filter.
Water-treatment clarifier sludges and backwashes are discharged to
a drain that empties into Sevier Branch, a tributary of the Holston River
(Station 45). This discharge (about 0.3 mgd) contains boiler blowdown
and some floor washdown.
The company monitors the raw wastes and the lagoon influent on a
daily basis. Sludges leaving the primary clarifier and the lagoon ef-
fluent are monitored on a weekly basis. Test parameters include flow,
BOD, SS, pH, color, and alkalinity.
-------
PROCESS FLOW
FINISHED
PRODUCT
CAUSTIC
EXTRACT
DYE
WATER TREATMENT EACKWASH
SANITARY WASTES
pN CONTROL
FLOW
RECORDER
\ /
TO IIOLSTDN RIYEIt
MIXING
CHAMBER
SOLIDS TO
DISPOSAL
EXTERNAL TREATMENT
HO 1 LAGOOM
NO 2 LAGOON
PRIMARY
HO 3 LAGOON
FROM H0LSTON RIVER
HIGH RATE
TRICKLING
FILTER
TO HOLSTOH RIVER
A SAMPLING STATIONS
b— RAH MATERIALS OR PRODUCTS
WASTFWATER |OR AS LABELED)
SLUDGE
Figure E-3 Wastewater Treatment System Flow Oiagrara lioliiston Hills, Incorporated
Kmgsport, Tennessee
-------
E-17
At the time of the initial EPA visit, poor housekeeping practices
were observed. A major portion of the spent color pastes, which are
supposed to be collected in barrels, were entering the floor drains.
Mollis ton Mills has some degree of water re-use in the desize-wash-scour
department; generally, desize solutions and washes are wasted to floor
drains as are spent thin-starch solutions. Cooling waters are used on
a once-through basis and then discharged into the river. Cleaning rags,
residues particularly from cleanup in the plastics plant, are picked up
and taken to the company landfill (non-combustibles) or the incinerator.
The incinerator consists of two chambers. Exhaust smoke from the first
chamber is further combusted in the second compartment. The latter is
reported highly efficient, according to company officials. There is no
scrubbing of the incinerator stack emissions, and the bottom ash result-
ing from the combustion process is removed to the company landfill area.
C. PLANT EVALUATION AND FINDINGS
For three consecutive days EPA personnel sampled the cooling-water
discharge (Station 45), lagoon influent (Station 52), and the lagoon
effluent (Station 46). Hourly samples were collected by SERCO automatic
samplers and composited on an equalvolume basis after a 24-hr period.
Three grab samples, for analysis of oil and grease and of phenolics,
were manually collected over a four-to-six-hr period and composited on
an equal-volume basis. A single grab sample was taken for sulfide analysis.
The river water intake (Station 44) was also sampled for three days
with a SERCO automatic sampler and composited on an equal-volume basis
-------
E-18
after each 24-hr period. Temperature, pH, and conductivity measurements
were made at least three times per rday. [Appendix C: station descriptions
and locations.]
Flows at Stations 45 and 46 were obtained from flow recorders
installed at company weirs. Station 52 was equipped with a Parshall
flume and a continuous-flow recorder.
The cooling-water waste stream (Station 45) contained suspended
solids and BOD loads of 94 lb/day and 30 lb/day, respectively [Table
E-4], The flow averaged about 0.28 mgd, considerably less than the
0.83 mgd reported by the Company personnel. While the concentration of
BOD remained essentially the same as the raw intake water [13 mg/1 vs
11 mg/1) the average concentrations of suspended solids increased from
19 mg/1 to 40 mg/1, total Kjeldahl-nitrogen increased from less than
0.7 mg/1 to 1.4 mg/1, total phosphorus increased from 0.2 mg/1 to
1.2 mg/1, and sulfate increased from 27 mg/1 to 66 mg/1, thus indicating
that the cooling-water was being contaminated by process wastes. At the
time of the initial plant visit, yellow and orange pigments (containing
lead chromate) were being used in the plastic plant. According to company
officials, with only a few exceptions, use of lead chromate pigments was
to be discontinued in December 1972. During the survey the concentration
of chromium in this stream ranged from 0.13 to 0.16 mg/1, thus indicating
a possible reduction in the use of these pigments. Phenolic concentra-
tions ranging from 0.01 to 0.03 mg/1 were found during the survey, indi-
cating that the plastics-coating area was probably completely enclosed
at the time.
-------
TABLE E-4
SUMMARY OF FIFLD MEASt^EYTWS AND CHEMICAL DATA
HOLLISTON KILLS IN'CO^PORATED
KINCSPCTT, TrNNPJSEC
6-8 DlCL^'ZR 19 72
Station Nu-sbcr 44 45 45 52
Station Inscription—^
Water
Intake
Cooling Water
Lrtp.oon
Effluent
Lagoon
Influent
(RM
130 0)
(RM 12 8 9/0
.7)
(
-------
E-20
Although the suspended-solids and sulfate loads of the lagoon influ-
ent were reduced by approxinately 20 and 41 percent, respectively, other
pollutant concentrations increased [Table E-4], Moreover, the influent
flow averaged 0.7 mgd, but the effluent averaged 0.6 mgd. The difference
in flows indicates excessive seepage from the lagoons.
The EPA interim Effluent Guidelines (22 September 1972) limit the
discharge from this type of mill to no more than six lb each of BOD and
suspended solids and 0.06 lb of sulfides per 1,000 lb of product per day
[Table E-5].
TABLE E-5
EPA INTERIM EFFLUENT LIMITATIONS
lb/day this
lb/1,000 lb prod. type plant lb/day at Ilolliston
BOD 6 700 1,970
SS 6 700 294
Chromium 0.03 3.5 0.73
Phenolics 0.03 3.5 0.1
Sulfides 0.06 7.0 221
Based on a production of 250,000 yd per day with an average weight of
7.5 oz/yd , the Ilolliston Mills discharge would be limited to a maximum
of 700 lb/day each of BOD and suspended solids and 7 lb/day of sulfide.
Currently the plant discharges a combined daily BOD load of 1,970 lb
and 221 lb of sulfides. The BOD discharged was approximately one half
of that reported in the RAPP application [Table E—6].
The 1969 F.-JQA survey concluded that, in order to maintain a minimum
* Company personnel had indicated, in the 10 November meeting, that con-
centrations of pollutants increased in passing through the lagoons.
-------
E-21
TABLE E-6
WASTEWATER DISCHARGED FROM HOLLISTON MILLS
DATA FROM R,\PP APPLICATION
25 JUNE 1971
Station No. 46 45
RAPP Discharge No. (001) (002)
Parameter mg/1 lb /day mg/1 lb /day
Daily Avg. Flow (mgd) 0.715 0.292
BOD 657 3,920 7.0 18.0
COD 1,896 11,320 14.0 35.0
Total Solids 2,560 15,300 506 1,230
Suspended Solids 144 860 55 134
Total Kjeldahl Nitrogen 15.8 94 15.4 37.6
Total Org-N 15.7 93.7
N03-N 0.49 2.92 1.5 3.66
NI13-N 1.07 6.38 13.4 32.8
Total Phosphorus 1.2 7.4 1.33 3.24
Alkalinity 779 4,650 85 207
Sulfate 148 883
•,'i
Phenolics 56 334
Vc
Chromium <200
-------
E-22
concentration of 3.0 mg/1 DO in the Holston River, the maximum BOD load
discharged from the Company should be limited to a maximum of 260 lb/day.
However, to maintain a minimum of 5.0 mg/1 DO, the official standard, in
the river, the maximum BOD discharge should not be greater than 150 lb/day.
The current wastewater-treatnent facility is not providing adequate treat-
ment to protect the water quality. Additional treatment measures, en-
ploying, as a minimum, best practicable control technology, are
necessary to reduce the pollutant loads. Monitoring of all discharges
and river water must be done on a continual basis to ensure that good
river water quality conditions are maintained.
D. SUMMARY AND CONCLUSIONS
1. Jlolliston Mills discharges cooling water containing a BOD and
suspended-solids load of 30 lb/day and 94 lb/day, respectively. The
average flow, 0.28 mgd, was considerably less than the 0.83 mgd reported
by the Company. While the concentration of BOD remained essentially the
same as the raw intake water, increases in the concentrations from back-
ground levels of suspended solids (19 mg/1 to 40 mg/1), total Kjeldah
nitrogen (0.7 mg/1 to 1.4 mg/1), total phosphorus (0.2 mg/1 to 1.2 mg/1),
and sulfate (27 mg/1 to 66 mg/1) indicated that the cooling-water was
being contaminated by process wastewater.
2. Process wastewater is treated prior to discharge. The influent
flow to the wastewater lagoon averaged 0.7 mgd and the effluent flow
averaged 0.6 mgd, thus demonstrating that excessive exfiltration from
the lagoon bottom was occurring. The suspended solids and sulfates in
-------
E-23
the polishing lagoon influent were reduced by 20 and 41 percent, respec-
tively. However, all other concentrations of pollutants increased or
remained essentially the same before discharge. The treatment system
was not performing efficiently.
3. The effluent from the lagoon contained a total load of 1,940 lb
BOD/day, 200 lb suspended solids/day, and 221 lb sulfide/day. The EPA
interim Effluent Guidelines limit the discharges of BOD and suspended
solids to 700 lb/day each and sulfide to 7 lb/day. However, the 1969
PWQA study concluded that, in order to maintain a minimum DO concen-
tration of 3.0 mg/1 in the Holston River, the maximum BOD discharge
from Holliston Mills should not exceed 260 lb/day. To maintain a minimum
DO concentration of 5.0 mg/1, the maximum BOD discharged should not be
greater than 150 lb/day.
E. RECOMMENDATIONS
It is recommended that:
1. To maintain a minimum concentration of 5.0 mg/1 DO in the
Holston River, the BOD in the effluent shall not exceed 150 lb/day.
The suspended solids shall not exceed 150 lb/day above background
levels. Chromium and phenolics, each shall not exceed 3.5 lb/day,
and sulfide shall not exceed 7.0 lb/day.
2. All additional effluent requirements established by the State
of Tennessee shall be met.
3. The cooling-water and process-wastewater streams shall be
segregated.
-------
E-24
4. llolliston Mills, Inc., in its manufacturing processes, shall
incorporate more in-plant control measures, re-use of cooling water,
and improved housekeeping in order to prevent solvents, sizing agents,
dyes, pigments, plastics, and other contaminants from entering the wasteuate
system.
5. A schedule and proposed method of treatment for achieving the
necessary pollution abatement be provided EPA, Region IV, by 15 October
1973.
-------
E-25
E-III. J. P. STEVENS AND COMPANY„ INC.
KINGSPORT, TENNESSEE
A. GENERAL
The J. P. Stevens Borden Plant was built in 1924. This facility
converts approximately 54,000 lb/day of baled cotton into greige cotton
(untreated condition, just as it comes from the loom) fabric by carding,
spinning, and weaving. After spinning and prior to weaving, approxi-
mately 50 percent of the yarn (warp) is sized with a 14-percent corn-
starch solution. The plant operates 24 hr/day, six days a v7eek, and
employs 700 people.
A RAPP" application has not been filed because all wastewater flows
into the municipal sewer system.
EPA personnel conducted an interview of plant personnel on 9 November
1972. J. Marshall Beck, plant manager, provided information and assistance.
The plant wastewater was sampled 1-2 December 1972.
B. WASTE SOURCES AND TREATMENT
The company purchases all of its water, 43,000 gpd, from the City
of Kingsport. Most of the water is used as once-through, non-contact
cooling water and for spray humidity control. Process water is recycled
and re-used. A cooling tower for th'e chilled air conditioning system
is used during the sunmcr season (5-6 nonths/year).
All wastes, including storm drainage, cooling tower blow down, and
approximately 50 gal. of process rinse water (10-15 percent cornstarch,
dumped once per week) is discharged to the Kingsport 'IUTP.
A The Federal Uater Pollution Control Act Amendments of 1972 provide
that the Refuse Act permit applications be processed through the
National Pollutant Discharge Himination System (NPDES).
-------
E-26
C. PLANT EVALUATION AND FINDINGS
On 1 December 1972, Rhodamine UT 20 Dye was mixed with the company
effluent at the last manhole on the prenises before entering the municipal
sewer. Forty-five minutes later the dye was observed in the discharge
from a 36-in. outfall to the South Fork of the Holston River (Station 40 -
RM 142.15/4.3). This outfall line carries excess storm water that
originates on company property. Mr. Beck was informed of the discharge,
and he contacted City of Kingsport officials. Trash and debris had
blocked the interceptor line and diverted the flow to the river. This
material was removed by City personnel on 6 December 1972, 6 days after
by-passing was determined.
Samples of the wastewater at Station 40 were collected manually
every two hr for 14 hr, beginning at 1600 hr on 1 December, and for
24 hr, beginning at 0800 hr on 2 December 1972. These samples were
composited continually on an equal-volume basis during each sampling
period. Temperature, pH, and conductivity were measured each time
samples were collected. Instantaneous flows were measured every two
hr with a Marsh-McBirney electromagnetic current meter. [Chemical
data and field measurements are summarized in Table E-7.]
The average flow was 1.3 mgd. However, the discharge included
domestic waste flows from residential areas. The BOD and suspended-
solids levels were 58 and 43 mg/1, respectively. The characteristics
of the waste indicate that the discharge was domestic in nature.
-------
E-27
TABLE E-7
SUMMARY OF FIELD MEASUREMENTS AND CHEMICAL DATA
J. P. STEVKIIS AMD COMPANY, INC.
ICIHGSPORT, TENHESSEE
1-2 DECEMBER 1<)72
Station Number and Description—
40 - Outfall
Pipe (RM 142
:i5'/4.30)
Date Sawnled 1
December
2 December
Average
» i b/
Parameter-
Flow (mc-.d) —
1.30
1.26
1.28
pll (standard units) , ran^e
6.5-7.0
6.2-7.3
6.2-7.3
Temperature (°C), range
20.0-21.0
13.0-23.0
18.0-23.0
Conductivity (ymhos/cm) , range
340-440
320-580
320-580
BOD
48
76
58
COD
72
127
100
TOC
18
29
24
Total Solids
306
339
322
Suspended Solids
37
48
43
Total Kjeldahl Kitropen-M
9.8
7.6
8.7
rnu-ti
3.4
3.3
3.4
M09 + KO^-IJ
0.3
0.4
0.4
TuLtii rnospnorus-iJ
3.3
6.6
5.0
a./ See Appendix C for Station Description.
b/ All values reported as mg/1, except where otherwise specified.
cj This discharge includes wastewater from residential areas. The flow
fron J. P. Stevens alone has been reported as 0.043 mgd.
-------
E-28
D. SUMMARY AND CONCLUSIONS
1. The J. P. Stevens Borden Plant discharges all wastewater to
the Kingsport WWTP. However, during the survey, wastewater was
overflowing to the South Fork of the llolston River because of a
blocked interceptor line which was subsequently cleaned.
2. The occurrence of by-passing because of plugged sewers empha-
size the need for development of a City maintenance program to provide
routine inspection, cleaning, and repair on the sewerage system.
-------
E-29
E-IV. KINGSPORT MUNICIPAL WASTEWATER TREATMENT PLANT
KINGSPORT, TENNESSEE
A. GENERAL
The Kingsport plant, located on Industry Drive adjacent to
Reedy Creek [Figure IV-1], discharges to the South Fork of the
Holston River (RIl 2.16). The residential population served is about
24,000. However, at the present tine this treatment plant also serves
a working force of approximately 34,000 persons during the week. In
addition to donestic wastes, the industrial waste sources discharging
to the Kingsport WJTP include; the Slip-Not Belt Company (tanning firm),
J. P. Stevens Borden Plant (processor of cotton goods), and the Kingsport
Press Company. According to WUTP personnel, sanitary wastes from the
Eaouia.i Gun^any (TEC) occasionally include spills of process
wastes which contain excessive floating and suspended solids and color.
[Table E-18 identifies TEC toxic compounds discharged to P^ino-sport UVTP.]
Treatment of community wastes commenced in 1957 with a primary
plant. The plant was upgraded in 1967 to a secondary facility with
single-stage, high rate trickling filters. Construction of this and
additional secondary treatment units was partially funded with Federal
assistance under Public Law 660 funds (Project No. IJPC-Tennessee-lSS).
Hie plant was designed for a flow of 6.5 ngd and an organic load equi-
valent of a population of 65,000. The average influent flow to the
plant is 6.59 mgd, with a BOD load of about 10,400 lb/day. Currently
the plant is manned 18/hr/day, seven days per week, by four operators.
An addi-tional operator is on call at all tines.
Information and assistance was provided by Rob Collins, plant
-------
E-30
superintendent, and Lamar Dunn, sanitary engineer of the Tennessee State
Board of Health.
B. WASTE-TREATMENT FACILITIES
All raw wastes receive preliminary treatment that consists of
screening, grit removal (two grit chambers in parallel, each 5 ft wide
by 43 ft long), and pre-chlorination for odor control at the main pump
station located on the north side of Reedy Creek [Figure E-4]. The bar
screens are manually cleaned, and grit is removed mechanically. Screenings
and grit are hauled to a sanitary landfill. Wastewater is pumped u*dor
Reedy Creek to the main plant site. Treatment facilities include:
Primary sedimentation
High-rate trickling filters
Secondary clarification
two basins: each 40 ft wide,
120 ft long, 10 1/2 ft deep
two circular filters: each
two basins: each 80 ft wide,
110 ft long, 10 1/2 ft deep
Final disinfection basin one contact chanber: 47 ft
(continuous gas application wide, 59 ft long, 7 1/2 ft
maintaining a 0.4-mg/l deep; and one gas chlorinator
chlorine residual in the at 500 lb/hr
effluent to the South Fork
of the Holston River)
Solids handling
a. Sludge thiclcner - -- -- -- 12 ft dia. and 15 ft deep
b. Anaerobic digesters ----- two each, 75 ft dia. and 26 ft deep
c. Holding ponds -------- two in series with 1-acre
total surface area
The effluent from the secondary clarifier is continuously recirculated
so that the trickling filters arc operated at their maximum hydraulic
capacity (13.5 mgd) thus minimizing the effects of shock loads in the
-------
RAW WASTEWATER
DIGESTER SUPERHATAMT
MAIN LIFT
STATION AMD
GRIT
CHAMBERS
BY PASS TO
SOUTH FORK
HOLSTOH
RIVER
PRIMARY
DIGESTER
SECONDARY
DIGESTER
26' DEEP
26' DEEP
RETURN SECONDARY SLUDGE
THICKENED SLUDGE
—a-
THICKENER OVERFLOW
— —|
PRIMARY SLUDGE
WASTE SECONDARY
SLUD6E
PRIMARY
CLARIFIER
PRIMARY
CLARIFIER
LAGOON GVERKOU
SLUDGE LAGOON
1/4 ACRE
TRICKLING
FILTER
13 6 "4>x 6'
TRICKLING
FILTER
13 6 '<$>* 6'
SLUDGE LAGOON
3/4 ACRE
FINAL
CLARIFIER
FINAL
CLARIFIER
8O'* 11O'x1O 5'
8 0 ' * 110'x10 5'
CHLORIHE CONTACT
CHAMBER
FINAL EFFLUENT TO
SOUTH FORK HOLSTOH RIVER
Figure E-4. Flow Diagram—Kingsport Municipal Wastewater Treatment Plant
Kmgsport, Tennessee
-------
E-31
plant influent. Primary sludge and a portion of the secondary settled
sludge is pumped to the sludge thickener. The remainder of the secondary
sludge is returned to the primary clarifiers. Sludge underflow from the
thickener is discharged to the primary digester; the thickener overflow
is returned to the primary clarifiers. Two stage anaerobic digestion
is provided. The digested sludge is discharged to sludge lagoons for
long-term storage. Digester supernatant and sludge lagoon overflow is
returned to the primary clarifier. The lagoons have been in operation
for two years, and the City anticipates an additional two years of use.
c• plaht OPERATION AND MAINTENANCE
Mr. Collins is a Class A (certified by State of Tennessee) operator
and supervises one chief operator (with a Class A State certification)
wlii.operators. I'art-tine student help is available
in the summer. Mr. Collins divides his time equally between the WiJTP
and the water treatment plant. In the case of an emergency or critical
manpower needs, help is available from the water treatment plant. Plant
personnel work nine-hr shifts. Two operators are present during the day
and one at night; the plant is unattended from midnight to 6:00 a.m.
In 1971 plant operation and maintenance costs were $48,775. [Tables
li-8 and E-9 list the routine operation and maintenance procedures followed
by plant personnel. Table E-10 lists the analyses performed on the waste-
water.] With one exception all laboratory analyses are performed at the
plant laboratory: the coliforn bacteria analyses are performed at the
* The five-man staff docs not meet the minimum qualifications established
in the Federal guidelines for wastewater treatment plants.
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E-32
TABLE E-8
OPERATION AND MAINTENANCE PROCEDURES
KINGSPORT MUNICIPAL WASTEWATER TREATMENT PLANT
FIRST-SHIFT SCHEDULE
1. Check entire plant for possible problems and go through the daily
check list [Table E-9].
2. Correct any operating difficulties and clean up any unexpected messes,
such as those from defective packing.
Monday Pick up trash along Industry Drive. During mowing season
mow around the tight spots that are not easily mowed with
the large mower. This mowing is to be down whether it is
needed or not. Clear any weeds between the two buildings
across the creek in the dirt fills. Sweep porches, walk-
ways, steps etc. at all buildings.
Tuesday Grease and/or oil, all basin collectors, screens, grinders,
drive chains, idlers, scum troughs, recycle troughs, grit
collectors, etc. Clean trickling-filter arms and grease
(one at a time). Replace any burned out light bulbs.
Wednesday Give all five piston pumps a thorough cleaning after re-
placing, adding or adjusting packing.
Thursday Clean digester building thoroughly. This includes a com-
plete dusting.
Friday Scour and paint day — pick out pieces of equipment to
scour and paint such as final sludge pumps, recycle pumps,
circulating pumps, or gas relief valves.
Saturday Run grit and clean completely the buildings across Reedy
Creek and wash-down c£ the wet well, removing all rags
and accumulations on the screens and grit collectors in
the basement.
Sunday Clean the chlorine building, final pump house, and the
primary pump house.
SECOND-SHIFT SCHEDULE
1. Skim, change baskets, hose down, keep baskets in repair.
2. Perform lab work, enter all results.
-------
E-33
SECOND SHIFT SCHEDULE (Cont.)
3. Grind.
4. Clean office building daily, include work shop, porches, walks
windows and without fail thoroughly clean the urinal, commode,
and wash basin.
5. Record septic tank tickets.
6. Check entire plant and take care of any operating difficulties.
-------
E-34
TABLE E-9
DAILY PLANT CHECK LIST
KINGSPORT MUNICIPAL WASTEWATER TREATMENT PLANT
PUMP HOUSE BUILDING ACROSS REEDY CREEK
1. If grinding is to be done, do this first to allow the grinders to
clear themselves while checking the rest of the buildings.
2. Check shear pins and limit switches,
3. Rotate pumps.
A. Check water seal.
5. Check pumps for unusual noise, packing problems, stopping drain
holes, an unusual amount of water on glands.
6. Make sure sump pump is working properly.
DIGESTER BUILDINGS
1. Record digester level.
2. Record digester temperature.
3. Drain drip traps in valve room.
A. If supernatant is being removed, check for stoppage.
5. Check heaters.
6. Start thickener nump to see if it is stopped up.
7. See if thickener is turning, level o.k.? Sludge level too high?
Record torque and hose down thickener.
8. Check sump pump.
9. Make sure circulating pumps are pumping by check valve rise and
that the packing does not need attention.
10. Check piston pump operation and add oil to oilers.
11. Drain drip traps.
12. Record gas meter reading.
13. Light gas burners if needed.
CHLORINE BUILDING
1. Make sure no chlorine is leaking. If leak is in evidence, shut off
chlorine and repair immediately. For safety, leave the valve wrench
on the cyclinder which is being emptied,
2. Are machines feeding?
3. Record scale reading and decide if cylinder change is desired before
morning.
FINAL PUMP STATION
1. Check chart for proper operation of the raw and recycle pumps. If
electrode operation of raw pumps is faulty, the electrodes should
be cleaned without undue delay.
2. Change flow chart and record total flow reading.
-------
E-35
FINAL PUMP STATION (Cont.)
3. Check compressors for faulty operation.
4. Shut off sample pump for backf]ushing after setting up for chlorine
test. Change sample jars, place sampler back in operation, clean
dipper, pour out dirty water and record chlorine reading.
PRIMARY PUMP STATION
1. Operate each sludge pump to see if each will raise the check valve.
2. Shut off flow to the sampler and open the by-pass on the second
sampler to flush the line. Replace the sample -jars with clean ones,
place samplers back in operation, clean dippers rinse, and pour
out rinse water.
3. Check water seal units, packing on sludge pumps, drainage.
4. Sump pump operation.
5. Store samples in refrigerator.
OFFICE
1. Make entrees on the monthly report sheet.
2. Remove dry dishes from the drying oven so that they will be ready
for weighing.
-------
TABLE E-10
KINGSPORT MUNICIPAL WASTEWATER TREATMENT PLANT
FREQUENCY OF LABORATORY ANALYSES
SAMPLING LOCATION AND NUMBER OF SAMPLES ANALYZED PER WEEK
Parameter
Raw
Wastewater
Primary
Effluent
Final
Effluent
Digester
Supernatant
Digested
Sludp,e
Receiving
Stream
BOD
7-
7
7
1
Suspended Solids
7
7
7
1
Settleable Solids
7
7
7
1
Dissolved Oxygen
7
7
7
1
Total Solids
7
7
7
1
pH
7
7
7
7
1
Temperature
7
7
7
1
Coliform Density
1
1
Residual Chlorine
7
Volatile Acids
7
Alkalinity
7
a/ Where seven analyses are made per
week, one
analysis is
made each day.
-------
E-37
Sullivan County Health Department Laboratory. Industrial waste sources
are not sampled because the staff cannot handle this additional work load.
D. DISCUSSION
The Kingsport WWTP was not sampled during the survey because of
hydraulic overloading due to combined sewers; the plant was by-passing
to the South For): of the Ilolston River. The by-passing commenced about
0700 hr, 10 December, and continued until about 1300 hr, 14 December.
The influent and effluent data collected during this period would not
be representative of plant operations under dry-weather flow.
A summary of plant records, for the period of November 1971 through
November 1972, for waste removals at the plant indicate that:
a) influent BOD was reduced by about 70 percent; and
b) influent suspended solids (SS) were reduced by 74 percent.
The average effluent BOD and suspended-solids levels were 57 mg/1
(3,130 lb/day) and 36 mg/1 (2,190 lb/day), respectively, which does
not meet the requirements of secondary treatment that have been proposed
i:
pursuant to the Federal Water Pollution Control Act Amendments of 1972.
The 1969 FWQA survey measured an average effluent BOD and SS load of
500 lb/day and 440 lb/day, respectively. To ensure that the water-
quality criteria established by the State of Tennessee for the Holston
River and the South Fork of the Ilolston River be maintained and that
the DO concentration in the receiving waters be maintained at 3.0 mg/1,
the 1969 report recommended the Kingsport WWTP effluent not exceed
* The EPA is currently proposing to limit NOD and SS, in the effluent, to
a monthly average of 30 rng/1 and to a weekly average of 45 mp./l, or
85 percent overall reduction, whichever produces better quality effluent.
-------
E-38
900 lb/day BOD. However, to maintain the official standard of 5.0 mg/1
minimum DO, the effluent should not exceed 500 lb BOD/day.
Uith the current practice of recirculating secondary-clarifier
overflow the overflow rate from the secondary clarifiers, at 13.5 mgd
2
flow, is 770 gpd/ft . If the flow was recirculated to the filters before
secondary clarification, the overflow rate, at 6.59 mgd (average daily
2
flow), would be 380 gpd/ft . This lower overflow rate would be expected
to reduce the BOD and suspended solids in the final effluent.
The wet-weather flow is almost double the dry-weather flow. [Table
E-ll lists the average monthly data selected for the high- and low-flow
months, from November 1971 Lo November 1972,]
TABLE E-ll
PLANT PERFORMANCE DATA FOR HIGH
AND LOtf-FLOT7 MOUTHS, NOV. '71-NOV. '72
KINGSPORT WASTEWATER TREATMENT PLANT
KINGSPORT, TENNESSEE
Average
Monthly
Maximum-
Flow Month
April/1972
Minimum-
Flow Month
Nov./1971
Flow (mgd)
8.64
4.44
Settleable Solids (ml/1)
Influent
* 3-5
3.7
Effluent
T
T
% Removal
VL00
^100'
Suspended Solids (nv*/l)
Influent
178
166
Effluent
44
32
% Removal
75.2
80.7
BOD (mg/1)
Influent
145
192
Effluent
64
47
% Removal
55.8
75.6
* T indicates trace amounts present.
-------
E-39
By-passing to the South Fork of the Hols ton River occurs auto-
matically at the plant when the raw, wastewater flow exceeds 13 ra^d.
Sewer overflows also occur within the sewerage system when individual
sewers and lift stations exceed normal carrying capacity. The .larfjc
increase in the wet-weather flow is fron coiabined sewers. The City
has no plans to mitigate these problens.
Plant operational problems have occurred due to the wastes from
several industries connected to the City sewers — in particular,
Slip-Not Belt Company and TEC. Plant personnel reported toxic materials
and highly colored wastewaters from Slip-Not which together with larp,e
quantities of suspended and floating solids fron TEC have been respon-
sible for operational difficulties. The digesters became inoperative
in late 3971 and to flat-** rause of the ivalfunction has "lot been
identified. During the 1972 survey organic compounds were identified
in the TEC sanitary wastewaters [Section F.-VII]. These compounds nay
be toxic to biological treatment systems or pass through untreaLed.
Plant personnel are confident that overall plant performance would im-
prove if the City enforced its Industrial Uacte Ordinance No. 1539
[Appendix F], The ordinance requires piretreaUucnt of high organic and
suspended solids wastes (>300 mg/1 EOD, >350 ng/l SS and that toxic
substances (iron, copper, lead, zinc, etc.) be limited in quantity so
that the total contribution will not cause interferance in nornal plant
operations.
A sever maintenance program is necessary in the City of Kin^sport.
On one occasion during the survey, a blocked interceptor resulted in
industrial wastewaters (fror.i J. P. Stevens Company) and domestic raw
sewage to be by-passed directly to the river.
-------
E-40
E. SUMMARY AMD CONCLUSIONS
1. The Kingsport WUTP was not sampled because of hydraulic over-
loading due to the combined sewer flow. The plant by-passed raw sewage
and storm-water runoff to the South Fork of the Holston River during
the period 10 through 14 December 1972.
2. Plant records indicate that the BOD and suspended solids are
reduced by 70 percent and 74 percent, respectively, durinp normal op-
erating conditions. The effluent contained an average of 57 mg/1
<3,130 lb/day) BOD and 36 mg/1 (2,190 lb/day) suspended solids, which
does not meet the requirements for secondary treatment that have been
proposed pursuant to the 1972 Amendments to the Federal Water Pollution
Control Act. (EPA proposes to limit BOD and SS, in the effluent to a
monthly average of 30 mg/1 and to a weekly average of 45 mg/1, or
85 percent overall reduction, whichever produces better quality. This
level of treatment is beyond the capability of the plant.)
3. The 1969 FNQA survey recommended that the Kingsport Wastewater
Treatment Plant effluent not exceed 900 lb/day BOD (92 percent removal)
to ensure that a minimum of 3.0 mg/l of DO is maintained in the Holston
River and the South Fork of the Iiolston River. To maintain the official
standard of 5.0 mg/1 minimum DO, the effluent should not exceed 500 lb
BOD/day (95.5 percent removal).
In the interim, until adequate facilities are constructed, some
improvement in treatment could be realized by changing the method of
recirculation to the trickling filter and by enforcement of the City
industrial waste ordinance.
-------
E-41
F* recommendations
It is recommended that City officials be formally advised that:
1. In order to maintain a minimum concentration of 5.0 mg/1 DO
in the liolston River, the BOD in the effluent shall not exceed 500 lb/day,
and the suspended solids shall not exceed 500 lb/day. Additional effluent
requirements established by the State of Tennessee shall be met.
2. The fccal-colifom bacteria] density in the effluent shall not
exceed 200/100 ml, as a monthly average, and 400/100 ml, as a veekly
average.
3. The industrial waste ordinance for the City shall be modified
to meet the requirements for pretrcatment when published in accordance
with the Federal Water Pollution Control Act Amendments of 1972.
4. Corrective measures shall be taken to preclude the by-passing
of untreated wastes from the plant or within the sewerage system due
to excessive combined sewer flows, and a sewer maintenance program shall
be developed to routinely inspect, clean and repair sewers and thus
preclude direct by-passing resulting from plugged lines, etc.
5. A schedule and proposed method of treatment for achieving the
necessary pollution abatement be provided EPA, Region IV, by 15 October
1973.
-------
E-42
E-V. MEAD PAPERS, DIVISION OF MEAD CORPORATION
KIHGSPORT, TENNESSEE
A. GENERAL
Mead Papers (a division of the Mead Corporation) , an integrated
Kraft Mill, manufactures 250 tons/day of pulp by the hot soda process.
The raw materials include cord wood and wood chips (waste products from
saw mills, furniture manufacturers, etc.). Mead Papers also imports
about 40 tons/day of short fiber pulp fron the Mead plant in Chillicothe,
Ohio, and 200 tons/day of long fiber pulp from a plant in Brunswick,
t
Georgia, which is jointly owned by Mead and the Scott Paper Company. The
pulps are combined to produce abc>ut 460 tons/day of paper, half of which
is sold in rolls and half, in sheets, to the printing industry. Fillers,
used in the processes, include kaolin, calcium carbonate, titanium diox-
ide, copper silicate, and diatom^ceous earth. The plant operates contin-
uously and employs 1,075 people.
ft
A RAPP application, filed in December 1971, lists four storm-water
outfalls and one process wastewater outfall.
EPA personnel conducted an in-plant survey on 1 through 3 December
1972. George Clark, manager of quality assurance, provided information
and assistance.
B' UASTE SOURCES AND TREATMENT
The company pumps approximately 17.8 mgd of water from the South
Fork of the Holston. River and purchases an additional 0.26 mgd from the
* The 1972 Amendments stipulate that the Refuse Act permit applications
be processed through the National Pollutant Discharge Elimination
System (NPDES).
-------
E-43
City of Kingsport. Approximately 18 ngd is used as process water, and
the remainder for sanitary purposes.
Discharges to the river include flows from Che pulping, bleaching,
and paper-making operations, wastes from the water-treatnent plant
(including spent sulfuric acid and caustic regenerants from the deminer-
alizers) , and cooling water from two direct-contact condensers. (One
condenser is on the black-liquor evaporator and one is used to condense
the steam released when a pulp digester is blown down.) The flow in
these two condensers contributes about 10 percent of the total 130D
leaving the plant. In 1973 the conpar.y intends to replace these con-
densers with non-contact condensers.
Approxinately 17 mgd of the wastewater is treated in a 150-ft dia.
ri n-r-i n r>r (mmvfi CT-. rate: 960 gpd/sq ft) before combining with untreated
wastes, including water-treatment plant wastes [Figure K-5] . The combined
flow is discharged to the South Fork of the Ilolston River (RM 142,15/2,5)
(Station 41: RAPP Serial No. 001). The sludge from the clarifier is con-
centrated to 40 percent solids by centrifugation and hauled to a land-
fill on the plant property.
Data, submitted to the State of Tennessee for the period May-October
1972, showed that the clarifier effluent had the following characteristics:
Para-meter Range Average
BOD, mg/1 75-136 120
SS, nig 11 657-1 ,078 860
Color, color units 300-1,100 675
The company is constructing an aerated lagoon to treat clic wastewater
-------
E-44
leaving the clarifier. The lagoon is to have a surface area of 23 acres,
by 12 ft deep, and provide a five-day detention time. The lagoon will
be aerated using eight 60-hp surface aerators. There are no plans to
build a sedimentation unit for clarification of the lagoon effluent. The
predicted quality of the lagoon effluent, reported in the RAPF applica-
tion, is as follows:
Parameter
Concentration, mg/1
Load, lb/day
BOD
<42
<6,000
COD
<85
<12,000
SS
110
15,600
Total fijeldahl Nitrogen
10
1,420
Aluminum
4
570
Copper
<0.1
<15
Zinc
<0.2
<30
Phenolics
0.15
22
The stream of process wastes entering the river is dark brown in
color and has a significant amount of foam on the surface. The company
is planning to incorporate a de-foaming process and to instal] a sub-
merged diffuser effluent pipe across the river to improve the dispersion
of the wastes.
Spent cooking liquors arc evaporated and incinerated in order to
recover sodium carbonate and sodium hydroxide. Hy the use of lime (CaO)
the carbonate is then converted to caustic; the calcium carbonate formed
is filtered and oxidized, in a lime kiln, to calcium oxide.
Process wastes, previously discharged to a pond containing black
-------
LEGEND
A SAMPLING STATIONS
2 MGD
PLANT
SANITARY
WASTES TO
CITY OF
KINGSPORT
WOOD
HANDLING
NO. 2 PAPERMILL
EVAP LOSS
03 MGD CITY WATER SUPPLY
NO 1 PAPERMILL
g^EVAP
J LOSS
SOFTENER
PLANT
(BO ILER FEED
WATERS)
STEAM
POWER
PULP MILL
n
FLY ASH
EVAP LOSS
CAUSTIC IZ ING
FRESH
WATER
TREATM ENT
EVAPORATORS
EVAP LOSS
SLUDGE
TO LAND
D ISPOSAL
INORGANIC
LAGOON
WATER PLANT BY-PASS
AND BACKWASH
PRIMARY CLARIFIER
42
< J43
RIVERIWATER
STORM
17 5 MGD
SUPPLY 18 0 MGD
WATER
OVERFLOW
f. misToa
Figure E-5. Flow Diagram-^,lead Papers
Kingsport, Tennsssse
-------
E-45
liquor (the pond effluent being formerly RAPP Serial Number 004), have
been diverted to the industrial waste outfall (001). However, the pond
still receives storm runoff. The pond could discharge to the river
during wet weather through an overflow structure.
Sanitary wastes (0.2 mgd) are discharged to the Kingcport VWTP.
C. PLANT EVALUATION AND FTKDIKCS
The effluent from the clarifier and the waste stream joininp this
effluent were each sampled for three days with automatic samplers, sup-
<
plied by the Head Paper Company, and composited continually over a 24-hr
period. Three grab samples for oil-and-grease analysis were manually
collected daily over a 4-to-6-hr period and composited on an equal-
volume basis. The river intake water was sampled with SE11C0 automatic
samplers, and the samples composited on an equal-volume basis at the
end of 24 hr. Temperature, pU, and conductivity measurements were made
at least three tines per day. Effluent flows were obtained from the
company flow recorders installed at the 1'arshall flumes of Mead Papers.
[Chemical data and field measurements are summarized in Table E-12.]
The effluent from the clarifier (16.1 mgd) had an average BOD of
160 mg/1 and suspended solids of 226" mg/1. The suspended-solids con-
centration was considerably less than the values (860 mg/1) reported by
the company to the State; the E0D was within the reported range. The
pH ranged from 6.4 to 10.0.
The untreated waste stream had an average flow of 1.4 m^d and a pIT
range of 2.4 to 7.2. Because the waste stream combines with the clarifier
-------
K
I
¦fc-
CT\
TABLE E-12
SUMMARY 0? FIELD MEASUREMENTS AND CHEMICAL DATA
XEAD PAPERS, DIVISION' OF MEAD CORPORATION
KIXGSPORT, TENNESSEE
1-3 DECEMBER 1972
Station Nimber 41 42 43
Station Description^'
Clarlfier Effluent
Water Treatment Backvash
Water
Intake
(RM 142.15/2.5)
(RX 142.15/2.5)
(RM 142
.15/2.6)
Parameter^-'
Range Average
RariRe Averap,e
Ranjje
Average
Flow (mgd)
15.9-16.4 16.1
1.32-1.56 1.4
17.8^'
pH (standard unlt3>
6.4-10.0
2.4-7.2
6.3-7.9
Temperature (°C)
23.0-32.0
17.0-25.5
11.0-18.5
Conductivity (pmhos/cm)
1,000-1 400
160^- 160
280-1,650
160-240
BOD
2.6-6.3 4.3
5.3-7.1
6.2
BOD (lb/day)
21,500
_/ 51
920
COD
275-326 309
44—
TOC
114-120 118
8-12 10.0
4-6
5.3
Total Solids
1,110-1,180 1,150
362-393 380
140-158
151
Suspended Solids
214-246 226
93-120 102
3-35
16
Suspended Solids (lb/day)
, 30,300
3.3^
1,200
2,400
Total Kjeldahl Nltrogen-N
<0.5-0.5 <0.5
N.D.
Total Kjeldahl Nitrogen-N (lb/day)
/ 451
1.2—
kh ,-V
N.D.
N.D.
(lb/day)
164
N.D.-'
1.1#
NO- + NO.-N
0.8-0.9
0.8
SO + NO^-N (lb/day)
0.55^7
14.3
126
Total Phosphorus-P
0.29-0.32 0.3
0.07-0.17
0.12
Total Pnosohorus-P (lb/day)
75
17.8
Oil and Grease
2-6 4
1-3 2
af See Appendix C for Station Description.
b/ All values reported as iag/1, except vhere otherwise specified,
c/ Tlie flow was determined from RAPP application,
d/ All values are the same,
e/ This Is based on one value.
fj N.D. - None Detected.
-------
E-47
effluent, the low pll Is neutralized before discharge to the river. The
BOD and suspended solids averaged 4.3 ng/1 and 102 rag/1, respectively.
The combined daily vasteload discharged contained 21,600 lb of BOD
(148 mg/1), 31,500 lb of suspended solids (216 mg/1), and 451 lb of
total ICjeldahl-nitrogen (3.3 mg/1). These BOD and suspended-solids loads
are equivalent to 47 ]b and 63.5 lb/ton of product, respectively. During
the survey the waste stream to the river was dark brown in color and had
a significant amount of foam on the surface.
The 1969 FUQA study reported an effluent quality similar to that
observed in 1972. The BOD, suspended solids, and total ICjeldahl-nitrogen
measured 163, 160 and 2.9 mg/l, respectively. The quality of the back-
wash from the water-treatment plant was not measured during the 1969
survey.
As discussed previously, a 23-acre aerated lagoon (eight 60-hp
surface aerators) designed to treat the primary clarifier effluent was
under construction at the time of the 1972 survey. The company also plans
to install a defoaming process and construct a submerged diffuser across
the river to provide better distribution. The State of Tennessee orally
informed the company that the waste load must be reduced to 6,000 lb/day
maximum (13 lb/ton of product). However, the State has not established
an implementation date or put this requirement in writing. Officials
of Mead Papers indicated that, if the aerated lagoon performs as antici-
pated, the effluent will meet the 6,000 lb of BOD/dav requirement.
EPA interim Effluent Guidelines have been established for the pulp
and paper industry based on best practicable control technology. These
-------
E-48
effluent limitations require that the BOD and suspended solids not exceed
9 lb/ton of product each (28 mg/1 of each at present flow of 17.5 mgd).
However, these limits are not stringent enough for this plant. The 1969
study determined that in order to maintain a minimum concentration of
3.0 mg/1 of DO in the llolston River and to protect the receiving waters,
the BOD load should not exceed 2,000 lb/day (4.4 lb/ton of product). However,
to maintain a minimum concentration of 5.0 mg/1 of DO, the official
standard, the BOD in the effluent should not exceed 1,100 lb/day
(2.4 lb/ton). To reduce the BOD to this level would require additional
facilities.
D. SUMMARY AND CONCLUSIONS
1. Mead Papers, an integrated Kraft Mill, discharges approximately
17.5 mgd of process wastes containing 21,550 lb of BOD (39.9 lb/ton of
product), and containing 31,500 lb of suspended solids (68.5 lb/ton),
and 450 lb of total Kjeldahl-nitrogen to the South Fork of the llolston
River. The lagoon system under construction is designed on the basis
of meeting an effluent limit of 6,000 lb/day of BOD. The present system
might not meet requirements for best practicable treatment currently
available or the requirements of the water-quality standards. The 1969
study determined that in order to maintaine a minimum DO concentration
of 3.0 mg/1 in the Holston River, the BOD load must not exceed 2,000 lb/day
(4.4 lb/ton of product). To meet the existing standard of 5.0 mg/1 DO
the BOD in the effluent should not exceed 1,100 lb/day (2.4 lb/ton).
* The limit for Kraft pulping and manufacturing of bleached grades was
used for half the production, and the limit for manufacturing "fine"
paper from purchased pulp for the other half of production was used
in the calculation of this value.
-------
E-49
E. RE C OHMEIi D AT I ON S
It is recommended that:
1. To maintain a minimum concentration of 5.0 mg/1 DO in the Nolston
River, the BOD in the effluent shall not exceed 1,100 lb/day. The
suspended solids shall not exceed 1,100 lb/day above background levels;
the pH shall be within the range of 6.0 to 9.0 at all times.
2. All additional effluent regulations established by the Sate of
Tennessee shall be met.
3. The aerated lagoon under construction shall receive all process
wastes and there shall be no discharge of wastes from the vater-treatment
plant xtfithout adequate treatment.
4. The effluent structure from the black-liquor pond shall be
sealed, and all storm water be diverted around the lagoon so that the
contents of the pond are not released.
5. A schedule and proposed method of treatment for achieving the
necessary pollution abatement be provided to EPA, Region IV, by
15 October 1973.
-------
E-50
E-VI. T1IE PENN-DIXIE CEMENT CORPORATION
KINGSPORT, TENNESSEE
A. GENERAL
The Penn-Dixie Ceraent Corporation, Kingsport Plant, produces port-
land cement for local use (in the construction industry). The plant
[Figure E—6] operates continuously; 123 people are employed. Approximately
1,550 tons per day of limestone, shale, and sand are mixed with raw
water from the South Fork of the Hols ton River and ground to about
38 percent moisture. This mixture is calcinated at 2,700°F in a horizontal
kiln (500 ft long by 12 ft in dia.) to produce clinkers. The clinkers
are dry ground to produce an average of 940 tons per day of cement.
Limestone is hauled by rail from Virginia, shale is quarried locally,
and sand is purchased from North Carolina. Six million cu ft of gas
are required to run the kiln during the warn months. Ground coal is
used in the vjinter due to a shortage of gas.
•.v
A RAPP application has been submitted for the wastewater discharge
from the air-and-solids waste-treatment system. The State also granted
a discharge permit for a five-yr period that terminates 21 January
1974.
EPA personnel visited the plant on 10 through 12 December 1972.
Information and assistance \?as provided by A. J. Snyder, plant manager.
B. WASTE SOURCES AND TREATMENT
The Company reported that municipal water is used in the plant at
* The Federal Water Pollution Control Act Amendments of 1972 stipulate
that the Refuse Act permit applications be processed through the
National Pollutant Discharge Elimination System (NPDES).
-------
CENTER ST
HEAD PAPERS
SEE FIGURE E 7 FOB WASTEWATER
TREATMENT SYSTEM FlOW DIAGRAH
RIVER HATER
FROM INTAKE
PRECIPITATOR
EAS TROU
KILit STACK
DUST SLURRY TO K UM
PENH DIXIE CEMENT CORP
LAGOON
NOT TO SCALE
HOt-STON
Figure E-6 Plaat Layact-Penn line Cement Corporation
Kisgspsrt, Tenaessee
-N-
LEGEND
A SAMPLING STATIONS
-------
E-51
the rate of 0.4 mgd. About 3,500 gpd is employed for sanitary purposes
and discharged to the Kin^sport IJl.'TP. The remainder is used for external
cooling of process equipr.ent bearings, the kiln coal burner pipe, and
the ceraent.
Approximately 0.55 1:153d of water is pu;nped from the South Fork of
the llolston River. Most of this water, used for the vet p,rinding of raw
materials, evaporates in the kiln, llivcr water is soretines used for
cooling, but its poor quality makes it undesirable for this purpose.
There is no recyclinj3 of water within the plant. The second ma-jor use
of river water (approximately 0.25 m^d) is in the air-and-solids waste-
treatnent system [Figure E-7] described in the following paragraphs.
The high concentrations of soluble alkalis in the dust fron the
kiln electrostatic precipitator make it unsuitable for immediate recycle
to the kiln. The dust is, therefore, mixed with water in a slurry tank
(6 ft dia. by 6 ft deep) and pumped into a thickener tank (45 ft dia.
by 10 ft deep). Thickened solids (underflow) are returned to the kiln,
and the overflow is channeled into a carbonation tank.
Kiln stack flue gas, which has been scrubbed and compressed is
bubbled through the carbonation tank at a controlled rate in order to
lower the pll. The effluent from the carbonation tank flows to a clari-
fier (32 ft dia. by 12.5 ft deep). The clarificr effluent is recarbonated
to a pll of 7.8, before being discharged to the river [Figure E-6, Station 48].
The sludge is recycled to the thickener.
Under optLnum operating conditions 1,050 tons of precipitator dust
are treated per month. The thickener-tank influent solids have a
-------
E-52
90-percent moisture content, and the thickener sludge, returned to the
kiln, has a moisture content of 75 percent. If the thickener is down
or being cleaned, untreated wastewater flows to the river.
Penn-Dixie collects one grab sample of this discharge three days a
week and submits data on pll, total hardness, sodium, total and settleable
solids, sulfate, and turbidity to the Tennessee Stream Pollution Control
Division [Table E-13].
The second discharge from Penn-Dixie to the South Fork of the Holston
River is cooling water (Station 47). Tlie waste stream flows in an
open ditch through plant property, then, into a culvert, as it leaves
the property at the Industry Drive border. At the time of the plant
visit by EPA, company officials could not provide information on the
final disposition of this waste stream after it left plant property.
Therefore, during the survey, EPA personnel introduced Rhodamine
WT 20 dye into the cooling-water discharge. Thirty minutes later the
dye was observed discharging from a 36-in. concrete outfall (Station 47)
located between Penn-Dixie and Air Products, an industrial facility
adjacent to the Penn-Dixie plant. Penn-Dixie was informed that this
discharge would require a NPDES permit.
Presently, Penn-Dixie is applying for an EPA grant to develop a
pilot-plant project for pumping alkalai wastes to Mead Papers,
a company located close to the Tenn-Dixie plant. The plan calls for
these wastes to be used in decolorizing wastes from the pulping operation
at Mead. The resultant mixture will be settled, and the effluent used
-------
DUST FROM
KILN STACK
PRECIPITATOR
RIVER WATER
FROf/1 INTAKE
SLUDGE FROM CLARIFIER UNDERFLOW
SLURRY
TAfJK
CLAR IF IE R
DUST SLURRY
TO KILN-=*=
C2
CARBOIiATION
Cj
FIBAL EFFLUENT TO
SOUTH FORK, HOLSTON RIVER
TANKS
FLUE GAS (CO2)
CONTROL
VALVE
PROCESSED FLUE GAS FROM
Figure E-7. Wastewater Treatment System Flow Diagram-Penn-Oixie Cement Corporation
Kingsport, Tennessee
-------
TABLE E-13
DATA SUBMITTED TO THE STATE OF TENNESSEE DEPARTMENT OF PUBLIC HEaLTH
BY PENN—DIXIE CEMEI'T CORPORATION
J 972
Flov
1000 gpd
j^IL
Total
Hardness
CaC03
mg/1
Sodium
nig/l
Total
Solids
mg/l
Sulfate
mg/1
Turbidity
JTU
Settleable
Solids
ml/1
Way-
Average
Range
210
3-252
7.1-7.9
560
220-S90
274
0-465
8390
1120-11760
3760
450-5328
23
10-50
0.0
0.0
June
Average
Range
185
60-216
7.2-7,1
506
300-760
479
250-900
15059
8234-24708
4482
3690-5642
30
10-50
0.0
0.0
July
Average
Range
171
60-216
7.0-8.9
288
160-410
411
155-760
3938
2649-5107
34
10-50
0.0
0.0-0.2
August
Average
Range
174
72-202
7.2-8.6
292 785
160-470 165-1300
38801
6996-59760
4128
2315-5116
50
50
0.0
0.0
September
Average
Range
167
6C-180
7.1-8.1
480
230-1000
542
40-1000
22410
1212-39G36
3864
617-5294
37
20-50
0.0
0.0
October
Average
Range
173
72-216
6.8-8.8
464
170-750
4389
3225-5223
50
50
0.0
0.0
-------
E-54
for scrubbing SO^ out of the Mead stack gas. Then, all sludges from
the Mead Papers primary clarifier will be sent to Penn-Dixie for use
in the kiln. However, a final decision has not been made on this plan.
C. PLANT EVALUATION AND FINDINGS
The Penn-Dixie Cement Corporation was sampled for three days using
SERCO automatic samplers in order to collect hourly samples from the
two discharges and the intake water. The sanples were corvposited on an
equal-volume basis at the end of each 24-hour period. Grab samples for
oil and grease were collected manually three times a day over a 4-to-6 hr
period and composited on an equal-volume basis. Temperature, pH, and
conductivity were measured at least three times per day. Flows were
also measured by NFIC-D personnel. [Chemical data and field measurements
are summarized in Table E-14.]
The effluent (0.284 mgd) from the air-solids waste-treatment system
(Station 48) contained 62 lb/day of suspended solids. However, data
from the permit application and the data submitted by the company to
the Tennessee Department of Public Health disclose that the solids
concentration normally exceeds the levels found at the time of the
survey.
AIR-SOLIDS UASTEUATLR EFFLUENT DATA
RAPP
Application
22 June 1972
Slate of
Tennessee EPA Survey
May-Oct. 1972 10-12 Dec. 1972
Average flow, gpd
380,000
180,000
284,000
Total Solids, mg/1
8,120
2,120
756
Suspended Solids, mg/1
] 60
31
The discharge (Station 47) of cooling water (0.49 mgd) contained an
average of 1,750 lb of suspended solids/day, almost 30 times that observed
-------
TA3LE E-14
SUMMARY OF FIELD MEASUREMENT 5 AND CHEKICAL DATA
PENN-DIXIE CEMENT CORPORATION
KINGS PORT, TE.ranSSEE
6-8 DECEMBER 19 72
Station Nu-oer
47
48
49
3 I
Station Description—
Process Waste
and
Cooling Water
Cooling Water
Water Intake
(RM 142.
15/2.6)
(RM 142.15/2.
.7)
(RM 142.15/2.75)
b/
ParaTe tei~-
Ran <*e
Average
P.anr.e
Average
Ranpe Average
Flcw (ngd)
0.46-0.51
0.49
0.21-0.35
0.29
0.5^
pH (stancard units)
6.9-8.0
6.6-8.2
6.8-7.6
Te-iperature (°C)
14.5-24.5
14.0-19.0
13.0-15.0
Conductivity (ynhos/cm)
260-380
520-1,600
230-250
TOC
5-13
9
5-8
6
5-7 6
Total Solids
280-946
548
507-1,090
756
158-190 171
Suspended Solids
246-608
427
12-66
31
12-30 20
Suspended Solids (lb/day)
1,750
62
83
Oil rnd Grease
2-8
5
<1-6
2
Sulfate
23-26
25
212-500
289
23-26 25
t'ercury, ug/1
<0.1-0.1
<0.1
N.D.
N.D.
Copper
C.01-0.OS
0.04
<0.01-0.02
0.01
<0.01-0.03 0.01
Cnroml utn
M. D.—
<0.01-0.03
0.02
N.D.
Cadnium
N.D.
N.D.
N.D.
Lead
0.1-0.3
0.2
<0.1-0.1
<0.1
<0.1-0.1 <0.01
aj See Appendix C for Station Description.
b/ All values reported as mg/1, except where otherwise specified.
cj Data was supplied by the Company,
d/ N.D. - Hone Detected.
-------
E-56
in the air-scrubber discharge. As mentioned previously, no application
has been filed for a Refuse Act permit for this discharge.
The EPA interim Effluent Guidelines (dated 21 September 1972)
developed for the Cement, Lime, Gypsum, Asbestos, and Flat-Glass industries
suggest that the proces-waste stream from a plant of this type should
be about 0.135 mgd (27,000 gal/1,000 bbl production). This flow is
based upon minimum water use, its time of contact with lcachable substances,
and upon the elimination of frequent and unnecessary spillage, overflows,
and inefficient washing methods. With the best applicable control
technology currently available, the suspended solids load would be
35 lb/day (7 lb/1,000 bbl product). The company was discharging suspended
solids at a rate (362 lb/1,000 bbl) more than 50 times greater than that
stated in the Guidelines.
The guidelines propose that a 24-hr composite sample be taken
for COD and suspended solids every two weeks and that the f]ow be
monitored continuously. It shall be considered a violation of the waste-
discharge permit if the average analyses over any 20 working days exceed
the proposed limitations or if any single composite sample exceeds these
limits by more than 50 percent. Four violations in any one single
year will require an action memorandum from the Regional Administrator
containing recommendations on what action is to be taken. Any single
violation of the permit is grounds for revocation. Implementation of
the above sampling and monitoring program is considered necessary to
ensure adequate pollution control and should be a requirement of the
permit issued to this industry.
-------
E-57
D. SUMMARY AMD CONCLUSIONS
The Perm-Dixie Cement Corporation discharged a total of 0.78 in^d
wastewater to the south Fork of the Ilolston River through two outfalls.
The wastewater contained a daily average load of 1800 lb of suspended
solids, or more than 50 times the limit (35 lb/day for a plant of this
type) recommended jn the EPA interim Effluent Guidelines. Ninety-six
percent of this loading cane from a supposedly uncontarainatcd coolinp;
water discharge, for which no permit application had been filed.
To achieve effective pollution control water re-use and conser-
vation must be practiced; the source of suspended solids in the
cooling-water stream must be isolated and treated.
E. RECOMMENDATIONS
it is reconmendcd that:
1. To meet the EPA interim Effluent Guidelines, based on the
best practicable control technology currently available, the total
COD and suspended solids discharged shall each not exceed 35 lb/day.
Additional effluent requirements established by the State of Tennessee
shall be met.
2. A schedule and proposed method of treatment for achieving
the necessary pollution abatement be provided EPA, Region IV, by
15 October 1973.
-------
E-58
E-VII. TENNESSEE EASTMAN COMPANY
KINGSPORT, TENNESSEE
A. GENERAL
The Tennessee Eastman Company, a division of the Eastman Kodak
Company, is one of the largest chemical manufacturers in the United States
and makes more than 275 different chemical products (14,500,000 lb/day),
falling into three principal categories: plastics, fibers, and chemicals.
This firm is one of the principal manufacturers of polyester, acetate
and modacrylic fibers, and cellulose plastics in the country and also
holds an important position in the production of organic chemicals.
Intermediate materials for the Kodak photographic products, fibers,
chemicals, and plastics for sale to other manufacturers are produced
at this plant.
There are four additional subsidiaries of Eastman Kodak in Kingsport:
Eastman Chemical Products, Inc.; Eastman Chemical Inter-American, Ltd.;
Bays Mountain Construction Company; and the Hols ton Defense Corporation,
which operates the Holston Army Ammunition Plant for the U. S. Army.
In Kingsport the Tennessee Eastman plant, which operates continu-
ously and employs more than 14,000 people, is located on 415 acres; the
property [Figure E-8] includes part of Long Island, formed by a sluice in
the South Fork of the Holston River.
In October 19 72, J. A. Mitchell, executive vice-president; R. H.
Morrison, assistant works manager; J. C. Edwards, manager, Clean Environ-
ment Program; and W. V. Walls, Clean Environment Program staff member,
supplied EPA and State of Tennessee personnel preliminary information.
During the in-plant survey, 4 through 9 December 1972, Messrs. Edwards
-------
B LOG
209
A SAMPLING STATIONS
PA RSKALL FLUKE
HALES
BRANCH
SAMPLER
-N-
B L D e
106/
TENNESSEE EASTMAN
COMPANY COMPLEX
BLDE
250
, LIFT
STATION
7/
MULTIPLE DISCHARGES
FROM WITHIN
FLANT
WATER
INTAKE
HASTES TO TEC^
rBEATUEHT SYSTEM
)N LCKC ISLAND
BLDG
269
1HCINEBAT0BS
INCINERATOR
/ ASH PIT „
LONG ISLAND
SIUICE/SAHPLE R
{SEE FIGURE E S FOR DIAGRAM OF TEC
WASTEWATER TREATMENT SYSTEH LAYOUT)
RIVER
NOT TO SCALE
SLUICE
Figure E-8. SatnpliBg Stations - Tenaessee Eastman Company
KiRFSisrt. Tenses?!??
-------
E-59
and Walls provided close assistance and cooperation to the EPA personnel.
B. WASTE SOURCES AND TREATMENT
•k
According to the RAPP application, filed 30 June 1971, the plant
withdraws a total of 358 regd of water from the South Fork of the Holston
River at three separate locations and purchases 0.14 mgd from the City
of Kingsport. Approximately ten percent of the intake water is treated
by coagulation (alum and lime), sedimentation, and filtration. The water
is used for cooling purposes (336 mgd), boiler feed (3.7 mgd), process
water (16.8 mgd), and for other, miscellaneous purposes (1.1 mgd).
The company recently installed two cooling towers to recycle cooling
water and is considering the installation of additional towers in order
to reduce the volume of the intake water. Sanitary wastes (0.35 mgd)
are discharged to the municipal WWTP, and 1.7 mgd of water is lost through
evaporation. Company personnel reported that cooling water and waters
from roof and floor drains are discharged directly to the river. Process
wastewaters are treated prior to discharge. Waste streams discharged to
the river are described in the following sections. [Station numbers refer
to sampling locations described in Appendix C. Characteristics of the wastes
reported in the RAPP application are listed in Table E-15.]
Except for Station 15, all of the outfalls are equipped with auto-
matic samplers. Samples are collected every few seconds, continually
being composited on an equal-volume basis over a 24-hr period, and
* The Federal Water Pollution Control Act Amendments of 1972 stipulate
that the Refuse Act permit application be processed through the
National Pollutant Discharge Elimination System (NPDES).
-------
TABLE C-15 M
I
CHARACTERISTICS OF WASTEWATER DISCHARGED TO THE SOUTH FORK OF THE HOLSTON RIVER £
TFNNESSEF, EASTMAN COMPANY. KINCSPORT, TFNTiCSSFE °
(RFFORTED IN REFdSE ACT PEPJ1IT PROGRAM APPLICATION)
Scadon
RAPP
Serial
Flow
BOD
COD
ss
NH->-N
TKN
NOi-N
P
Nurijer
Sucber
ssid
op/1 lb/day
En r/ 1
lb/diy
np/1
lb/da/
mf./l
lb/dav
ns/1
lb/dav
ns/1
lb/day
ms/1
lb/day
12
001
297
4.5 10,200
13
32,100
21
51,900
1.1
2,500
0.96
2,400
0.19
470
0.02
50
14
004
7.2
23 1.500
124
ivfi!
19
1,100
0.79
60
1.01
98
0.18
10
0.04
4
15
008
0.2
7.8 13
17
28
24
40
0.19
0.3
1.3
2.2
0.27
0.45
0.06
0.1
17
002
9.4
141 11,600
449
35,000
400
31,500
99
7,800
134
10,400
4.4
340
6.9
540
19
003
0.09
200 156
226
180
38
30
1.0
0.81
2.1
1.6
0.21
0.16
0.25
0.2
22
005
4.5
6.2 200
15
600
31
1,200
0.27
10
0.9
30
0.48
20
0.10
4
2}
006
9.4
1.7 130
5
390
8
600
0.17
13
0.9
70
0.56
44
0.03
2
b/
007^
_36J
1.8 550
4.9
1,500
10
3,000
0.19
57
0.97
290
0.39
120
0.02
6
TOTAL
354.1
24,349
69,918
89,370
10,441
13,292
1,004
606
Co
Yn
N1
Cu
Zn
Oil
& Crenae
Phenola
eie/1 lb/day
tnp/1
lb/day
ns/1
lb/day
o?,/l
lb/day
oik/1
lb/day
=k/1
lb/day
n*/I
lb/day
12
001
95
230^
83
200
3.0
7.400
22
54
16
004
23
1
2.9
170
12
1
15
008
12
20
17
002
SO 6
57
4,400
6
5
93
7
5.6
440
28
2
19
003
5
4
3.7
3
22
005
222
8
27
1
3.9
150
23
006
27
2
3.4
270
9
1
b /
007—'
20
6
4.1
1,200
4
1
TOTAL
6
4,634
5
8
217
9,653
59
aj Values appear to have been alscalculated by Company officials,
b/ This ocaclon vao not sanpled.
cj Discharge So. 007 reported In RAPP application now contains otona water and groundwater infiltration.
-------
E-61
analyzed in the Tennessee Eastman laboratory- The company sends analyt-
ical results of the intake water, sluice discharge (Station 14), Hales
Branch (Station 12) and the aerated lagoon discharge (Station 17) to the
State of Tennessee Stream Pollutaion Contro] Division.
Station 12
A small stream, Hales Branch, enters the plant grounds and has a
flow of approximately 1 mgd. Cooling xjater from the entire plant,
sludges from the water treatment plant5 and some process water (report-
edly low in BOD) are discharged to the stream, all of which increases
the flow to 350 mgd. The rate of flow is continuously recorded, and a
composited sample is collected as the discharges pass over a weir into
the South Fork of the Holston River (RM 142.15/4.5).
Station 14
Wastewater from storm and floor drains located in the south-plant
area and a small amount of the water from the cooling towers is pumped
through two 36-in. lines under the South Fork of the Holston River and
discharges into the sluice (RM 142.15/5.5/4.3).
Station 15
Two rotary kiln incinerators and one coal-fired incinerator are
used to burn 130,000 lb/day of waste chemicals, sludges, and solid
wastes. A continuous flow of cooling water from the incinerators, joined
by an intermittent flow of water used to wash ashes out of the incin-
erator, discharges to a ditch that flows to a small lagoon. The lagoon
discharges through a submerged, 12-in. pipe to the South Fork of the
Holston River (KM 142.15/5.8).
-------
E-62
Station 17
Process wastes have been separated into two waste streams, one
containing high levels of suspended solids and one containing mostly
dissolved contaminants. Both waste streams are acidic.
The waste stream with a high concentration of suspended solids is
neutralized with limestone and pumped to a quiescent lagoon designated
Kit Bottom (28 acres, 120-day detention time). Solids are not removed
from the lagoon, and the company estimates that Kit Bottom has storage
capacity for another five years. When the lagoon becomes filled, another
site will be selected. The company stated that there have been no direct
discharges to the river in three years. The overflow is pumped to the
aerated lagoons described herein [Figure E-9].
The waste stream with the dissolved contaminants is neutralized
with lime and pumped from the lift station in Building 250 to two
aerated lagoons (having a total area of 20 acres, 5-day detention time,
operated in series) on Long Island equipped with forty-five 75-hp
aerators. Every five minutes a continuously recording Total Carbon
Analyzer samples the effluent stream from the Building 250 lift station.
If the total carbon concentration in six consecutive samples exceeds
800 mg/1, 80 percent of the flow is sent to the diversion basin. Later,
the flow is pumped to the aerated lagoons at a controlled rate in order
to minimize the effect of shock loads. Process wastes generated on Long
Island are pumped by the Long Island lift station to the aerated lagoons.
The effluent from the second aerated lagoon discharges intermit-
tently to the South Fork of the Holston River (RI1 142.15/3.5). An
-------
S°UTH
PUD LI BIDS 250
LIFT STATION
LAGOON E F FI u E N T
17 A
OUTLET
HO 1
0AERATION BASIN
1 1 6 75 lip
AERATORS]
HO 2
AERATION DASIH
|29 75 bp AERATORS]
A
TRANSFER
PUMP
DIVERSION
I BASIN
20 lnnT
rROt) BLDG 122
LIFT STATION
LONG ISLAND
LIFT
STATION
SETTLING
BASIN
MOT TO SCALE
HOLDING
BASIN
*/>
u, %
rt„y//
LCN6 ISLAND DRAIN
(RECEIVES RUNOFF AMD
HISC WASTES FROH
LOHG ISLAND]
LEGEND
SAMPLING STATIONS
Figure E-S Wastewater Treatment System Layout (Long Island and Kit Bottom]
Tennessee Eastnao Company
Hingsport, Tennessee
-------
E-63
electronically operated valve, activated when the lagoon reaches a
pre-set level, allows the effluent to discharge to a wet well and then
to the river.
Station 19
Surface runoff from Long Island and the overflow from the Long
Island lift station are discharged to the South Fork of the Holston
River (RI-1 142.15/4.5) via a ditch designated the Long Island Drain.
The flow is intermittent.
Station 22
The discharge from the 13th Street sewer outfall consists of storm
water, cooling water, floor and roof drainage, and some storm runoff
frcr^ ll.z Lincoln Street area of the City of Kingsport. Solids, collected
by air pollution equipment, are periodically flushed through the outfall.
The flow is discharged to the South Fork of the Holston River
(RM 142.15/5.2) through a 54-in. pipe.
Station 23
The 14th Street sewer, containing storm water, cooling water, and
floor and roof drainage, discharges to the South Fork of the Holston
River (RM 142.15/5.3) through a 60-in. pipe.
Currently, the company is completing the construction of a pilot
treatment facility to reduce the BOD discharged from the aerated lagoons
on Long Island (Station 17). Plans call for: the use of the aerated
lagoon as part of an activated sludge facility; a final clarifier to
-------
E-64
follow the aerated lagoons, with a portion of the solids to be returned
to the clarifier; and the excess solids to be aerobically digested. The
pilot plant is scheduled for start-up early in 1973 and is to be operated
for one year with engineering for the full-scale plant proceeding con-
currently.
C. PLANT EVALUATION AND FINDINGS
Samples were collected over a 24-hr period for each of five days
with automatic samplers at all locations; the exception was Station 16
(influent to Kit Bottom lagoon) where grab samples were collected man-
ually every two hr for a 24-hr period. All samples were composited on
an equal-volume basis. Three grab samples each for phenolic materials
and oil and grease were collected every two hr and composited over a
four-to-six hr period. Temperature, pH, and conductivity were measured
at least three times each day. Flows were obtained from existing company
flow recorders at Stations 12, 13, 14, 16, IS, 20, 21, and 24. NFIC-D
personnel measured the flows at Stations 15, 19, 22, and 23.
Discharges to the River
There are three sources of intake water, Buildings 63, 269, and 28.
Samples were collected upstream of the Tennessee Eastman Company outfalls
(Building 269, Station 24), and downstream from several company outfalls
(Building 63, Station 21) [Table E-16]. The BOD levels were 1.1 mg/1 and
1.6 mg/1, respectively; the suspended-solids concentrations were 14 mg/1
and 19 mg/1, respectively; and the nitrate-nitrite-nitrogen concentrations
were 1.0 mg/1 and 1.9 mg/1, respectively. The concentrations of other
-------
TABLE E-16
SUMMARY OF FIELD MEASUREMENTS AND CHEMICAL DATA
TENNESSEE EASTMA-I COMPANY
KINGSPORT, TENNESSEE
4-9 DECEMBER 1972
Station Number 21 24
fl/
Intake 63
Station Description—
Intake 269
(RM 142.15/4.
80)
(RM 142.15/5.
70)
- hf
Parameter-
Range
Average
Ranize
Average
Flow (mgd)
312.5-321.9
316.8
49.5-51.0
50.1
pll (standard units)
6.6-7.6
6.6-7.6
Temperature (°C)
10.0-12.5
9.0-13.0
Conductivity (umbos/cm)
220-270
200-260
BOD
0.5-2.6
1.6
0.5-1.6
1.1
BOD (lb/day)
4,220
452
TOC
1-9
4
1.0-5.0
3.0
Total Solids
99-186
129
81-221
127
Suspended Solids
2-43
19
6-26
14
Suspended Solids (lb/day)
48,800
N.D.—^
6,050
Total Kjeldahl Nitrogen-N
<0.5-0.8
<0.5
NH -N
<0.5
<0.5
N.D.
NO^ + NO -N
0.9-6.0
1.9
0.9-1.1
1.0
NO^ + NO^-N (lb/day)
5,100
396
Total Phosphorus-P
0.03-0.06
0.05
0.03-0.04
0.04
Total Phosphorus-P (lb/day)
137
15.6
Mercury, yg/1
<0.1-0.1
<0.1
<0.1-0.2
<0.1
Copper
0.01-0.03
0.02
<0.01-0.02
0.01
Chromium
<0.01-0.02
<0.01
<0.01-0.02
<0 .01
Manganese
0.03-0.06
0.04
0.02-0.03
0.03
Cadmium
N.D.
N.D.
Nickel
N.D.
N.D.
Zinc
0.03-0.05
0.03
0.04-0.05
Lead
<0.1-0.1
<0.1
N.D.
a./ See Appendix C for Station Description.
_b/ All values reported as mg/1, except where otherwise specified,
c/ N.D. - None Detected.
-------
E-66
constituents were not significant. Effluent guidelines for this industry
for discharges to receiving streams are being developed on the gross loads.
Therefore, the data reported herein has not been adjusted to reflect net
loads. [Chemical data and field measurements are summarized in Table E-17.-]
A waste-source evaluation and stream survey conducted in July 1969
revealed that waste discharges in the Kingsport area degraded the water
quality of the South Fork of the Kolston River and the Kolston River. At
the time of the survey the Tennessee Eastman Company was discharging ap-
proximately 69,300 lb of BOD; 16,100 lb of total Kjeldahl-nitrogen;
10,800 lb of NH^-K, 1,800 lb of total P, and 7,800 lb of suspended solids
daily to the South Fork. The BOD and TKN discharged comprised about 50
and 83 percent, respectively, of the total BOD and TKN loads discharged
from the waste sources evaluated. The 1969 report concluded that in order
to maintain a minimum concentration of 3.0 mg/1 DO in the Hols ton River,
the total pollution loads discharged within the Kingsport area should be
limited to a maximum of 14,040 lb BOD/day and 1,940 lb TKN/day, to prevent
further degradation of the receiving waters. The limits are equivalent
to a 92-percent reduction of BOD and TKN. It was also concluded that the
total Kjeldahl-nitrogen must be removed and not converted to nitrates
before discharge as the aquatic weed population would still increase from
assimilation of the nitrates. In addition, it was found that the temper-
ture of the South Fork of the Hols ton River was increased by more than
11.0°C by heated discharges from TEC and HAAP "A". It was concluded that
cooling devices would be necessary to preclude violations of the stream-
temperature standards for fish and aquatic life [Appendix A-Item 3(g)],
-------
TABLE E-17
SUMMARY OF FIELD MEASUREMENTS AND CHEMICAL DATA
DISCHARGES TO SOUTH FORK HOLSTON RIVER
TENNESSEE EASTMAN COMPANY-KINGSPORT, TENNESSEE
4-9 DECEMBER 1972
Station Nunber
12
14
15
17
a /
Station Description—
Hales
Branch
Sluice
Outfall
Incinerator Ash
Scrubber
Aerated Lagoon
Effluent
(RM 142
.15/4.50)
(RM 142
.15/4.50)
(RM 142.15/5
.60)
(RM 142.15/3
1.50)
b/
Paranater*-
Range
Averace
Range
Average
Range
Average
Range
Average
Flow (ngd)
306-317
311
5.8^
5.8
0.289-0.384
0.325
9.98-10.9
10.4
pH (standard units)
6.3-7.5
6.7-7.9
7.2-8.6
6.7-7.3
Temperature ("C)
22.5-25.0
17.0-23.5
16.0-21.5
13.5-19.0
Conductivity (umhos/cm)
240-340
200-260
200-280
1,400-4,000
BOD
3.2->9.1
>5.6
5.9-23
>11.0
7.5-15
>9.6
280-620
>400
BOD (lb/day)
>14,000
>526
>26
>35,100
COD
869-985
941
TOC
2.0-5.0
4.0
2.0-11.0
6.0
4.0-34.0
12.0
238-300
272
Total Solid3
83-172
136
67-201
154
82-374
197
3,340-3,640
3,480
Suspended Solids
4-31
12
6-14
10
4-26
12
410-820
648
Suspended Solids (lb/day)
30,800
484
N.D.—^
33
56,100
Total Kjeldahl Nitrogen-N
<0.5-0.5
<0.5
<0.5-0.5
<0.5
89-140
120
Total Kjeldahl Nitrogen-N (lb/day)
"
10,400
93
NH -N
N.D.
N.D.
N.D.
90-100
NH^-N (lb/day)
_ /
8,130
t.O, + MO -N
0.7-0.9
0.8
0.8-1.0
0.9
0.6-0.7
0.6
0.1-'
0.1
*50^ + NOj-N (lb/day)
2,070
43
Total Ph6sphorus-P
0.03-0.05
0.04
0.02-0.06
0.04
0.06-0.26
0.11
5.8-13
9.8
Total Phosphorus-P (lb/day)
109
840
Oil and Crease
<1-3
<1
1-10
6
2-10
6
Phenols
N.D.
0.6-1.1
0.8
Mercury, vg/1
<0.1-0.2
0.1
<0.1-0.1
<0.1
0.1-0.3
0.2
Copper
0.02-0.03
0.03
0.02-0.04
0.03
0.10-0.21
0.13
Chromium
N.D.
N.D.
0.31-0.40
0.36
Iron
0.5-0.9
0.7
Manganese
0.15-0.29
0.22
0.02-0.04
0.03
100-108
103
Cadniua
N.D.
N.D.
N.D.
Nickel
N.D.
N.D.
0.1-0.2
0.2
Zinc
0.06-0.07
0.06
0.04-0.06
0.05
5.1-6.5
5.8
Lead
N.D.
N.D.
<0.1-0.2
0.1
CT*
-------
M
(
ON
00
TABLE E-17 (Cont.)
SUJMARY OF FIELD MEASUREMENTS AND CHEMICAL DATA
DISCHARGES TO SOUTH FORK HOLSTON RIVER
TENNESSEE EASTMAN COMPANY-KINGSPORT, TENNESSEE
4-9 DECEMBER 1972
Station Number
19
22
23
3 /
Station Description
Storm Drainage
Overflow
13th St.
Sever
14th St.
Sewer
(RM 142.15/4
.50)
(RM 142.15/5.20)
(RM 142.15/5.30)
Parage ter^
Ranp,c
Average
Range
Average
Ranc-.e
Average
Flew (rigd)
0.101-0.174
0.136
4.1-4.6
4.3
10.3-11.5
io. a
pK (standard units)
6.0-7.3
6.5-9.0
6.7-8.1
Temperature (®C)
11.0-26.5
15.5-24.0
18.0-23.5
Conductviity (ymhos/cm)
400-950
240-300
220-340
BOD
42;600
200
14-37
>26
4.9-29
>14
BOD (lb/day)
230
>939
53^
>1,250
COD
60-1,480
452
42-83
59
TOC
12-200
54
8-19
12
3.0-11.0
6.8
Total Solids
674-833
764
392-1,020
621
103-210
134
Suspended Solids
44-143
100
172-632
471
6-25
15
Suspended Solids (lb/day)
113
16,700
1,320
Total Kjeldahl Nitrogen-N
1.3-3.6
2.5
<0.5-2.3
<1.1
<0.5-1.2
0.8
Total Kjeldahl Nitrogen-N (lb/day)
31
33
NH -N
(lb/day)
NOj + NO -N
1.5-2.7
2.0
<0.5-0.5
<0.5
N.D.
11
0.1-0.4
0.3
0.7-0.8
0.8
0.9-1.0
1.0
NC + (lb/day)
ToEdl Phosnhorus-P
28
88
0.32-1.3
0.67
0.27-1.6
0.91
0.01-0.09
0.05
Total Phosnhoru3-P (lb/day)
32
Oil and Grease
3-46
19
Phenols
<0.01-0.04
0.03
Mercury, wg/1
<0.1-0.4
0.1
N.D.
Cooner
0.02-0.05
0.04
0.03-0.04
0.03
Chronium
<0.01-0.05
0.01
<0.01-0.02
<0.01
Manganese
0.07-0.12
0.08
0.03-0.05
0.04
Cadmium
N.D.
N.D.
Nickel
N.D.
N.D.
Zinc
0.07-0.14
0.09
0.05-0.07
Lead
<0.1-0.1
<0.1
N.D.
aj See Appendix C for Station Description,
b/ All values reported as rig/1, except where specified.
cj All values are the same.
N.D. - None Detected,
e/ This is based on one value.
-------
E-69
During the 19 72 EPA survey the combined flow from the seven outfalls
was approximately 343 mgd. The BOD discharged was more than 52,000 lb/day.
This load is less than the load discharged in 1969, but much greater than
the 28,800 lb/day reported in the RAPP application. The waste streams at
Stations 12 (Hales Branch) and 17 (Long Island lagoons) contributed more
than 14,000 lb/day and 35,000 lb/day of BOD, respectively.
The total Kjeldahl-nitrogen discharged averaged 10,400 lb/day, a
decrease of 5,700 lb from the 1969 survey. The nitrite-nitrate nitrogen
discharge averaged 2,180 lb/day, but the concentrations were equivalent
to concentrations in the raw intake water.
The State of Tennessee has verbally requested that the Company not
discharge more than 17,500 lb BOD/day. However, to maintain a minimum
concentration of 5.0 mg/1 DO, the official standard, in the Holston River
and to protect the water quality of the receiving waters, the recommended
waste load limits, are 3,350 lb BOD/day and 400 lb TKN/day. To meet these
recommended limits, the cooling waters and process waste streams must be
separated completely.
The suspended solids load discharged increased from the 1969 value
(7,800 lb/day) to 106,000 lb/day (the RAPP application reported
86,400 lb/day). Waste flows at Stations 12 and 17 contributed 30,800 lb/day
and 56,100 lb/day, respectively. The suspended solids discharged from
Station 22 (13th Street sewer) averaged 16,700 lb/day. The RAPP appli-
cation reported that 600 lb/day were discharged from this location; the
increase in solids might be attributable to the solids that are flushed
to the outfall from the air pollution equipment. Approximately 950 lb/day
-------
E-70
of phosphorus were discharged; 840 lb/day were contributed by the waste
stream at Station 17.
Several heavy metals are used at the plant as catalysts including
manganese (preparation of hydroquinone). The highest concentration of
a heavy metal found was manganese, 103 mg/1 at Station 17 (8,990 lb/day).
More than 500 lb/day of zinc were also discharged from this outfall.
Although present in low concentrations, significant amounts of iron
(1,800 lb), manganese (564 lb), and zinc (163 lb) were discharged daily
from Hales Branch (Station 12). Sediments downstream from these outfalls
I
[Section VII Stream Survey] had concentrations as high as 22,725 mg/kg
for iron and 2,080 mg/kg for manganese.
Wastewater from Station 14 (outfall to the sluice) contributed
0.22 mg/1 of diphenyl ether [Table E-18], The effluent from the lagoons
(Station 17) contained a complex mixture of at least 40 organic compounds.
Among the compounds detected were alkylated phenols, alkylated and chlo-
rinated aniline derivitives, aliphatic hydrocarbons, alkylated benzenes,
and phthalic acid esters. Trichlorobenzene (0.75 mg/1) and trichloro-
aniline (0.08 mg/1) were identified, both of which are known to be toxic
to aquatic life, especially from continuous exposure. Chlorohexadecane
and chloroheptadecane, di-l-2-ethylhexyadipate, di-n-octylphthlate,
and 4,4-dimethyl-l-pentene were also present. The continued discharge
of these compounds could cause localized degradation of the South Fork
of the Hols ton River.
Static bioassay studies were run on five waste effluents from TEC
(Stations 12, 14, 17, 22 and 23). The waste from Stations 12, 14, 22,
-------
E-71
TABLE E-18
ORGANIC POLLUTANTS IDENTIFIED
TENNESSEE EASTMAN COMPANY
KINGS PORT, TENNESSEE
Concentration Load
Compound (tk;/!) (lb/day)
Station 14
1,4-dimethylcyclohexanc *
diphenyl ether 0.22 11
Station 17 A
4.4-diniethyl-l-pentene 0.06 5.2
trichlorobenzene ^5
trichloroaniline 0.08 6.9
bis-(2-ethylhexyl)fumarate £
prob. (chlorohexadecane) 0.50.v 43
prob. C _ (chloroheptadecane) 0.25 22
di-(-2-echylhexyl)adipate 0.08 6.9
di-n-octylphthalate 1.83 A 158
Several subs, alkanes & oromatics .05 to .50 4.3 to 43
Station 20
m- & p-xylene 0.08 .20
ethoxyethyl acetate 0.70 1.7
2-ethyl-l-hexanol 0.13 .32
w-chloroaniline 0.025 .06
tt-tricosane 0.025 .06
rc-tetracosane 0.05 .12
n-pentacosane 0.12 .30
n-heptacosane 0.25 .62
n-octacosane 0.25 .62
n-nonacosane 0.25 .62
n-triacontane 0.20 .49
n-hentriacontane 0.15 .37
n-dotriacontane 0.12 .30
rc-tritriacontane 0.12 .30
n-tetratriacontane 0.05 .12
2.5-dimethyltetradecane *
methyl indole *
n-hexacosane 0.18 .44
* Estimated-Standard not available for confirmation.
-r ^
-------
E-72
and 23 were not toxic to fathead minnows in 100-percent concentrations
for 96 hours. However, the studies showed that wastewaters from Station
17 were toxic to fish. The 96-hr TL derived from the static bioassays
m
with fathead minnows was 64 percent. Other static bioassays using blue-
gills showed the 96-hr TL to be a waste concentration of 36 percent.
ra
Based upon 1/20 of the 96-hr TL it was calculated that toxic wastewater
m
from Station 17 would have to be diluted by maintaining approximately
800 cfs in the South Fork of the Holston River in order to protect
aquatic life.
Waste-Treatment Facility
The performance of the Long Island treatment system was evaluated.
The effluent from the Kit Bottom lagoon is pumped to the aerated lagoons.
Therefore, Kit Bottom was considered as part of the treatment facility.
[Wastewater characteristics of the three influents, Stations 13, 16,
and 18, are summarized in Table E-19, characteristics of the effluent,
Station 17, in Table E-17.]
The combined influent flow was 10.4 mgd, with the influent at
Station 13 (Lift Station in Building 250) contributing 9.9 mgd. The
total influent BOD and suspended-solids loads were greater than
76,500 lb/day and 50,600 lb/day, respectively. The daily effluent load
discharged to the South Fork of the Holston River contained more than
35,100 lb of BOD and 56,100 lb of suspended solids. The treatment ef-
ficiencies of the facility were as follows:
-------
TABLE E-19
SUMMARY OF FIELD MEASUREMENTS AND CHEMICAL DATA
INFLUENT TO INDUSTRIAL WASTEWATER TREATMENT FACILITY
TENNESSEE EASTMAN COJfPANY-i*I!!GSPORT, TENNESSEE
4-9 DEC£tt3ER 1972
Station Nu-.ser 13 16 18
3 /
Station Description—
250 Li t Station
Effluent
Influent, Kit
Bottom Lagoon
Long Island
Lift
S tation
(RM 142.15/4
.50)
(RM 1&2
.15/4.60)
(RM 142
.15/3
.70)
b/
Parameter—
Panf;c
Average
Ka"<;e
Avera.ee
Ranpe
Average
Flcv (rrgd)
9.59-10.4
9.93
0.169-0.394
0.282
0.219-0.239
0.227
pi: (standard units)
2.4-9.9
1.3-6.6
4.2-9.5
TetrDerature ('C)
32.O-3S.0
18.0-28.0
21.5-42.0
Conductivity (unhos/crn)
2,000-4,500
4,300-60,000
260-800
BOD
>38->810
>492
>6,000-18,000
>10,000
1,100-1,700
1,400
BOD (lb/day)
>50,600
>25,900
2,620
COD
1,850-2,040
1,9 20
21,300-38,600
29,500
1,070-3,290
1,830
TOC
340-440
391
5,800-9,100
7,200
130-580
325
Total Solids
2,320-2,480
2,410
25,400-47,500
35,500
384-1,090
689
Suspended Solids
89-248
159
8,820-25,800
15,400
28-298
9S
Suspended Solids (lb/day)
liipn
37,200
183
Total Kjelda'il Nitrogen-N
100-140
ri2o)
230-500
382
2.6-30
8.4
Total Kjeldahl Nitrogen-N (lb/day)
Il0,100 T
904
15.8
NH -N
Nii (lb/day)
NO, -»¦ J.O ->i
96-110
a 104 i
33-600
341
1.2-10
3.3
0.7-1.7
Us.660 1
1.0
' 1.4-36
763
12.7
0.2-1.2
6.25
0.3
1,0 + NO^-M (lb/day)
84.1
34
ToEal Phosphorus-P
7.7-33
19
6.4-51
tJ 760-2,200
25
2.3-15
7.5
Total Phosphorus-P (lb/day)
1,570
65.5
14.3
Manganese
4.3-5.6
4.8
1,290
1.31-7.2
3.0
a/ See Appendix C for Station Description. tn
b_l All values reported as pg/1, except where otherwise specified. ^
OJ
-------
E-74
Parameter
% Removal
BOD
COD
SS
54
65
10 (increase)
NH -N
Total P
14
49
The aerated lagoon effluent had an average manganese concentration of
103 rag/1. The major in-put into the aerated lagoons is from Kit Bottom
which had an influent manganese concentration averaging 1,290 mg/1 (the
Kit Bottom effluent was not analysed). The high manganese concentration
present in the aerated lagoon system may have inhibitory effects on
biological treatment. The lagoons were not achieving adequate treatment
during the survey.
Wastes Discharged to the Municipal Sewer
Wastewater discharged (Station 20) to the Kingsport WUTP had average
BOD and suspended solids levels of 400 mg/1 each [Table E-20]. In addi-
tion, eight long-chain alkanes were detected, ranging in concentrations
from 0.05 to 0.25 mg/1 [Table E-18]. Also identified were m-chloroaniline,
2-ethyl-l-hexanol, m- and p-xylene, and ethoxyethyl acetate. These
organic chemicals could be toxic to biological treatment systems at the
wastewater treatment plant or pass through the plant untreated.
D. SUMMARY AND CONCLUSIONS
The Tennessee Eastman Company discharged 343 mgd of cooling water
and process wastewater to the South Fork of the Holston River. The
total loads of BOD and total Kjeldahl-nitrogen exceeded 52,000 lb/day
and 10,400 lb/day, respectively. The suspended-solids load averaged
-------
E-75
TABLE E-20
SUMMARY OF FIELD MEASUREMENTS AND CHEMICAL DATA
TENNESSEE EASTMAN COMPANY
SANITARY WASTES
Station Number 20
a/
Station Descrintion—
Sanitary Wastes
Parameter^
Range
Average
Flow (rogd)
0.181-0.407
0.295
pH (standard units)
2.7-8.4
Temperature (°C)
18.0-22.5
Conductivity (pmhos/cm)
320-1,500
BOD
290-560
403
BOD (lb/day)
1,100
COD
214-1,750
735
TOC
58-]84
103
Total Solids
401-4,960
1,740
Suspended Solids
70-968
401
Suspended Solids (lb/day)
857
Total Kieldahl Nitrogen-N
22-30
27
Total Kjeldahl Nitrogen-N (lb/day)
70
NH.-N
13-24
17
NHII-N (lb/day)
46
Nof + NO -N
0.3-2.3
0.9
Total Phosphorus-P
4.2-5.9
4.8
Total Phosphorus-P (lb/day)
12.5
Oil and Grease
5.5-39
21
Phenols
1.0-15
7.5
Mercury, tig/1
0.5-2.7
1.4
Copper
0.01-0.09
0.05
Chromium
0.04-0.09
0.07
Manganese
0.27-0.37
N. D-—
0.32
Cadmium
Nickel
N.D.
Zinc
0.24-0.43
0.33
Lead
0.2-0.3
0.3
a/ See Appendix C for Station Description.
b/ All values reported as mg/1, except where otherwise specified,
c/ N.D. - None Detected.
-------
E-76
106,000 lb/day during the five-day survey. Flows from Hales Branch
(Station 12) and the Long Island lagoons (Station 17) contributed more
than 49,000 lb BOD/day while the lagoon effluent contained 100 percent
of the total Kjeldahl-nitrogen discharged. The State of Tennessee has
concluded that in order to protect water-quality standards for a minimum
DO concentration of 5.0 mg/1 in the Hols con River, the raw waste loads
from TEC must be reduced to not more than 3,350 lb BOD/day and 400 lb
TKH/day. If a minimum DO concentration of 3.0 mg/1 is to be maintained,
the loads of BOD and total Kjeldhal-nitrogen in the effluent must not
exceed 6,000 lb/day and 1,600 lb/day, respectively.
A number of organic pollutants were identified in the TEC discharges.
The impact of these pollutants on aquatic life, through chronic exposure,
is presently unknown. However, compounds such as trichlorobenzene and
trichloraniline (both measured in the Long Island lagoon effluent) are
known to be quite toxic and undoubtedly contribute to the toxicity of
this discharge.
Static bioassay studies showed that wastewaters from the Long Island
lagoons were toxic to fish. The 96-hr TL derived from the static bio-
m
assays with fathead minnows was with a 64 percent waste concentration.
Other static bioassays using bluegills showed the 96-hr TL^ at a waste
concentration of 36 percent. Based upon 1/20 of the 96-hr TL^ it was
calculated that toxic concentrations in the wastewater from the Long
Island lagoons would have to be reduced by 95-percent to protect aquatic
life in the South Fork of the Holston River. The discharge of toxic
-------
E-77
substances constitutes a violation of the Water Quality Standards for
fish and aquatic life [Appendix A, Item 3(g)—Toxic Substances].
Analyses of heavy metals disclosed that 9,500 lb of manganese and
660 lb of zinc were discharged daily, the majority of which was contained
in the Long Island lagoon effluent. The manganese load caused a viola-
tion of the Tennessee Water Quality Standards occurring at Church Hill
Bridge (Station 56).
E. RECOMMENDATIONS
It is recommended that:
1. To maintain a minimum concentration of 5.0 mg/1 DO in the Hols ton
River, all process wastewater shall be immediately segregated from the
once-through, non-contact cooling water. The total BOD and TKN discharged
in the process wastewaters shall not exceed 3,350 lb and 400 lb/day, re-
spectively. These loads are based on requirements necessary to maintain
a minimum concentration of 5.0 mg/1 DO in the Holston River. The suspended
solids in the process wastewater shall not exceed 30 mg/1 over background
levels. The total heavy-metals content shall not exceed 1.0 mg/1 and the
nitrite + nitrate-nitrogen shall not exceed 1.0 mg/1 with a pH within the
range of 6.0 to 9.0 at all times. There shall be no detectable discharge
of potentially toxic organic wastes.
A suggested treatment system to meet these effluent limitations
could incorporate:
a) Pretreatment measures to protect biological treatment process
b) Activated sludge
-------
E-78
c) Deep-bed filtration
d) Carbon adsorption
e) Dentrification
2. Pretreatment regulations shall be established for the waste dis-
charged to the Kingsport WWTP requiring the removal of potentially toxic
organic substances and other pollutants to levels that will not inhibit
biological treatment processes or pass through the systems in concentra-
tions or loads inconsistent with effluent limitations which will be estab-
lished pursuant to the Federal Water Pollution Control Act Amendment^
of 1972.
3. All additional effluent requirements established by the State of
Tennessee shall be met.
4. A schedule and a proposed method of treatment for achieving the
necessary abatement of pollution be provided to EPA, Region IV, by 15
October 1973.
5. The permit issued to this industry require a routine monitoring
and sampling program of sufficient detail to ensure compliance with the
effluent limits and protection of the receiving water quality.
-------
E-79
E-VIII. HOLSTON ARMY AMMUNITION PLANT-AREA A
A. GENERAL
The Holston Army Ammunition Plant (HAAP) is located on two separate
sites (Area A and Area B) in the vicinity of Kingsport, Tennessee. Area
A, within the corporate boundaries of Kingsport, occupies about 134 acres
and borders on the South Fork of the Holston River [Figure IV-1], Area A
abuts industrial properties of the Tennessee Eastman Company (TEC) and
the ASG Industries.
Area A is the organic acid manufacturing facility of HAAP, whereas
Area B is the nitric acid and explosives manufacturing facility. Major
processes at HAAP, Area A, include the manufacture and refining of
acetic anhydride and the concentrating and refining of acetic acid,
principally recovered from HAAP, Area B.
HAAP is the only munitions plant under the auspices of the Army
Procurement and Supply Agency (APSA) that is devoted to the manufacture
of RDX-HMX explosives. RDX and I1MX are admixed with TNT (TNT being
received from the outside) and various chemicals, densensitizing agents,
fillers, etc., for primary use in manufacturing military explosives.
Additionally, explosives are prepared for the National Aeronautics and
Space Administration. HAAP reports the manufacture of about 50 RDX-HMX
product variations of which Composition B is the most prominent; it is
an extremely powerful explosive made up of RDX, TNT, and wax.
At Area A, waste acetic acid from Area B is concentrated, refined
and re-used in process operations. Areas A and B, are interconnected
by a railroad spur that is part of the Clinchfield Railroad System and
-------
E-80
by a series of stainless steel pipelines laid along the railroad tracks
which convey raw materials and intermediate products between the two
manufacturing facilities.
The Holston Army Ammunition Plant, owned by the Department of the
Army, is operated and managed by the Holston Defense Corporation (HDC -
a subsidiary of the Tennessee Eastman Company) on a contractual agreement
with the Department of the Army. Line command proceeds downward from
the Department of the Army through Army Materials Command (AMC) to the
Army Ammunition Procurement and Supply Agency (APSA), then Munitions
I
Command (MUCOM), and then to HAAP.
The Department of the Army has undertaken a long-term program for
modernizing its munitions and loading facilities. This modernization
program, under APSA, spans from 1969-1980 at a projected cost of
$2.5 billion. The largest aspects of the program are mechanization,
replacement, new construction, and pollution abatement. Modernization
program funding is controlled by Congressional appropriation to the
U. S. Army Corps of Engineers for military construction, i.e., MCA. The
Army is responsible for funding pollution abatement measures necessary
to conform to State standards and criteria; the requirements under
Federal legislation and Executive Order 11507; and most recently, the
best practicable control technology currently available and best avail-
able treatment measures as described in the Federal Water Pollution
Control Act Amendments of 1972.
HAAP Areas A and B are operated continuously and are staffed by two
Army officers, AO Civil Service personnel, and approximately 1,950 employees
-------
E-81
of the Holston Defense Corporation. During late 1972, the HAAP manufac-
turing facilities were being operated at around 43 percent of full
capacity.
Permit applications under the 1899 Refuse Act have previously been
filed with the U. S. Corps of Engineers for all waste discharges from
HAAP, Areas A and B, There are 13 waste outfalls from Area A and 8
outfalls from Area B.
EPA personnel from NFIC-Denver and Cincinnati, and Region IV,
Atlanta, Georgia together with Tennessee State Health Department repre-
sentatives met with HAAP personnel at Kingsport, Tennessee, on ]6 October
1972. They discussed process operations and the pollution potential of
existing wastewater streams. Considerable information was obtained but
Federal and State representatives did not view the process or wastewater
operations. Subsequently, the EPA personnel conducted industrial site
and river water pollution surveys. Area A, was studied from 30 November
to 3 December 1972. Mr. Robert Banner, Jr., Chemical Engineer at HDC;
provided information and assistance during the industrial surveys.
B. UTILITIES AND WATER SUPPLY
HAAP, Area A, purchases electricity, potable water (approximately
200,000 gal./day), and domestic sewer services from the City of Kingsport.
Area A has a central steam generating plant consisting of seven boilers
fired by "non" low sulfur content coal. Furnace fly ash is slurried
into a 4 ft by 4 ft settling compartment followed by a 10 ft by 20 ft
pit having continuous overflow. Coal is also utilized in the manufac-
ture of producer gas at HAAP A. The producer gas is added to the
-------
E-82
cracking furnaces in forming the acetic anhydride. Producer gas is
basically a gaseous fuel formed from the incomplete combustion of coal
or coke, and consisting mostly of nitrogen, carbon monoxide, hydrogen
and carbon dioxide. It is also a viable source of phenolics in re-
sulting wastewaters.
Various amounts of water for cooling and process needs are withdrawn
from the South Fork of the Holston River; previously reported figures
on total withdrawals vary considerably. River water is diverted into
a canal located on the south bank of the South Fork and originating a
short distance upstream of the Tennessee Eastman Company waste outfalls.
River water enters Area A via a putnp station with attendant trash racks.
A portion of this flow is treated on-site. Average river water intake
varies from about 45 to 65 mgd. The cooling water (once-through) flows
for the total facility range from 42 to 60 mgd; process water flows
range from 0.8 to 4.4 mgd. The wide range in water use figures report-
edly is due to the lack of precise measurement of incoming water flows.
This study assumes that approximately 42 mgd is employed for once-
through cooling and 0.8-0.9 mgd for processing at Area A. Furthermore,
recent data from HAAP indicate that about 1.5 mgd of intake water is
treated (softened and filtered) of which about 0.8 mgd is used for
boiler feed and 0.7 mgd for process waters. Spent cooling waters, water-
works filter sludges, and industrial process wastewaters from Area A
are discharged without treatment to the South Fork of the Holston River.
C. PROCESS OPERATIONS AND WASTE SOURCES
The general layout of manufacturing buildings at Area A is shown
-------
E-83
in Figure E-10. A simplified flow sheet of Area A is presented in
Figure E-ll. The major processes conducted at Area A are as follows:
1. Concentration and refining of waste acetic acid (received ftom
HAAP B) by means of azeotropic distillation units in Building 2
yields an acetic acid whose concentration is increased from
60 percent to approximately 99 percent pure (glacial acetic
acid). About one-third of the glacial acetic acid is returned
to Area B for explosives manufacturing; two-thirds are employed
in the manufacture (within Area A) of 98 percent acetic anhydride.
Interim storage of the refined acid (99 percent pure) is pro-
vided for in the tank farm areas.
2. Acetic anhydride manufacturing is carried out (in Buildings 7
pre1 ?Q) by fir^t catalytically cracking glacial acetic acid In
special cracking furnaces (fueled by producer gas) and secondly
absorbing the cracking products in glacial acetic acid to yield
the crude anhydride, which is then refined (Building 6).
3. Generation of producer gas (Building 10) is carried out upon
demand by the cracking furnaces in the acetic anhydride manu-
facturing processes.
4. Refining of the crude anhydride by distillation (Building 6)
produces a high purity acetic anhydride, required for the
various explosives manufacturing operations in HAAP, Area B.
It should be noted that Building 6 has two distinct functions:
a) acetic anhydride refining and b) azeotropic distillation to
purify and concentrate acetic acid.
-------
E-84
5. Mechanical refrigeration services (Building 5)
6. Generation of steam with coal fired boilers (Building 8) pro-
vides for the needs of the entire HAAP, Area A complex.
Acetic Acid Concentration and Refining—Building 2
In azeotropic distillation, the nearly pure acetic acid is with-
drawn from the bottom of the column, and the n-propylacetate-and-water
mixture is removed from the top of the column and condensed. Separation
of water from the acetate is accomplished by decantation. The propyl
acetate is then returned to the azeotropic distillation column. The
decanted waters are passed through a flash column for further solvent
recovery before they are discharged to the sewer.
During distillation there is a undesirable buildup of solids in the
distillation column. Sludge bleedoff is necessary, with this material
being sent to a sludge-heating operation. Under elevated temperature
and vacuum, additional acetic acid is distilled and recovered via the
overhead streams until the acid concentration falls below the level
deemed economically recoverable. At this point the sludges are dumped
into the sewer. Sludge heating is a batch operation. Exhausted sludges
are dumped sporadically, between two to four times each week. Occas-
sionally spent sludges contain heavy metals (including Cr, Cu, Fe, and
Mn) from the corrosive destruction of materials which form the distil-
lation columns.
Flash column effluent waters and sludge heater wastes are cited in
the 1971 Army Environmental Hygiene Agency (AEHA) Report as totaling
24,000 gpd and 16,000 gpw, respectively. However, the 1971 MUCOM
-------
OPEN DITCH
ASe INDUSTRIES
WASTEWATER EFFLUENT
CETIC
ACETIC
ANHYDRIDE
HAHUFACTU8IHG
ACETIC
ACID
TANK
MAIN TANK FARM
^ SAHPIIHG ST ATlOt)
MANHOLE
FILTER PLAMT
AHHOLE
STEAK PLAMT
BLDG 8
SLUICE PIT
r>DITCH FROM
1 TAR TAHKS
OT TO SCALE
5TON RIVER
SOUTH FORK HO
Figure E-10. Plant Layout- Holston Army A^munitien Mast-Area A
Kingsport, Tennessee
-------
dilute; (61%)
AC".TIC ACID
)
GLACIAI,
ACETIC ACID
CD aREA B)
A
j ACtTIC
J ACID
| cc: ce'h'ttlmT
1 (TEDG 2)
ION'
FHODUCEH
GAS
PLANT
(eldg ic)
_V_
GLACIAL
ACETIC } ACETIC
/ CI1') J ;C i iD"\ID
—^
C7.ACI-.I
:-,A j'.'1 GIL RE
(r.j.ncs 7 & 20)
CTVL i
DILUiE
-t ACr.iIC aCIP
j\^L i J.0
ACID
ANHYDRIDE
ACETIC
ANHYDRIDE
(TO A\EA E)
A
ACETIC
Ar.liT PRIDE
TZTI (ING
(HLDP 6)
ACETIC
ACID
CONCENTRATION
(r.LfiC 6)
Figure E-ll. SIMPLIFIED FLOWSHEET-AREA A, HOLSTON ARMY AMMUNITION PLANT
Courtesy of USAEHA, Edgewood Arsenal,
Aberdeen Proving Ground, Maryland
Taken from USAEHA Study No. 24-021-71/72
-------
E-85
report for HAAP reports a process wastewater flow of 312,000 gpd from
Building 2 (also, presumably for the decant waters). These process
effluents range in pH'from 2.8 to 3.8 and contain nitromethane, methyl
nitrate, acetic acid, n-propyl acetate, nitric acid and trace amounts
of explosives.
Cooling and condensing water usage (in Building 2) for the distil-
lation units and peripheral operations are estimated as 24.0 mgd. Acetic
acid (99 percent) production is about 1.3 to 1.6 million lb/day. Cooling
waters, process waters and sludges are mixed in the Building 2 indus-
trial sewer and discharged into the "Main Outfall Ditch" adjacent to
Building 2. This ditch was sampled at Station 2 during the NFIC-D,
1972 survey, immediately before its entry into the South Fork of the
Holston River [Figure E-10],
Another pollution source from the acetic acid operations (Building
6), is vent gas from the azeotropic distillation columns. Under current
production rates, these vent gases contain about 530 lb/day of methyl
nitrate liberated in a total, untreated mixture of nitromethane, methyl
acetate, propyl formate, propyl acetate and methyl nitrate. The weight
of solvent vapors vented to the atmosphere approaches some 1,070 lb/day.
Methyl nitrate is toxic and highly explosive.
Acetic Anhydride Manufacturing—Buildings 7 and 20
Glacial acetic acid (from Building 2) is vaporized and fed to the
cracking furnace (in Buildings 7 and 20) together with triethyl phos-
phate, a reaction catalyst. Furnace vapors are passed through a con-
denser which separates the process stream into a) uncondensed vapors and
-------
E-86
b) unreacted acetic acid obtained from the bottom of the condenser.
The unreacted acid is 6ent to Building 6 for re-concentration.
Uncondensed vapors are directed through a series of five scrubbing
units; the primary, secondary, anhydride, weak acid and water scrubbers.
The scrubbers employ recycling of feed, bottoms, and intermediate product
streams. The vapor stream is scrubbed with glacial acetic acid, and
ketene originating from catalytic cracking is absorbed to form the anhy-
dride. Crude anhydride is taken off the bottom of the secondary scrub-
ber and subsequently sent to the distillation unit (Building 6) for re-
fining. Wastewaters from acetic anhydride production (Buildings 7 and
20) are principally generated at the fifth (i.e. the water) scrubbing
unit. Vapors entering the fifth unit are scrubbed with water; after a
single pass they enter a drain sump and the plant sewer. Non-conden-
sables off the top of the fifth unit are captured in a barometric con-
denser that likewise discharges to the drain sump. Both the barometric
system and drain sump are vented to rid the production area of noxious
fumes. It is likely that drips, leaks, spills, etc., in the production
area are also directed to the drain sump.
Spent gases from the cracking furnaces are sent to a waste heat
boiler that receives deionized water for low pressure steam generation.
Flue gas from the boiler, in addition to any unburned producer gas, is
directly vented to the atmosphere.
The flow of the process wastewater streams that include the water
scrubber discharges and barometric condensates previously mentioned
ranges from 500,000 to 550,000 gpd. These wastewater streams are
-------
E-87
reported to contain acetic anhydride, acetic acid, acetaldehyde,
acetonitrile, methyl acetate, methyl nitrate, ethanol, methanol, ethyl
acetate, propanol, propyl acetate, etc. A previous Array report equates
the water scrubber discharge to 3,100 lb BOD/day.
The volume of the cooling waters for anhydride manufacturing amount
to 2.0 to 2.3 mgd which are mixed with process wastewaters in the
building sewer for discharge to the South Fork of the Holston River.
These discharges were collectively measured and analyzed 3t the Process
Waste Outfall (Station 3) during the EPA survey, 30 November-3 December
1972. The conditions just expressed are representative of acetic
anhydride production rates in the range of about 510,000 to 640,000 lb/day.
Pollutants similar to those found in the wastewater streams can be
expected in the various off-stream gases vented to the atmosphere (from
Buildings 7 and 20). Of the contaminants resulting from anhydride manu-
facturing some 16,500 lb/day of air pollutants are estimated to be cur-
rently discharged (from Buildings 7 and 20); this total is comprised of
5,440 lb/day of hydrocarbons, 6,360 lb/day of carbon monoxide and
4,700 lb/day of carbon dioxide mixed with hydrogen.
Producer Gas Plant—Building 30
Producer gas manufacturing facilities (Building 10) are rated at a
capacity of about 2.0 million cubic feet of gns per day. A heated, satu-
rated steam-air mixture is added to coal, burning in the gas producer
furnaces, where combustion is maintained around 1,100°F. Ashes are
withdrawn from the bottom of the furnaces and disposed of by removal to
a landfill.
-------
E-88
The products of this combustion pass through water sprays, a tar
trap, and then into two large water scrubbing units in series. Scrub-
bing removes dust, tars, phenolics, etc. from the gases but these pol-
lutants then find their way into the wastewater flows. Spent water from
the header sprays and the scrubbing units is decanted for removal of
tars which are sent to the steam plant as fuel. Decanter effluents
flow through a cascade cooler prior to being recycled to the sprays and
scrubbers or are discharged to the plant sewer. Total water usage and
ensuing wastewater discharges associated with the manufacture of pro-
ducer gas heavily depend upon the degree of recycling of decanter efflu-
ents back into the system. The Army reports that flows of "excess"
cooling and condenser water from the producer gas building amount to
from 170,000-180,000 gpd. Flow measurements made at Station A during
the 1972 EPA survey (November-December) 1972 indicate the wastewater
contribution from Building 10 was many times higher than that reported
by the Army. However, wastewater loads from this plant, as measured at
both Stations 3 and 4 (EPA survey stations), were reflected, within the
results obtained.
Other pollution sources within the producer gas area include sludges
from an on-site evaporator and cleanout of the tar traps. These materials
are disposed of at a sanitary landfill. Air contaminants from the pro-
ducer gas furnace vent gases include particulate matter, and sulfur and
nitrogen oxides.
General operations data indicate that approximately 56 cu ft of
producer gas are obtained for each pound o£ coal burned and that about
-------
E-89
14.3 cubic feet of producer gas are consumed per pound of crude acetic
anhydride formed.
Acetic Anhydride Refining—Building 6
Building 6 actually houses two different process operations:
acetic anhydride refining, accomplished by distillation, and acetic
acid concentration accomplished by azeotropic distillation. Anhydride
refining constitutes the major operation. Crude anhydride is received
from the dehydration process (Buildings 7 and 20) or from storage tanks,
whereas the low-grade acetic acid is obtained as a by-product of the
anhydride refining columns.
Crude anhydride, acetic acid and impurities are received into
two-stage refining columns heated in the lower stage. Refined anhydride
is withdrawn from the lower stage, sent to a second (small) column for
removal of color bodies, and is then ready for storage or pipeline
transport to HAAP, Area B, The vapors from the top of the two-stage
anhydride column contain acetic acid, 15 percent anhydride plus some
impurities. This vapor is condensed, part being returned to the
refining column and the majority sent to a stripping column. In
stripping, separation is made into a) acetic acid and anhydride (off
the bottom of the stripper) which are returned to the refining column,
and b) 90-percent acetic acid vapors off the top of the stripper. These
vapors serve as the feed for the azeotropic stills (located in Building 6).
Azeotropic distillation of acetic acid for purification and concen-
tration is similar to that performed in Building 2 (production of 99 per-
cent pure acid). In Building 6 the acetic acid feed to the stills contains
-------
E-90
low-boiling compounds that must be removed before azeotropic distil-
lation. Prior to distillation, the feed is passed through a stripping
column, to reduce the low boilers and release these compounds to the
atmosphere. Vented streams contain acetonitrile, methyl acetate, acetal-
dehyde, methanol, ethanol, methyl nitrate, ethyl acetate, propanol and
propyl acetate, all of which Chen become air pollutants. Other sources
of air pollution exist in Building 6. The major source is the azeotropic
stills, for which there is no waste load information presently available.
Sludge bottoms from the various stills in Building 6 are recovered.
Sludges from the refining columns are sent to a ball mill, then heated
under vacuum to distill off additional acetic anhydride. When the
anhydride falls below an economically recoverable level, the sludges
are dumped to the sewer, a daily occurrence. Sludges from the azeotropic
stills, because of their anhydride origin, receive preparatory treatment
by sulfuric acid to break down the acetamide in the sludges. The sludges
are then sent to sludge heaters and handled in a similar fashion to
those in the acetic acid purification process (Building 2). In like
manner exhausted azeotropic still sludges are eventually discharged into
the plant sewer.
Process wastewater sources from anhydride refining (Building 6)
include a) 70,000 gpd ball mill sludges containing carbon polymers,
acetic anhydride, etc.; b) 8,100 gpd of sludge heater sludges that are
dumped four times per week — containing carbon, ammonium phosphate,
acetamide, and various polymers; and c) flash column effluent, in the
acetic acid concentration area, having unknown volume but found to
-------
E-91
contain acetone, ethyl acetate, acetonitrile, and methyl cyanide.
Total spent cooling and condensing waters from anhydride refining
(Building 6) arc estimated by the Army as around 9.5 mgd. All spent
flows leaving Building 6 are untreated and mixed together in the indus-
trial plant sewer. These streams were collectively analyzed with other
wastewaters passing Station 2 during the EPA 1972 survey. Conditions
described are representative of acetic anhydride production in the
range of 600,000 to 700,000 lb/day and acetic acid production of
120,000 to 150,000 lb/day.
Mechanical Refrigeration—Building 5
The anhydride scrubber medium (in Buildings 7 and 20) is cooled
by an ethylene glycol solution. The glycol, after use, is cooled by
mechanical refrigeration equipment (located in Building 5) and, in a
closed loop system, is returned to the anhydride units. Spent cooling
waters from the refrigeration operation (Building 5) have been esti-
mated to range from 0.164 to 2.3 mgd. These waters are expected to
contain substantial amounts of heat.
Steam Generation at Steam Plant—Building 8
Except for a single boiler that employs pulverized coal, steam-
producing boilers (Building 8) are stoker fired. Tar sludges received
from the producer gas builing are also put into the boilers. Boiler
feed consists of a mixture of deionized water and return steam con-
densates. In order to minimize corrosion in the boilers, sodium sulfite
is added to the feed waters. Sodium phosphate is added directly to the
-------
E-92
boiler drums to reduce corrosion and scale formation on the boiler tubes.
The boilers are blown down more or less continuously so as to prevent too
high a solids concentration in the boiler system. Both high and low-
pressure steam are produced for needs throughout Area A. Compressed
air requirements for Area A are met by equipment within Building 8.
Spent ashes from the bottom of the boilers are slurried into an
ash pit followed by a sluice pit. The overflow from the sluice pit is
estimated from 100,000 to 140,000 gpd; the flow was sampled at EPA
survey Station 10. The Army describes this water as strong in phosphates
and sulfites. Pump gland drainage from the water pumping house adjacent
to the steam plant also contributed a considerable amount of flow passing
EPA Station 10.
Boiler blowdown is released into the drainway, monitored by
Station 9 during the EPA survey. This discharge reportedly has a high
temperature and contains significant quantities of phosphates, sulfates
and sulfites. The Army has provided a flow figure for boiler blowdown
(from Building 8) of approximately 30,000 gpd although survey results
for Station 9 indicated some 690,000 gpd; this reflects additive wastes
such as general washdown and cleanup waters, spills, leaks, or unknown
water uses.
Coal tars recovered from the producer-gas building are conveyed to
storage tanks directly ad-jaccnt to the steam plant. Tar deposits on the
grounds around the storage tanks are slowly leached into the drainway
on the southeast side of the steam plant and eventually discharged to
the South Fork of the Holston River. This drainage was sampled at EPA
-------
E-93
Station 8 and shown to be very heavily laden with organics, notably
phenolics.
Relative to air pollution from the coal-fired steam plant, substantial
abatement could be indicated in the forthcoming period of time. MUCOM,
in the 1971 survey of HAAP, indicated that discharge of air pollutants
from the boilers amounts to 16,000 lb/day of particulates, 8,000 lb/day
of sulfur oxides, plus unknown amounts of other materials.
D- REFUSE ACT PERMIT APPLICATION (RAPP) DATA
Wastewater characteristics submitted by HAAP in May 1971 have been
summarized [Tabic E-21], The summary also includes the total waste loads
determined by the U. S. Army Environmental Agency (USAEA) and corresponding
RAPP and CPA 1972 survey station numbers.
Of the 13 RAPP outfalls, two are Inactive (010 and Oil) and three
(002, 003, and 004) discharge sludge (from the settling basins within
the waterworks) to the River, only once every three or four months.
However, to say that the waterworks discharge minimum amounts of coagu-
lated sludge is not necessarily true. In fact, it is highly probable
that large amounts of settled sludge are being continuously swept out
. of the sedimentation basins and onto J:he waterworks filters. The large
majority of these chemical sludges are likely being flushed to the river
on a routine daily basis via the unloading and backwashing of the filter
beds through RAPP outfall 005 (EPA 1972 Survey Station 6).
RAPP Outfall 013 (EPA Station 2) reflects the addition of some
0.52 mgd wastewater from ASG Industries introduced upstream of HAAP
into this "Main Outfall Ditch," which in turn discharges into the South
-------
M
1
VO
¦C-
TABLE E-21
OUTFALL CHARACTERISTICS FROM RAP? APPLICATION, HOLSTOX ARMY AMMUNITION PLANT - AREA A
KINGSPORT, TENNESSEE
RAPP
Outfall
EPA
Stn.
No .SJ
Flow
BOD
COD
SS
NHv
-N
NO v-N
P-
-Total
Nunber
»Rd
.®s/1
lb/day
mg/1
lb/day
mf>/l
lb/day
ms/1
lb/day
lb/day
lb/day
001
3,4
4.9
4
163
47
1,909
18
731
-
-
1
40
1
49
002
b/
0.3
56
140
1,233
3,082
8,112
20,274
-
-
-
-
-
-
003
b/
0.3
56
140
1,233
3,082
8,112
20,274
-
-
-
-
-
-
004
b/
0.3
1
4
-
-
22
55
-
-
-
-
-
-
005
6
0.05
5
2
62
26
50
21
-
-
-
-
-
-
006
7
0.01
84
7
276
23
96
8
-
-
-
-
-
-
007
b/
0.03
5
1
320
80
20
5
-
-
-
-
-
-
008
8
0.0005
-
-
3,600
15
-
-
-
-
-
-
-
-
009^'
9
-
-
-
-
-
8
4
-
-
-
-
-
-
012
10
1.1
2
20
69
634
85
781
-
-
-
-
-
-
013
2
33.3
34
9.443
60
16,663
93
25,828
10
278
12
333
15
417
TOTALS
40.3
9,920
25,514
67,981
278
373
466
TOTALS FROM
USAEHA REP0ST-
37.6
9,359
13,200
6,060
650
259
a/ These station numbers refer to the 1972 study.
b/ This outfall was not sampled.
zl Outfalls 010 and Oil are inactive discharges.
d/ This refers to the U.S. Amy Environnental Hygiene Agency Report (19 March - 28 June 1971).
-------
E-95
Fork of the Holston River. [For EPA 1972 Survey Stations, see Figure E-10.]
E. DISCUSSION OF 1972 EPA FINDINGS
During the EPA field sampling survey of 30 November to 3 December
1972 ten wastewater sampling stations were established [Figure E-10 and
Table E-22], Major wastewater streams include Stations 2, 3, and 4.
Stations 2 through 4 and 7 through 10 were manually sampled at two-hr
intervals for 72 consecutive hours beginning at 8:00 AM, 30 November.
[See Appendix B for description of Sampling Procedure.] These grab samples
were composited on an equal volume basis into three 24-hr composite samples.
At Station 6 the ion exchange regeneration wastes and filter backwash from
the water works were grab sampled at times of discharge. Unnamed Creek
(background location) and the plant raw water intake, respectively Sta-
tions 1 and 11, were sampled twice daily and composited into daily samples.
Data on waste loads from ASG Industries (discharges into open ditch that
flows into the main outfall ditch) was obtained with concurrent sampling
and were extracted from the results of the 1972 NFIC-D & C survey findings
on ASG Industries.
At Stations 2, 3, and 7 through 10 special samples for analyses of
oil and grease and of phenoli c materials were taken every two hr and
continuously composited over a 24 hr period. At Station 6 grab samples
for oil and grease analysis were collected twice each day and composited
into a daily sample. Temperature, pH, and conductivity were measured
each time a sample was collected. [See Appendix D for Methods of Anal-
ysis and Sample Preservation.]
EPA flow measurements were made at the following stations:
-------
S'uir.b
1
2
3
4
6
7
8
9
10
11
TABLE E-22
EPA SAMPLING STATIONS, HAAP, AREA A, KINGSPORT, TENNESSEE
EPA SURVEY OF 30 NOVEMBER-3 DECEMBER 1972
Refuse Act Permit
Discharge Number
Type
Sample
Station Location
013
001
001
005
006
008
009
012
2 Grab/Composite
Composite
Composite
Composite
Grabs
Composite
Composite
Composite
Composite
Unnamed Creek, upstream from confluence with
HAAP "A" discharge
Main Outfall stream, at chain like fence near
river bank
Process waste outfall at manhole 8, prior to
mixing with "manhole 7 wastes" and discharge
to South Fork of the Holston River
Process waste outfall at manhole 7, prior to
mixing with "manhole 8 wastes" and discharge
to the river.
Zeolite regeneration wastes and backwash from
waterworks
Process waste outfall to the river originating
from main tank farm
Leached wastes from area of tar tanks on dis-
charge line close to the river bank
Floor drainage and steam-plant effluent at
manhole on outfall.
Discharge from steam plant, principally an ash
pit overflow, together with pump gland drainage
originating from (water) pump house
2 Grab/Composite
Raw water intake into water works
-------
E-97
1. Stations 3, 4, 7 - measured every 2 hr with a Marsh-McBimey
electromagnetic water-cuirent mecer.
2. Stations 1 and 2 - gaged several times daily and rating curves
were established.
3) Station 8 - flow recorder was installed for continuous
measurement.
Flow data for remaining sampling stations wore extracted from HAAP
records and/or generally compiled from special Army studies.
The EPA 1972 survey revealed a total (net) wastewater discharge
from HAAP, Area A, of 43.3 mgd, but the 43.3 mgd does not include A3G
Industrial Wastewater discharges and the natural flow in Unnamed Creek
that contribute to overall flows in the "Main Outfall Ditch." The RAPP
applications reported a total water intake of 65 mgd pumped from the
South Fork of the Hols ton River. Because the USAEHA 1971 waste survey
showed only 37.6 mgd of wastewaters being discharged from Area A, HDC
decided to measure, during June to July 197 2, the total plant intake
water with pitot tubes during June-July, 1971, and consequently the
survey showed an average intake flow of 48.7 mgd. Of course the EPA
figure of 43.3 mgd reflects spent waters leaving HAAP, Area A, and
does not take into account water lost in product, evaporation and
steam losses, and some 0.35 mgd of pumphouse trash rack wastewater.
The complex nature of pollutants contained in the wastewater from
Areas A and B, presented unusual difficulty to EPA personnel who con-
ducted the analyses. It is likely that the important waste characteri-
zation parameters of BOD, COD, and TOC were affected in varying degree
-------
E-98
by the kind of wastewaters encountered. Many HAAP wastes are relatively
non-biodegradable and are potentially toxic to biological life, hence
yielding comparatively low BUD values. The presence of acetic acid,
straight-chain aliphatics and aromatic hydrocarbons all of which are
prevalent in HAAP wastes, are relatively resistant to COD measurement.
Survey results for TOC were noted as exceptionally low relative to the
BOD and COD values, leading one to suspect some interference in these
determinations. Procedural difficulties were also experienced in
undertaking the complex organic analyses. Refined analytical methods
and possibly some research on modified analytical techniques, directed
specifically to HAAP-type wastewaters, would seem advisable. Results
for BOD, COD, and TOC, obtained from the EPA 1972 sampling survey, are
considered to represent the near minimum values.
Specific water and wastewater sampling results obtained from the
30 November to 3 December 1972 EPA survey of the HAAP A installation are
discussed as follows: [The summary of analytical data from the EPA
survey is presented in Table E-23.]
Unnamed Creek At Station 1
This creek had a natural average flow of 0.69 mgd, and the water
quality was similar to that found in the South Fork of the Hols ton River
(as compared to plant water intake at Station 11) except for slight
increases in values of BOD and conductivity.
Main Outfall From HAAP, Area A, Station 2
The main outfall from Station 2 collects the majority of spent
-------
TABLE E-23 "
SUMMARY OF FIELD MEASUREMENTS AND CHEMICAL DATA
HOLSTOM ARMY AMIfUNITIC* FLANT APEA A
KIKGSPORT, THKN'ESSEE
1-3 Dr.ci:;3F.R 1972
Station Number 1 2 3 4
a/
Froccss
Waste ar.d
Station Description—
Unnaned Creek llnstream
fain Outfall Ditch
Process Waste
Outfall
Cooling Wi
atcr Outfall
(RM 142.
.15/4.04)
(RM 142
.15/4.04)
(RM 142.15/4
.30)
(RM 142
.15/4.30)
b/
Para~e tcv—
Range
Average
Ranrc
Ave rage
Range
Average
Range
Average
Flow (-rgd)
0.52-0.96
0.69
33.5-33.7
33.6
3.97-5.40
4.65
3.8S-4.S6
4.40
p1' (standard units), range
6.9-7.0
6.2-7.6
6.2-7.4
6.1-7.5
Tenocrature (°C) , range
5.5-6.0
18.0-20 .0
14.0-16.0
14.0-17.0
Conductivity Cumbos/cm), range
320-480
160-300
200-350
180-360
BOD
2.4-5.8
3.80
56-71
65
20-75
41
4.6-12
8.5
BOD (lb/day)
24
18,800
1,5 00
320
COD
64-66
65
TOO
6-8
6.7
6-11
8.7
4-29
14
Total Solids
193-325
276
133-164
147
123-138
132
125-211
160
Suspended Solid3
10-45
29
3-21
9 .6
4-14
9
8-22
15
Suspended Solid3 (lb/day)
N. D
190
2,700
350
520
Total Kjeldahl Nitroger.-N
<0.5-0.5
<0.5
<0.5-0.5
<0.5
<0.5-0.6
<0.5
NH -X
M.D.
N.D.
N.D.
N.D..
1.0^
so, + :;o -s'
0.5-1.8
0.9
0.8-1.9
1. 3
0.8-1.0
0.9
1.0
SO, + NO^-S' (Id/day)
6.30
354
35.0
36.7
Total Phospnorus-P
0.28-0.67
0.45
0.19-0.22
0.21
0.18-0.20
0.19
0.12-0.14
0.15
Total Phosnhorus-P (lb/day)
2„ 80
57.9
7.24
5.52
Oil and Crease
2-3
2
<1-2
<1
Phenols
N.D.
N.D.
N.D.
N.D.
M
I
vo
VD
-------
PJ
I
H1
O
O
TABLE e-23 (Cont.)
SUMMARY OF FIELD MEASUREMENTS AND CHEMICAL DATA
HOLS TON ARMY AMMUNITION ?LANT AREA A
KINGSPORT, TENNESSEE
1-3 DECEMBER 1972
Station Number
6
7
8
o
21
Station Description—
Filter Plan
t Backwash
Tank. Far
v. Wastes
Tar Tank A
rea
Stean Plant Effluent
(RM 142.
15/4.25)
(RM 142.
15/4 .24)
(R>[ 142.15/4
.20)
(RM 142.
15/4.19)
b/
Para-etcr^
Range
Averase
Range
Average
Range
Average
Range
Averape
Flow (rage!)
o.o^
0.18
0.005-0.008
0.
,007
0.69^'
pH (standard units), range
6.4-7.1
4.5-7.6
5.8-8.1
6.7-11.2
Te-morature (°C), range
9.5-10.3
14.0-24.0
13.0-65.0
15.0-21.5
Conductivity (umhos/crn) , range
230-360
200-460
500-26,000
220-640
BOD
22-36
29
20-32
26
>800->2,700
>2,030
6.9-7.2
7.1
BOD (lb/day)
9.7
37
>122
40
COD
4,800-10,600
7,957
TOC
7-18
12.5
3-7
5
1,300-2,800
2,130
3-8
5
Total Solids
229-475
352
72-268
173
2,400-5,300
4,020
196-202
199
Suspended Solids
118-236
177
7-57
25
64-98
84
15-47
27
Suspended Solids (lb/day)
59
29
4.
,5
160
Oil and Grease
<1-2
1
31-89
63
<1-3
2
Phenols
<0.01-0.04
0.023
1,100-5,800
3,600
1.3-5.0
2.1
Phenolics (lb/d3y)
202
12.1
-------
TABLE E-23 (Cont.)
SUMMARY OF FIELD MEASURE" EE NTS AND CHEMICAL DATA
HOLSTON ARMY AiCtlNITION PLANT AREA A
KINGSPORT, TEMNES S EE
1-3 DECE^tBER 19 72
Station Number 10 11
a/
Station Description—
Sluice Pit Outfall
Raw Water Intake
(PJ1 142.
.15/4.10)
(R>I 142
.15/4.08)
b/
Parameters-
Range
Average
Range
Average
Flow (rngd)
1.0^
48.1-
pH (standard units), range
6 .5-8.2
6.1-6.9
Temperature (°C), range
27.5-38.0
9.0-10 .0
Conductivity (pmhos/cm), range
150-320
240-230
BOD
2.9-3.9
3.4
1.0-1.4
1.1
BOD (lb/day)
51—
28
460
COD
57
TOC
8-17
11
2-4
3.3
Total Solids
161-173
167
125-143
134
Suspended Solids
16-36
29
6-35
22
Suspended Solids (lb/day)
240
8,800
Total Kjeldahl Nitrogen-N
<0.5-0.5
<0.5
SK -N
N.D
KO^ + NO -N
1.0=-'
1.0
Kof + NO^-N (lb/day)
406
To^al Phosphorus-P
0.06-0.22
0.12
Total Phosnhorus-P (lb/day)
47.4
Oil and Grease
<1-2
<1
a/ See Table 2 for station description.
b/ All values reported as mg/1, except where otherwise srcecified.
c/ K.D. - None Detected,
d_/ All values are the same.
e/ The flow was determined from RAPP application,
f/ This is based on one value.
-------
E-102
cooling- and process-water flows from the Area A manufacturing facilities.
An average flow of 33.6 mgd was observed within the large drainway that
includes some 0.52 mgd wastewater flow contributed by the ASG Industries
and the respective flow of Unnamed Creek [Figure E-10]. The creek carries •
a negligible waste load into the drainway, but the ASG pollution loads
are equivalent to 3,600 lb/day suspended solids added to the upper section
of the Main Outfall. However, some solids rapidly settle out, both with-
in the open drainage ditch and within parts of the Main Outfall. Near
its terminus point at Station 2 it was found to be conveying average
loads of 18,800 lb/day BOD; ]8,200 lb/day COD; and 2,700 lb/day suspended
solids directly into the South Fork of the Holston River. Using any
criterion of measurement, these are very large waste loads. More than
90 percent of the total BOD and COD loads discharged from Area A were
found in this single outfall. Surprisingly so, at least during the
three-day survey, no phenolic materials were detected at this location,
and nutrient levels were fairly similar to background waters. No
detectable amounts of heavy metals were found at Station 2. However,
a number of metals sources exist within the HAAP A complex, especially
from the sludge-heater system and corrosion of the aezotropic distil-
lation columns (Buildings 2 and 6). These could contribute to a metals
problem. Using fathead minnows as the test fish species, bioassay
studies were conducted on a 24-hr composite sample of the Main Outfall,
the 96-hr TL (50 percent fish kill) obtained from static bioassays
m
was 56.0 percent of the wastewater concentration. When one considers
the magnitude of flow at Station 2, these toxicity results are highly
significant as will be explained later in this report.
-------
E-103
Two Process Waste Outfalls, Stations 3 and 4
Outfalls at Stations 3 and 4 are located in a vertical plane one
above the other and eventually join together prior to their combined
discharge into the South Fork of the Holston River. These outfalls
contain various spent process and cooling waters from the producer gas
plant (Building 10), and the acetic anhydride manufacturing areas
(Buildings 7 and 20). These two drains comprise the second largest BOD
load from Area A into the South Fork of the Holston River. The combined
discharge was about 9 mgd containing 1,820 lb/day BOD, 680 lb/day TOC,
and 870 lb/day of suspended solids.
Outfall At Station 6
This outfall originates from the HAAP A waterworks and carries ion
exchange regeneration wastes and sludges from filter bed backwaohing.
This outfall discharges on an irregular schedule. Previous data (from
the U.S. Army Environmental Hygiene Agency) indicate 40,000 gpd being
discharged via this outfall. A wide discrepancy exists between this
flox-r figure and the 1-million-gpw figure of waterworks sludge mentioned
in the November 1971 MUC0M report for HAAP A. Waste loads from this
outfall, at least as measured by the EPA Survey, were relatively minimal.
Still remaining are questions as to the frequency and magnitude of sludge
loads released from the other three waterworks outfalls. The dumping
of water treatment sludges into receiving streams is unsatisfactory.
Tank Farm Area Drainage, Station 7
Drainage from the main tank farm area (principally acetic acid
storage) averaged 188,000 gpd containing mean BOD and suspended solids
-------
E-104
loads of 37 lb/day and 38 lb/day, respectively. However the pH values
were somewhat erratic, ranging from 4.5 to 7.6. Spills and inadvertant
waste releases associated with HAAP chemical storage areas are treated
later in this report.
Tar Tank Storage Area, Station 8
The leachate and drainage accruing from the grounds around the tar
tank storage area, measured at Station 8, amounted to about 7,000 gpd
and was categorized as a noxious and heavy organic-laden waste stream.
Average BOD, COD, and TOC values were, respectively, greater than
2,030 mg/1, 7,960 mg/1, and 2,130 mg/1. Concentration of phenolics was
found to be 3,600 mg/1. This discharge, upon entering the South Fork
of the Holston River, caused an intense reddish coloration, detectable
about 100 yd into the main river. Waste loads in this outfall approxi-
mated 460 lb/day COD and 200 lb/day of phenolics. Flow-through bioassay
studies were conducted on this waste stream. Results, with fathead
minnows as the test species, disclosed that a 0.17 percent waste con-
centration would kill one-half of the test fish within 96 hr. This
toxicity is within the same range as some of the more potent pesticides.
Steam Power Plant, Station 9
Boiler blowdown and floor and miscellaneous drainage from the steam
power plant, as measured at Station 9, yielded an average discharge of
0.6 9 mgd, containing BOD, suspended solids, and phenolics loads amounting
to 40 lb/day, 160 lb/day and 12 lb/day, respectively. The phenolics
are probably attributable to coal tar and/or coal used as fuel for the
boilers.
-------
E-105
Ash Pit Overflow and Pump Seepage, Station 10
Ash pit overflow (originating from the steam plant), together
with packing gland seepage from pumps in the water intake house, were
measured at Station 10. HAAP recorded an average flow of 1.0 mgd for
Station 10 during the EPA survey. Sluice pits used for settling the
ash slurry (from the steam plant) represent the only external waste
treatment presently found in Area A. Waste loads being discharged to
the South Fork of the Holston River approximated 240 lb/day suspended
solids and 470 lb/day COD. Oil and grease values were negligible. The
*
EPA survey results suggest that unreported waste sources may be contri-
buting to this outfall.
Raw Water Supply, Station 11
The raw water supply for Area A pumped from the South Fork of the
Holston River, Station 11, was approximately 46.7 mgd, according to
special HDC pi tot tube studies that have been partially substantiated
by EPA and USAEHA calculations. The incoming river water was reported
to be of good quality with a BOD of 1.1 mg/1 and with 22 mg/1 of sus-
pended solids. Nutrient levels were low with the exception of 1.0 mg/1
of nitrite-nitrate, indicating some enrichment from upstream sources.
A summation of wastewater loads from Area A, for the period of
the EPA survey, discloses that 20,300 lb/day BOD, and 4,060 lb/day of
suspended solids were collectively being discharged to the South Fork
of the Holston River. Included in the suspended solids load was
3,600 lb/day being contributed by ASG Industries to the upper section
of the Main 11AAP Outfall, although much of this load actually settled
-------
E-106
out in the open (ASG) ditch before reaching the main outfall. As
mentioned previously in this report, the mean total volume of wastewater
discharge from the overall HAAP Area A was 43.3 mgd. This figure excludes
the flow contribution from Unnamed Creek and the ASG wastewaters.
Comparison of the 1972 EPA summary data to the 1971 USAEHA studies
and the RAPP application data is as follows:
WASTEWATER VALUES - SUM OF ALL ONFALLS*
USAEHA RAPP 1972 EPA
Flow (mgd) 37.6 40.3 43.3
BOD (lb/day) 9,360 9,920 20,300
COD (lb/day) 13,200 25,500 19,100
(approximately)
SS (lb/day) 6,060 68,000 4,060
By comparing the RAPP data to the EPA 1972 results, it is seen that
only the flow values are in reasonable agreements. Differences between
the 1972 results and the previous USAEHA data series are especially
critical because the latter figures were supposed to provide specific
engineering design criteria for upcoming 11AAP A waste treatment pro-
cesses. USAEHA Loadings for BOD and COD arc about one-half the 3 972
EPA loads. Although many other questions concerning MUCOM's approach
and the waste-abatenent plans for HAAP remain unanswered, the differences
expressed herein could alone greatly alter the expected performance of
the planned aeration basins at HAAP A. Design specifications that ap-
parently arc being eriployed at the present time will fall far short of
attaining effluent limitations predicated uoon "best practicable control
technology currently .lvailable."
* Production levels have remained constant.
-------
E-107
F. FUTURE WASTE-ABATEMENT SCHEDULE
The HAAP pollution-abatement plans comprise part of the AMC Moderni-
zation Program, subject to Congressional appropriation. These projects
under the Military Construction appropriations are expected to abate
serious air and water pollution problems at military installations as
addressed by Executive Order 11507. Furthermore, under the "Federal
Water Pollution Control Act Amendments of 1972," Section 313, all
Federal facilities having discharge or runoff of pollutants, are now
instructed to comply with Federal, State, interstate and local require-
ments regarding control and abatement of pollution to the same extent
that any "person" (as rigorously defined in the Act) is subject to the
requirements of the Act.
Pi*rfin<=»ni: ceeMons of *:h«a Act that »-'Ould occm to have application
to Federal facilities and Army munitions manufacturing plants are
Sections 301 and 302 dealing with Best Practicable Control Technology
required by 1 July 1977, and Best Available Technolocy required by
1 July 1983, both of which are directed to the national goal of elim-
inating the discharge of all pollutants. Additionally, Section 306 and
307 deal with standards of performance to be established through best
available demonstrated control technology for new pollution sources and
the establishment of toxic and prctreatment effluent standards, respectively.
However, under Section 313 of the Act, the President can exempt
any Federal facility effluent source if it is in the paramount interest
of the United States to do so; no such exemptions shall be granted in
waiving requirements under Sections 306 and 307 of the Act. It is also
-------
E-108
stated that no such exemptions shall be granted because of a lack of
appropriations, unless the President has specifically requested such
appropriation as part of the budgetary process, and Congress has failed
to make available such requested appropriation.
The November 1971 MUCOM report for HAAP specifically states that
HAAP has a planned program for abatement of each of its major pollutants;
the program is being implemented as rapidly as Federal funding permits.
As of the end of 1971, the report cites that progress in planning has
not been manifested in construction. It appeared doubtful that any ,
significant construction would be accomplished prior to December 1972.
We note the pilot aeration lagoon which is the first major item of
construction at Area A, and which was scheduled for completion in
December 1972, has not, at this date, been actually completed.
To gain the necessary background in understanding the envisioned
pollution abatement plans at HAAP one must be aware of the preceeding
and current criteria and standards under which these plans are being
formulated. Earlier standards/criteria include the State of Tennessee
air and water quality requirements and the CERL engineering design
criteria. An Army report, "Effluent and Airbient Air a>id Water Quality
Standards and. Regulations Applicable to Arrmj Ammunition Plants" has
been recently completed, but copies have not yet been received. The
most extensive and perhaps the most important set of criteria covering
Army munitions manufacturing plants Is that incorporated under the APSA
Guidelines that give proposed air and water quality standards for both
effluents and boundary conditions. These Guidelines are more complete
-------
E-109
and as limiting as any specific set of State or Federal standards, and
according to the Army, can be applied universally across the entire
MUCOM munitions manufacturing complex. MUCOM, in a recent Senior
Scientist Steering Group Briefing of February 197 3, compared future
waste abatement performance expected at its various Government Owned-
Company Operated (GOCO) facilities, specifically with the ArSA load limits.
Based upon this understanding, the APSA Guidelines should be judged
to be the controlling criteria for waste-abatement plans and activities
at most Army munitions facilities. EPA Effluent Limitations for muni-
tions manufacturing, if developed for purposes of Sections 301 and 304
of the Federal Water Pollution Control Act Amendments of 1972, will
rely heavily upon the APSA Guidelines. The APSA Regulations are
la chis report [Table E-24] as are the MUCOM pruposed schedules
for identified pollution-abatement projects at HAAP, Area A [Table E—25].
No funds have been appropriated beyond Fiscal Year 1973. During the
EPA survey, construction was in progress on a 4.5 million gal. pilot
aerated lagoon (Phase I Pond) for HAAP A,
In the case of the Holston Army Ammunition Plant, the effluent
limitations should be controlled by Water Quality Standards which call
for a minimum DO content of 5 mg/1 in both the South Fork and the
Holston River. These limitations are shown in Table E-26.
Relative to the overall MUCOM pollution-abatement schedule for
HAAP — based upon a preliminary analysis of the schedule, a number of
potenLial deficiencies in the schedule are apparent [See the "remarks"
column in Table E-25]. Additional information is necessary to ascertain,
-------
E_110 TABLE E-24
DEPARTMENT OF THE ARMY
AMMUNITION PROCUREMENT & SUPPLY AGENCY
PROPOSED GUIDELINES
APSA Regulation Proposed Air Quality Standards
Number 11-13
Design and Operating .Standards (Proposed)
Pollutant
Acidity
Ammon ia
Carbon Monoxide
Hydrocarbons
Hydrogrn Sulfide
Lead
Nitrogen Oxides (a)
Oxidants
Ozone
Particulates
Particulates, Incinerator
Sulfur Dioxide, Power Vlant
Sulfur Dioxide, Acid PJant
Boundary
Standard
_l2IEL_
12ug/M3(l)
0.15
0.15
0.20
0.02(b)
0.jug/M3(4)
0.10(2)
0.04
0.03
80ur/M3(4)
8Cug/M3(4)
0.04(3)
0.04(3)
Stack
Emission
Standard
(PP"0
50mg/M3
3 00.
200
100
• • •
200
?00tng/M3-,f
450mg/M3**
500
200
(1) Maximum value not to be exceeded mere than 170 of the hours per year.
(2) Average value for measurable limits over a 1 hour period is not to
be exceeded more than 1.0 percent of the time over a three month period.
(3) Maximum value not over L7> of uhe time in a 24-hour sample period.
(4) Maximum value for any 24-hour sample period.
(5) Average value for \ hour not to bo exceeded more than twice a year.
* This value is calculated from figure 1-] of AR 11-21.
** This value is calculated from value given in paragraph 1-7C.(2) of
AR 11-2].
(a) Nitrogen oxides include NO + N02.
-------
E-lll
TABLE E-24 (Cont.)
APSA Regulation Proposed Water Quality Standards
Number 11-11
Desip.n and Operating Standards - Ionic Materials (Proposed)
Pollutant Effluent Boundary
Standard Standard
ppm ppm
Aluminum
1.0
0.1
Ammonia
0.1
.01
Antimony*
0.05
0.01
Arsenic*
0.05
0.01
Barium*
1.0
0.1
Beryllium
0 05
0.01
Bicarbonate
35
35
Bismuth*
1.0
0.5
Boron
1,0
0.1
Bromide
1.0
0.5
Calcj urn
100
50
Cadmium*
0.01
0.01
Chlor ide
150
25
Cesium
1.0
0.1
Chromatc
0.05
0.05
Chromium
1.0
0.1
Cobalt*
1.0
0.1
Copper*
0.2
0.02
Cyanide
.025
0.01
Floride
1.0
0.7
Germanium*
.5
0.05
Iron
0.3
0.05
Lanthanum
1.0
0.1
Lead*
0.05
.01
Lithium
0.5
0.1
Magnesium
30
15
Manganese*
0.05
0.01
Mercury
0.01
0.01
Molybdenum*
1.0
0.1
Nickel*
1.0
0.1
Nitrate
5.0
0.5
PhosphaLe
0.5
0.05
Platinum*
.5
.05
Potassium
10
10
Radioactivity, Total
**
**
Selenium
0.01
0.01
Silicon Oxide
6
6
Silver*
0.05
0.01
Sodium
100
10-60
Strontium*
10
.1
Sulfate
200
50
Sulfite
2.0
0.1
Tantalum*
1.0
0.1
Tellurium
0.1
0.1
Thorium*
1.0
0.1
Tin*
1.0
0.1
Titanium*
1.0
0.1
Tungsten*
1.0
0.1
Uranium*
1.0
0.1
Vanadium*
0.5
0.1
Zinc
0.5
.05
Zironium*
1.0
0.1
Total Heavy Metal
5.0
5.0
* Heavy Metal
** Radioactive - gross
beta activity in the known
absence of Strontium
90 and alpha emitters not to exeped 1000 micromi crocunes
pel. litei at any ticre. "Absence of" is defined as not
more than 10 pico curies of Strontium 90 and 3 pico
curies of alpha ladiation
-------
E-l] 2
TABLE E-24 (Cont.)
Design and Operating Standards - Non Ionic Materials (Proposed)
Pollutant Effluent Boundary
Standard Standard
—EE2L- PP'n
Color (Color Units)* 3-30 3-30
Maximum Temperature C0!7) a 90
Oi] (ppm) 15 No Visible Oil
on Water Surface
Oxygen Dissolved
Minimum Value (ppm) 5 5
Biological Oxygen Demand (ppm) 15.0 2.0
Chemical Oxygen Demand (ppm) 20.0 2.0
Total Organic Carbon (ppm) 30.0 3.0
Phenols (ppb) 10 10
pH (pH Units) 6.0-3.5 6.0-8.5
Solids, Dissolved (ppm) 500 200
Solids, Suspended (ppm) 25 25
Irsecti c j.des Chlorinated
Hydrocarbons (ppb) 0 0
Insecticides Organic
Phosphorous (ppb) 0.5 0.1
insecticides Carbamate (ppb) 0.5 0.1
Herbicides (ppb) 0.1 0.1
Bacteria-Monthly Average (5000)-20
(No./100 ml)-7o of samples (2000)-5
(Coliform count)
TNT and Nitrobodics (ppm) 0.5 0.3
ppb - parts per billion
ppm - parts per million
a state water ambient temperature shall not be increased for more
than 5°F, with the hourly temperature change of the state water not
to exceed 1°F.
* color units are based on platinum-cobalt standard
-------
TABLi E-25
PROPOSED POLLUTION-ABATEMENT SCHEDULE
HAAP, AREA A - KINC-3PORT, TENNESSEE-
Item
Funding
FY
Esti Hated
Completion FY
Remarks
Aerated Lagoon, Pilot Plant only 70
(Phase I)
Aerated Lagoon, Full Scale (Phase II) 73
Separation of uncontaminated cooling
water from process waters
WATER
72
75
See comments on exnected performance, this
report but are presently not expected to
meet water quality standards requirements
Design and performance criteria not known
by EPA
Specified in 1971 MUCOM report but no real
followup evident in pollution abatement
schedule
Tank-Farm Dike System 72 74
Water- and Mr-Pollution Monitoring 73 -75
Systems
Waterworks sludge settling and land 72 74
disposal
Boiler Blowdown to Aeration Lagoon 72 74
Pumphouse Trash Disposal 72 74
Spill Containment dikes with routing of spilled
materials back to industrial wastewater
treatment system (See other continents in
this reoort.)
Sludge to be disposed of onto Area B grounds.
Because supernatants are designed to enter
lacoon, full objectives will not be met
until FY 76
Lagoon will not be completed until FY 76,
effectively causing delay in project
objective until 76, rather than 74
Further details sought
m
i
H-1
M
U)
-------
TABLE E-25 (Cont.)
PROPOSED POLLUTION-ABATEMENT SCHEDULE
HAAP, AREA A - KINGSPORT, TENNESSEE—
Item
Funding
FY
Estimated
Completion FY
Remarks
Replacement of distillation columns
serving sludge-heater sludges in
order to combat metals problem in
effluents, Bldg. 2
Asn pit waters, Bldg. S
Flash column improvements, Bldgs. 2
and 6, to improve propyl acetate
recovery
Control and/or elimination of
drainage from the tar tank area
Possible substitution of surface
condenser in lieu of barometric
condenser(s), Bldgs. 7 and 20
Alternative means of handling and
disDOsing of ball mill and sludge-
heater sludges
Removal of methyl nitrate, and
recovery of volatile gases from
azeotropic stills, Bldgs. 2
and/or 6
73
73
73
75
74
AIR
76(?)
Plans not known
Plans not known
Further details sought
Indicated as essential by EPA survey
Means of reducing water pollution
Likely a major waste source that should be
handled and disposed of in slurry or
semi-solids form
In feasibility stage only. Control for
Bldg. 6 apparently unplanned
Precipitators for the Pulverized
Coal Boiler (Area A?)
70
73
Further details sought
-------
TABLE E-:i5 (Cont.)
PROPOSED POLLUTION-ABATEMENT SCHEDULE
HAAP, AREA A - KINCSPORT, TENNESSEE-
I tern
Funding
FY
Est:, mated
Completion FY
Remarks
Precipitators on Boilers (Not known
if Area A and/or B)
Control and treatment of noxious
vent gases from anydride manufac-
turing (Bldgs. 7 and 20)
Vents from producer gas building
Vents from Bldg. 6, anhydride
refining operations
73
Further details sought
Determined by Army as a major air-pollution
source
Cited in USAEHA report
Cited in USAEHA report
NO control and treatment
x
SO control and treatment
x
Both NO and SO abatement technology being
studied by MU^OM on an overall facilities
basis. Prototype units now in development
stage including molecular sieve for NO
x
which is fairly advanced. NO and SO
X X
problems considered reasonably critical.
SOLID S—^
Trash Disposal Incinerators (to
serve bouth Areas A and B?)
72
74
Further details sought
aj Other items have been cited in MUCOM, USAEHA, and HAAP reports, but these items are either ambiguous or do not
have a demonstrated impact on waste-abatement progress.
W Open burning procedures for trash, debris, packaging materials spent process and explosives materials, etc.
continue to represent current practices. Even though this report has not emphasized the problems of open
burning and solid waste disposal, air pollution from open burning has been severe in many instances.
Advanced technology is urgently needed.
-------
E-116
TABLE E-26
*
STATE OF TENNESSEE EFFLUENT LIMITATIONS
FOR HAAP-AREAS A AND B
Parameter Effluent Limitations, lb/day
HAAP A
BOD 1,050
HAAP B
BOD 1,430
TKN 76
TN 620
NH 76
NO^ 556
* These are effluent limitations required to maintain a DO of 5 mg/1
in the South Fork and Hols ton Rivers.
-------
E-117
step by step, planned activity to be undertaken by HAAP. Certain
essential abatement items have not been either adequately described
or incorporated into the plans or appropriated to date under the MUCOM
schedule. Most importantly, no method seems available whereby the MUCOM
technology implementation schedule could be translated into a concise
statement as whether and when the effluent limitations can be met for
the HAAP installation. Further coordination and detailed review of
the HAAP waste abatement plans are needed between MUCOM, HAAP and the
Region IV, EPA Enforcement and Federal Activities Program Offices. ,
There are two aspects of the HAAP biological treatment systems that
pose serious concern about the success of this approach and that warrant
much more attention. Past design criteria for the aeration lagoons have
been liberal, and the effluent limits as specified will not meet the
effluent limitations. The biological systems as now described to the
EPA are not consistent with "best practicable control technology cur-
rently available." The other aspect deals with the kinds and amounts
of wastes being treated and their inherent impact upon the efficiency of
a biological system. If it is assumed that future HAAP A activities will
almost necessarily include the strict segregation of cooling waters from
process flows (the latter to receive treatment), then the (remaining)
0.6 to 4.0 mgd process wastewaters may be more adaptable to chemical/
physical treatment than to biological treatment, as now being planned
by HAAP.
Increased recycling, re-use, and recovery of process flows together
with strict segregation of cooling waters could hold the total process
-------
E-118
wastewaters at Area A down to 1 mgd, or less. Available data strongly
suggest that these process effluents per se, are extremely strong in
COD, complex organics, toxicity, and, possibly, metals content. Unfor-
tunately, proper data do not exist relative to the characteristics of
individual process flows: this is partly because the cooling and process
flows are now combined within the existing sewer system inside each
manufacturing building. Based upon similar experiences and with the
pieces of data now on handf the implied risk in using biological treat-
ment with the I1AAP wastes is abnormally high. Mixing, with additional
cooling water, and enlarging the size of the biological units are not
likely to substantially improve the creditability and performance of the
biological approach. Characterization of the separate process flows
could serve to clarify this most important issue.
-------
E-119
E-IX. HOLSTON ARMY AMIIUNITION PLANT-AREA B
A. GENERAL
Area B, the nitric acid and explosives manufacturing facility, is
situated on 6,370 acres immediately downstream of the confluence of the
North and South Forks of the Hols ton River [Figure IV-1) and approximately
6 miles west of the City of Kingsport and Area A.
Major processes at Area B, include nitric acid and ammonium nitrate
production; the preparation, manufacturine,, and packaging of various
explosives; and the recovery of waste acetic acid for shipment to Area A.
Area B was studied from 12 through 15 December 1972. Mr. Robert
Banner, Jr., chemical engineer at HDC, provided Information and assistance
during the industrial surveys.
B. UTILITIES AND WATER SUPPLY
Area B purchases its electricity and potable water (0.2 mgd) from
the City of Kingsport. HAAP records show that about 84.4 mgd of water
is pumped through an intake screen from the Holston River at two pumping
stations. About 14.5 mgd of this is treated by flocculation, sedimenta-
tion, and filtration to produce process water; about 0.75 mgd of this is
deionized for use as boiler-feed water.
Wastewaters discharged to the river totaled 84.6 mgd. A natural
stream entering the plant grounds (Arnotts Branch) contributed 11.4 mgd,
thus producing a net waste flow of 73.2 mgd.
Only one of the two water filtration plants was on stream at the
time of the EPA survey. The wastewater from cleaning the intake screens,
-------
E-120
backwashing the filters, and desludging the sedimentation basins enters
the river at Station 25. Pollution-abatement plans at the water treat-
ment facility call for land disposal of material removed from the intake
screens and for continuous sedimentation of filter backwash water with
solids going to thickeners, followed by sand bed drying and ultimate
disposal at a landfill. The sedimentation basins treating the main flow
will be converted to continuous sludge removal. Sludge from these basins
will also be thickened, dried on sand beds and disposal of at a landfill.
Wastewaters from the steam-production buildings consist of boiler
blowdown; ion exchanger backwash, regeneration wastes, and rinse water;
cinder decant water; condensate and cooling water. These wastes are
discharged through the main outfall, at Station 33. Present abatement
plans call for these wastes to be diverted to the industrial waste treat-
ment facility.
Sanitary wastes from Area 3 and from a few homes in the immediate
area are treated at a secondary treatment plant on the grounds, consisting
of primary sedimentation, trickling filters, secondary sedimentation and
chlorination. The adequately treated waste Is discharged to the Hols ton
River at Station 26.
C. PROCESS OPERATIONS AND HASTE SOURCES
The main activities at Area B include production and concentration
of nitric acid; production of ammonium nitrate: production, purification,
and packaging of explosives; and the recovery of dilute acetic acid,
which is then returned to Area A.
Nitric acid is produced by the oxidation of anhydrous ammonia to
-------
E-121
nitrogen oxide that, when dissolved in water, produces dilute nitric acid.
It is concentrated to 99 percent by extractive distillation with magnesium
nitrate. The process wastewaters from these operations include ammonia,
nitric acid, the nitrite ion, and a small amount of oil from the compres-
sors used in the ammonia oxidation process. These process wastes and
the cooling water from the processes are discharged at Station 33
[Figure E-12],
The concentrated nitric acid is, together with anhydrous ammonia,
employed in the production of a nitric acid-ammonium nitrate solution,
an intermediate step in this manufacturing process. Essentially all of
the waste flow from the operation is cooling water, low in contamination.
It was included in Station No. 33.
Manufacture of the explosive compounds takes place in a series of
facilities which receive glacial acetic acid (conveyed in tank cars) and
acetic anhydride from Area A, nitric acid and the ammonium nitrate-nitric
acid solution (conveyed in tank cars) from Area B, and other materials
purchased for use. These materials include hexamine (hexamethylene
tetramine), wax, TNT (trinitrotoluene), lacquer and several desensitizing
agents.
In the "Preparation" complex [Figure E-13] a number of operations are
carried out. Hexamine is dissolved in glacial acetic acid. The ammonium
nitrate-nitric acid solution is stored for use elsewhere. Lacquer mix-
tures for use later in the process are also prepared. Waste flows from
the Preparation complex include spilled hexamine and negligible amounts
-------
E-122
of acids and other organics. The wastes from these operations were
monitored at Stations 28 and 33.
The hexamine-acetic acid solution is pumped to the "Nitration"
operation where the hexamine solution is batch nitrated, with the nitric
acid-ammonium nitrate solution, to produce crude RDX (C.H.0,N,,) or I1MX
J O 0 o
(C.Ho0oNo). Acetic acid and acetic anhydride are also added to the
4 O O O
reaction vessel. After initial reaction, the mixture is "aged" and then
diluted with wastewater from a vent scrubber on the reaction vessel plus
other water from a later washing operation. Contaminants in the explosive
mixture at this point include acetic acid, ammonia, nitric acid, and
numerous abphatic and cyclic nitro compounds. Contaminated waste streams
from the nitration operation are routed through a catch basin in route
to the industrial sf.wer. The waste flows from this operation include
cooling water, condensate, agitator seal water, and floor and equipment
washdown water. The contaminants include RDX, HMX, acetic acid, and
other materials, mostly from leaks and spills in the nitration operation.
The flows from the various nitration facilities were monitored at Sta-
tions 28, 29, 31 and 33.
The crude RDX or HMX slurry is pumped from "Nitration" to "Washing."
Another source of crude explosive is the "B-line" (to be discussed later).
In the washing operation, the explosive is filtered, washed, and reslur-
ried for transfer to another scries of processing areas. The filtrate
and most of the water used to wash the explosive, at a 60 percent acid
concentration, are sent to the "B-line" area for recovery of acetic acid
and ammonia. The final dilute filtrate is sent to "Nitration" to be used
-------
KINGSPORT UNIVERSITY CENTER
MT CARMEL
ADMINISTRATION AREA
RAW WATER RESERVOIR*
!"o? , O
BARRIER PENINSULA
35
HAAf-l BOUID/ST
M ASA HUE ARIA
7 NMLES TO HOLUSTON
UHOKIA RECOVERY
EXPLOSIVES MANUFACTURING AREA
SODIUM NITRATE
U&OQNS
STEAM PLANT
SODFUM NITRATE
LA600KS
WASTEWATER TREATMENT PLANT
3 O
27
CLOSED CONDUIT
1000
1000
SCALE IN FEET
SURFACE WATER AH0 / OR 0PEH DITCH
36
SAMPLE LOCATION
Figure E-12 Sanpiinj Stations Holstoo Urnj AinssBiitioa Plant - 6
Ringspoft. Tennessee
-------
¦(W-TI3T !B$P££Tiea
PACKAGES
BECjlYSTALLIZATiOK -(G^'
OUTSIDE
VEUD08S
Figure E-13. SCHEMATIC OF EXPLOSIVE PRODUCTION LINE-AREA B, HOLSTON ARMY AMMUNITION PLANT
Courtesy of MTD, Picatinny Arsenal, Dover, N.J.
Taken from W. Heidelberger Report, Nov, 1971.
-------
E-123
as dilution water. The washed explosive is reslurried and pumped to
another complex for further processing. The contaminated wastes, con-
taining explosives, acetic acid, nitric acid, and other components of the
mixture, pass through baffled catch basins before entering the industrial
sewer. They were sampled at Stations 28, 29, 31 and 33.
The washed explosive slurry is then pumped to the "Recrystallization"
facilities, which, in addition to recrvstallization, accomplish dewatering
and compounding of special-purpose explosives. The slurry is pumped into
dissolvers containing solvents. Depending upon the type of crystal de-
sired in the explosive, the solvents used can be cyclohexanone, acetone,
or toluene. After dissolution, the solvent is distilled off, condensed,
and re-used. The batch is then cooled and either dewatered in the crystal-
lization process or cpnt on ar= a slurry to the "De^atering" operation.
The wastewaters — mostly cooling water, seal water, and condensate, were
sampled at Stations 28, 29, 30, 31 and 32. The contaminated flows pass
through baffled catch basins before being introduced to the sewers. The
contaminants include solvents, explosives, lacquers, and other compound-
ing agents.
The explosive slurry or dewatered explosive is then sent to "De-
watering" for grinding or dewatering and grindine. All grinding is done
in a water slurry. In order to remove explosives, which are later sent
to receiving tanks, the filtrate is settled, and the overflow water drains
to a catch basin and then to the sewer. The ground, dewatered explosives
(as a wet cake) arc then sent to another scries of facilities for com-
pounding. The wastewaters, containing explosives, solvents, condensate,
-------
E-124
acetic acid, settling tank overflow, and wash water are sampled at Sta-
tions 28, 29 and 31.
Compounding of the final product is accomplished in the "Incorpo-
ration" process where RDX or HMX are mixed with melted TNT (the resultant
water layer being sewered) to form Composition R. This material is
heated, wax is added, and then the mixture is solidified by passing it
onto a cooled conveyor belt. In other operations in this scries, the
explosive in wet cake form is dried in kettles, perforated trays, or in
drying ovens. In all cases the air used in drying is scrubbed with
water before being discharged to the atmosphere. The wastewaters, con-
taining explosives (including TNT), were sampled at Stations 28, 29 and 31.
In the TNT-receiving area, TNT is brought in by truck, unpackaged,
and dumped into melt kettles for transportation to the "Incorporation"
operation. Packaging of some compounded explosives is also carried out
at these buildings. Explosive dusts are drawn to a wet scrubber for
removal. The scrubber water and floor wash water flow to an industrial
sewer through catch basins and were sampled at Stations 28 and 31.
The final step in explosives manufacturing occurs in the "rack-
aging" area. The explosives, received in barrels or carts, are packaged
and loaded on trucks for shipment to local storage or to railroad loading
docks. Dust is exhausted from the buildings and scrubbed with water.
The scrubber water and floor and equipment washdown water were sampled
at Stations 28, 29 and 31.
The 60-percent acetic acid solution from the "Washing" operation is
sent to the "B-line" facilities for recovery of the acetic acid. The
-------
E-125
solution contains acetic acid, nitric acid, and a small amount of RDX
and HMX. First the solution is neutralized with sodium hydroxide and
sent to a primary evaporator. About 80 percent of the feed is volatil-
ized, condensed, and recovered as 60 percent acetic acid. The remaining
20 percent is withdrawn from the bottom of the evaporator as a siudge.
The sludge is diluted and heated to about 100°C. During cooling, an
RDX. slurry is added as seed to aid crystallization of the RDX-liMX. The
crystallized explosives are returned to the "Washing" operation.
The remaining liquid is sent to a secondary evaporator that recovers
more acetic acid. The sludge from the secondary evaporators is steam
stripped to recover the remaining acetic acid. (A1J recovered acetic
acid is sent to Area A for purification and concentration.) Sodium
hydroxide is added to the stripped sludge. This converts the ammonium
nitrate in the sludge to sodium nitrate and ammonia, the residual acetic
acid to sodium acetate, and the residual RDX and HMX to ammonia and
sodium nitrate. The ammonia released in the reactor is absorbed in
water and sent to an ammonia recovery area. The sludge from the reactor
is pumped to storage lagoons for storage until a fertilizer facility is
constructed. The waste flows, containing acetic acid and a small amount
of ammonia, were sampled at Station 33.
Aqueous ammonia from the "B-line" is distilled to recover anhydrous
ammonia, which is used as fertilizer, for impurities in the recovered
anhydrous ammonia prevent its further use in manufacturing of explosives.
The major impurities in the column bottoms are methyl amine and dimethyl
amine; these are sampled at Station 33.
-------
E-126
D. REFUSE ACT PERMIT APPLICATION (RAPP) DATA
In September 1971, the Holston Army Ammunition Plant submitted an
application for a permit to discharge under the Refuse Act Permit Pro-
gram [Table E-27]. This table also shows the total pollutant loads from
the Army Environmental Hygiene Agency survey of March to June 1971, the
EPA survey station numbers consistent with the RAPP codes, and totals
from the EPA survey.
The RAPP data and EPA survey results for BOD and SS agree closely.
However, ammonia loads do not agree. A critical consideration is that
the total content of ammonia in the waste stream will determine whether
or not a special ammona-removal process is necessary. It is recommended
that the ammonia content of the waste streams be closely surveyed before
designing the final treatment processes.
E. DISCUSSION OF 19 72 EPA FINDINGS
There were 12 sampling points at Area B [Figure E-12 and Table E-28].
Stations 25, 28, 29, 30, and 33 were manually sampled at two-hr inter-
vals and composited on an equal-volume basis. Stations 26, 31, 32, 34,
and 36 were sampled using a SERCO automatic sampler and composited on
an equal-volume basis at the end of 24 hr. Grab samples were collected
manually from stations 27 and 35 twice daily and combined to make one
composite sample for each station. Temperature, pll, and conductivity
were measured each time a manual sample was collected and at least three
times per day at stations where automatic samplers were used. Samples
for oil-and-grense analysis were 24-hr composites consisting of well-
mixed grab samples collected every two hr (except for Station 31 which
-------
TABLE E-27
OUTFALL CHARACTERISTICS FROM RAPP APPLICATION", HOLSTON ARMY AMMUNITION PLANT-AREA B
KIXGSPORT, TENNESSEE
RAPP EPA
Outfall St-i.
Flow
BOD
COD
SS
Ml
TKN
NOi-N
P-Total
Kn
Nurrber No.£/
mp,d
tn^/1
lb/day
er/1
lb/day
ms/1
lb /day
re/1
lb/day
ms/1
lb/day
ihr/1
lo/dav
ite/1 lb/day
irg/l lb/aav
001 25
1.0
36
304
455
3,790
1,653
13,774
1
9
3
26
1
11
1 4
2 17
002 26
0.1
5
4
23
19
4
3
7
6
6 5
003 27
SURFACE DRAINAGE ONLY - NO
INFORMATION GIVEN
004 23
1.2
70
726
180
1,796
18
183
4
36
4
40
10
104
1 8
005 29,30
33.0
21
6,500
61
19,175
51
16,142
3
854
3
1,076
1
325
0.5 127
0.5 149
006 b/
0.0001
007 31,32
2.4
166
3,323
386
7,712
25
507
3
63
3
73
1
21
1 13
5
008 33
54. 7
13
5,903
30
13,623
25
11,407
3
1,506
3
1,689
2
8S5
1 456_
TOTALS
97.4
16,760
46,115
42.016
2,468
2,904
1,352
613
171
TOTALS FROM
USAEi'A REPORT-'
TOTALS FROM
EPA Su"R\E"f
77.1
84.6
<6,500
14,750
22,250
9,760
31,493
802
102
1,120
<600
1,670
2,482
<250
86
£/ These station numbers refer to the 1972 study,
b/ This outfall was not sampled.
£/ This refers to the Ij.S. Amy EnvironTental Hygiene Agency Report, 19 March - 28 June 1971.
M
I
(—1
NJ
-------
Survey
Station
Number
25
26
27
28
29
30^
31—7
2,2—
33
34
35
36
TABLE E-28
DESCRIPTION OF EPA SAMPLING STATIONS, HAAP, AREA B
KINGSPORT, TENNESSEE
EPA SURVEY OF 12 THROUGH 15 DECEMBER 1972
M
I
M
ho
00
Refuse Act Permit
Discharge Number
001
002
003
004
005
005
007
007
008
Type of
Sample
Composite
Composite
Grab
Composite
Composite
Composite
Composite
Composite
Composite
Composite
Grab
Composite
a/ Flows at
Stations
Stations 29 and 30 mixed together
31 and 32.
Station Location
Filter plant backwash, at manhole adjacent to perimeter
road
Sewage treatment plant effluent, prior to chlorination
Surface water drainage from production lines 9 and 10,
at open ditch adjacent to perimeter road
Process wastes at sewer outfall, adjacent to perimeter
road
Process wastes and cooling water at outfall, adjacent
to perimeter road
Coolinf; and surface waters from production lines 6 and 7,
at sewer outfall adjacent to perimeter road
Process wastes from production lines 3, 4, and 5, at
sewer outfall adjacent to perimeter road
Cooling water from production lines 3, 4, and 5, at
sewer outfall adjacent to perimeter road
Main outfall ditch, at HAAP effluent water quality monitor
station
Raw-water intake at Building 201 pumphouse
Arnotts Branch, upstream of nitric-acid production area
Raw-water intake at Building 209 pumphouse
before entering the river. The same is true of flows at
-------
E-129
was a composite of three equal volume grab samples taken over a 4 to 6
hr period).
Flow measurements were made at the following stations:
1. Measurements carried out at Stations 25 and 31 were made on
instantaneous flows at two-hr intervals with a Marsh-McBirney
electromagnetic water current meter. With the flow at Station
31 only being measured for 24 hr because the high river stage
surcharged the outfall pipe;
2. Flows measured at Stations 26 and 27 were obtained using
V-notch weirs and flow recorders;
3. The waste streams at Stations 28, 29, 30, 32, 33, and 35 were
gaged several times daily during the study period, and a rating
curve was established.
The flows at the remaining stations were extracted from HAAP records.
The flows and analytical data obtained have been tabulated [Table E—29].
The BOD of the raw water entering the plant was, from Arnotts
Branch, 100 lb/day and, from the water in the Holston River, 4,130 lb/day.
For suspended solids the load from Arnotts Branch was 4,400 lb/day and in
the intake from the Holston River, 32,570 lb/day. The total BOD leaving
the plant was 14,750 lb/day and the total suspended-solids content was
31,493 lb/day.
Therefore, the net contribution of the plant was about 10,000 lb
BOD/day, The streams leaving the plant had about 5,000 lb of suspended
solids/day less than the entering streams. This net loss of suspended
solids cannot be explained on the basis of the information available.
-------
w
I
(—1
160
> 94
BOD (lb/day)
16
39
35
550
COD
41-407
224
TOC
5-6 5.6
7-8
7.3
5-9
6.6
12-115
47
Total Solids
313-441 369
314-335
324
161-176
167
249-350
269
Suspended Solids
7-36 21
2-15
8
12-42
22
11-80
34
Suspended Solids (lb/day)
160
43
240
220
Total Kjeldahl Nitrogen-N
N.D.-S/
0.9-1.1
1.0
0.6-1.0
0.77
8.8-35
17.6
Total Kjeldanl Kitrogen-N (lb/day)
5.70
106
nh3-n
N.D.
< 0.5-0.6
< 0.5
N.D.
6.5-26
13.1
(lb/day)
< 2
78.8
N0o + J.O--N
0.6-3.1 1.6
3.6-4.0
3.8
1.5-1.6
1.5
1.5-5.4
3.1
NO~ + SO^-N (lb/day)
13.3
21.5
16.6
180
Total Pnosphorus-P
0.04-0.07 0.05
0.45-0.49
0.47
0.06-0.07
0.07
0.02-5.9-
2.0
Total Phosphorus-P (lb/day)
13.2
Oil and Grease
1-23
10
Manganese
0.3-0.5 0.4
-------
TABLE e-29 (Cont.)
SUMMARY OF FIELD MEASUREMENTS AND CHEMICAL DATA
HOLSTON ARMY AMMUN LTI0>J PLANT-AREA B
KIKGSPORT, TENNESSEE
13-15 DECIDER 1972
Station Naxber 29 30 21 32.
Station Description^/
Process
Wastewaters
Cooling ar.d
Surface Waters
Process Wastewaters
Cooling and Surface Waters
CRM 139.6)
(RM
139.6)
(RM 139
2)
(RM 139.2)
Para-eterb/
Range
Average
Range
Average
Range
Average
Range
Average
Flo<; (rpgd)
3.02-3.97
3.54
11.5-14.4
13 2
2.1-2.5
2.3
8.22-9 11
8.8
p-i (stanoard units), range
4.1-6.8
6.8-8.4
6.5-7.3
6.5-7.7
Ter.peracure (°C) , range
20.0-22 5
15.0-19.0
15.0-13.0
12 5-15.5
CoiductiMty (yshos/ctn) , range
260-380
200-340
230-340
210-260
BOD
150-240
193
7.6-13
10.2
110-350
213
9.5-14.0
12
BOD (lb/day)
5680
1101
4090
840
COD
42-235
175
69-151
97
TOC
24-56
44.2
4-8
6.3
24-38
28.7
8-10
8.7
Total Solids
197-231
217
156-199
180
180-228
203
218-246
232
Suspended Solids
10-20
15
32-41
36
6-11
8
67-96
79
Suspended Solics (lb/day)
440
3940
150
5800
Total Kjeldahl Nitrogen-N
1.0-7.1
3.95
0.6-0.7
0.6
0.9-1.6
1.2
0.6-0.8
0.73
Total Kjeldahl Nilrogen-N (lb/day)
120
n.d.£/
70.1
24
53.5
1.K3-N
< 0.5-2.0
0.8
N.D.
N.D.
NhU-!.' (lb/day)
24.3
:.02 - :,o3 -n
3 9-8.8
5.9
1.2-3.6
2.0
2.1-2.7
2.4
0.9-1.0
1.0
'..02 — NOj -I! (lb/day)
170
212
47
70.4
Total Pbos,»horus-p
0. 02-0.04
0.03
0.10-0.14
0.11
0.03-0.06
0.04
0.16-0.18
0.17
Total Pbospnorus-P (lb/day)
12.7
,
12.4
Oil ard Grease
4-10
7
0.3^
5-23
11
Marganese
0. lx-0.2
0.15
0.3
I
I-1
-------
M
1
UJ
NJ
TABLE E-29. (Cont.)_
SUMMARY OF FIELD MEASUREMENTS AND CHEMICAL DATA
KOLSTON ARMY AXMUSITICS PLANT-AREA B
KINC-SPORX, TENNESSEE
13-15 DECEMBER 1972
StatioT Number
33
34
35
36
Station Description^/
Main Outfall Ditch
Intake Building 201
Arnott
Branch
Intake Building
209
(RM
; ]37.S)
(RM 141.1)
(RM 137
.9/0.8)
(RM 139.0)
Parameter—^
Ran Re
AveraRe
Ranpe Average
Range
Average
Range
Average
Flow (ngd)
46.7-58.8
53.0
29 SJ
9.87-12.9
11.4
55. ^
ph (stardard units) , range
6.5-7.8
6.8-7.8
7.2-7.4
7.2-7.9
Terpcrature (°C), range
li-0-17.0
10.0-12.5
11.5-12.0
10.5-11.0
Conductivity (umhos/cm), range
270-520
200-360
320-360
210-290
BOD
3.5-7.A
5.5
1.4-2.8 2.2
0.4-2.0
1.1
6.9-8.7
7.3
EOD (lo/day)
2400
4 If 4
100
TOC
5-6
5.7
4-10
6
7 V
7
lotal Solids
215-287
255
162-199 173
229-402
295
205-229
218
Suspended Solids
22-65
47
22-25 24
32-54
43
52-62
58
Suspended Solids (lb/day)
20,500
N D..S/
4400
Total Kjeldahl Nitrogen-N
v 0.5-0.5
< 0.5
< 0.5-0.6 0.5
< 0.5-0.5
< 0.5
Total Kjeldahl Kitrogen-N (lb/day)
<221
m3- m
N.D.
N.D.
N.D.
N.D.
ko2 + N03-}|
3.2-5.8
4.3
0.9-1.7 1.2
1.2-1.6
1.4
1.1-1.9
1.5
NO + NO —N
1920
137
Total Phosphorus-P
0.09-0.10
0.10
0.09-0.10 0.10
0.03-0.20
0.09
0.08-0.12
0.10
Total Phosphorus-P (lb/day)
42.7
8.24
Oil and Grease
< 1-2
< 1.0
< 1-5
2
j /
Manganese
0.08-0.1
0.09
0.2-0.3 0.2
0.1^
9.1
a/ See T.ible 7 for Station Description.
b/ All values reported as ng/1, except where otherwise specified,
c/ ;; D. - None Detected,
d/ All values are the same.
e/ This value was obtained from HAAP records.
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E-133
It seems likely that the BOD reading (14,750 lb/day) is not
representative of total organic content because of the presence of
complex organic materials that may not exert an oxygen demand. The TOC
leaving the plant totaled only about 6,100 lb/day. (Very few, if any,
organic materials are resistant to the TOC analysis.) The presence of
suspended solids may have made the TOC readings low in that, possibly,
a representative sample was not introduced into the TOC analyzer.
Only about 100 lb/day of ammonia were in the effluent streams,
but almost 2,500 lb/day of oxidized nitrogen a°d NO^) are released
to the river, and this should be reduced before being discharged.
Complex organic analyses were performed on samples collected from
Stations 28 and 29 with a combined flow of 4.24 mgd. These waste dis-
charges result from the explosives manufacturing phase of the HAAP Area B
process [Table E—28]. Samples were also collected from Stations 31 and 33
and analyzed for complex organics. These waste discharges had a com-
bined flow of 55.3 mgd and resulted from process effluents from produc-
tion lines 3, 4 and 5, as well as the Main Outfall [Table E—28]. The
analyses were conducted on an equal aliquot from the listed outfalls.
Compounds isolated are listed in Table E-30. The quantities of tri-
nitrotoluene (TNT) and cyclohexanone discharged by the Holston Army
Ammunition Plant, Area B, represent a serious hazard to aquatic life in
the receiving waters of the Holston River. The amount of cyclohexanone
discharged from Stations 28 and 29 ranged between 15.3 lb/day and
76.9 lb/day. The quantity of TNT in this discharge was between 9.1 lb/day
and 46 lb/day. The amount of cyclohexanone discharged in the effluents
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E-134
TABLE E-30
ORGANIC POLLUTANTS IDENTIFIED
HOLSTON ARMY AMMUNITION PLANT-AREA B
DECEMBER 197 2
Sample
Stations Compound
28 and 29 cyclohexanone
2,4,6-trinitrotoluene
2-cyclohexylcyclohexanone
31 and 33 cyclohexanone
2-nonanone
di-n-butyIketone
2,2-dimethyloctanol
1,11-dodecadiene
2 or 4-sec-butylcyclohexanol
phthalic acid esters (unidentified)
3,6-dimethyl-6-isopropyl-2-
cyclohexanonc
2-cyclohexylcyclohexanone
Concentration
(m%/l)
1.30
0.78
•k
0.02
i
1.40
A
0.02
0,005*
0.005*
0.005*
0.030*
ft
0.50
0.015*
0.010*
* Estimated - Standard not available for confirmation.
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E-135
from Stations 31 and 33 ranged between 54 lb/day and 1,240 lb/day. These
quantities are likely to result in adverse effects of a chronic nature
through continuous exposure of aquatic life.
Static bioassay studies on streams 29 and 30 after mixing, but
prior to entering the river, had a 96-hr TL value of 23 percent. The
m
combined flow was 16.72 mgd. A factor 1/20 was employed to obtain a
river flow that would dilute this so that there would be no long-term
impact on aquatic life. A bioassay on stream 31 (at 2.3 mgd) also
indicated a 96-hour TL^ of 23 percent. Similar calculations were per-
formed on this flow. The summation of the two bioassay calculations
disclosed that a minimum flow of 2,600 cfs would have to be maintained
in the river to ensure no long-term impact on aquatic life from toxic
effects. This figure Uul include dilution water thaL would be
necessary to protect the aquatic life from wastewater discharges at
Area A or from other sources in the area.
F. FUTURE WASTE ABATEMENT SCHEDULE
The Federal Water Pollution Control Act Amendments of 1972 and
Executive Order 11507 apply to Area B as well as to Area A. [See dis-
cussion of the Act in Appendix E-VIIL.]
MUCOM has proposed schedules for identified pollution abatement
projects at I1AAP, Area B [Table E—31]. No funds have been appropriated
beyond Fiscal Year 1973. During the EPA survey, no construction had
been started for Area B pollution control facilities.
Relative to the overall MUCOM pollution-abatement schedule — based
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TABLE E-31
PROPOSED POLLUTION-ABATEMENT SCHEDULE
HAAP, AREA B - KINGSPORT, TENNESSEE-
M
I
u>
Item
Funding
FY
Estimated
Conplction FY
Remarks
Boiler blowdown Bldgs. 200, 222
treatment to aerated lagoon
Filter-plant sludge
Process-area dike system
Pumphouse trash removal
Industrial waste treatment -
aerated lagoon
72
72
72
72
72
WATER
74
74
74
76
Design criteria complete. Architect-Engineer
evaluating design criteria.
Design complete. Design and performance
criteria not known by EPA. Includes
7-acre drying bed.
Contract let and contractor working 10/72.
Includes 2 spill containment ponds. Effluent
from these ponds to be returned to Area B
treatment system.
Solids removed and sent to incinerator.
Design completed. Contract being negotiated
with Clark-Dietz. Design criteria as
specified by CERL not satisfactory. APSA
guidelines should be used as design criteria.
Total segregation of uncontaminated
cooling water from process water
Remove sodium nitrate from holding
ponds and replace sodium nitrate
process units
Specified in 1971 IIUCOM Report but no real
follow up in pollution abatement schedules.
Plans unknown
Water and Air Pollution Monitoring
System
73
75
Ammonia-rich waste streams should be
subjected to ammonia stripping
Plans unknown
-------
TABLE E-:.l (Cont.)
PROPOSED POLLUTION-ABATEMENT SCHEDULE
IIAAP, AREA B - KINCSPORT, TENNESSEE—
I ten
Funding
FY
Esti nated
CoTTiplc tion Ti
Remarks
Electrostatic precipitators on
pulverized coal boilers
Ammonia oxidation Dupont AOP units
Magnesium concentration units
(MAGGIE units)
72
72
AIR
73
75
No details
Pilot test using molecular sieve on AOP unit
to remove MO from air.
x
Deferred to October 1975. No details on
design.
NO Control and Treatment
x
SO Control and Treatment
x
Refuse disposal incinerator
nonexplosive
Explosives incinerators
72
73
SOLIDS
74
76
b/
Both NO and SO _ abatement technology being
studied by JiU&DM on an overall facilities
basis. Prototype units now in development
stage including molecular sieve for NO _
which is fairlv advanced. NO and SO
X X
problems considered reasonably critical
Completion date October 1973. Twenty ton/day
Two incinerators: a 2 ton/day and an 11 ton/day
These three incinerators should eliminate
all open-pit burning.
a./ Other items have been cited in MUCOM, US^EHA and HAAP reports, but these items are either ambiguous or do not
have a denonstrated impact on water-abatement progress,
b/ Open burning procedures for trash, debris, packaging materials spent process, and explosives materials, etc.
continue to represent current practices. Even though this report has not emphasized the problems of open
burning and solid-waste disposal, air pollution from opan burning has been severe in many instances. Advanced
technology is urgently needed.
M
I
U>
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E-138
upon a preliminary analysis of Che schedule, a number of potential de-
ficiencies are apparent [mentioned in the "remarks" column in Table E-31].
Water Pollution
On the basis of a survey by the Army Environmental Hygiene Agency,
the Army Construction Engineering Research Laboratory (CERL) provided
recommendations and design criteria for pollution-control facilities
at Area B. These recommendations included:
1. The water treatment plant settlers should be revised to permit
continuous sludge removal, with the sludge being thickened
and spread on sand beds for dewatering to approximately 20-
percent solids and then disposed of in a sanitary landfill.
2. All non-contaminated cooling-water streams should be separated
from process waste streams and discharged directly to the river.
3. Ammonia-rich waste streams should be treated at the source by
ammonia stripping to reduce the ammonia content prior to intro-
duction to the industrial waste treatment system.
A. The combined industrial wastes, with phosphate added as a
nutrient, should be treated in aerated lagoons with a minimum
of 15 hr aeration, and the mixed liquor should be settled and
the settler effluent discharged to the river with waste sludges
being stabilized by aerobic digestion and ultimately disposed
of by land spreading.
Standards established by the State of Tennessee were used by CERL
as the basis for the design of the waste-treatment facilities. These
standards require maximum effluent limitations of 450 mg/1 BOD and
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E-139
180 mg/1 suspended solids. The Array Ammunition Procurement and Supply
Agency has proposed standards (APSAR 11-11) requiring a maximum BOD of
15 mg/1 and a suspended solids content not to exceed 25 mg/1. The
maximum ammonia content was set at 0.1 mg/1 and nitrate at 5 mg/1.
The maximum TNT and nitrobodies content was set at 0.5 mg/1. The total
heavy-metals content was set at 5.0 mg/1 (max).
CERL has conducted treatability studies on selected effluents from
the llolston Army Ammunition Plant explosives-manufacturing area. Using
acclimated organisms, the Laboratory found that the wastes were not
toxic to organisms and were, therefore, treatable by a biological process.
Because of the complex and toxic organic materials present it is ques-
tionable whether a biomass can be kept viable under these conditions.
If the biomass does survive, it is most unlikely that it will degrade
complex organic materials such as RDX, 11MX, TNT, and cyclohexanone.
It is recommended that HAAP proceed immediately with separation of
non-contaminated cooling water from the process-waste streams. If the
resultant process-waste stream is compatible with biological treatment,
this should be the first stage in the treatment system. If biological
treatment is not applicable, the first stage could consist of chemical
coagulation followed by flocculation and sedimentation. Either process
should be designed to give a product with a suspended-solids content
of 30 mg/1 or less.
Regardless of whether the first stage treatment is biological or
chemical in nature, a second stage, possibly consisting of adsorption
on activated carbon or oxidation with ozone, will be necessary. Because
-------
E-140
of the explosive nature of some of the contaminants, thermal regeneration
of the carbon may not be feasible, and ozonation would be the process of
choice. This second-stage treatment is necessary, even after biological
oxidation, to remove the complex organic materials that, In many cases,
are extremely toxic substances.
If the concentrated waste stream is not amenable to biological
oxidation, and if the first two stages consist of chemical treatment and
carbon adsorntion, it is likely that acetic acid and any other low mole-
cular weight organic materials will not be adsorbed on the carbon or*,
at best, will be adsorbed to only a slight degree. If the ratio of
low-molecular-weight organic materials to the nitrate ion is not too
high, these materials will be removed in the denitrification process
(discussed in the next paragraph). If the low-molecular-weight organic
materials are in excess of that needed for dentrification, an aerobic
biological-treatment process should be carried out after carbon adsorption.
Because of the high concentration of nitrate ions in the wastewater,
even after the first and second stages, a nitrogen-removal step will be
necessary to reduce the high algae growth potential of the receiving
stream. Because all of the nitrogen will be in the oxidized state, a
biological denitrification process is the logical step for this stage.
It is conventional to use methanol as a substrate for this process but,
In this case, it could be less expensive and more convenient to use
acetic acid as the substrate. It could also be necessary to add phos-
phate ion to the denitrification reactor.
The final effluent from this series of operations will be low in
-------
E-141
oxygen demand, suspended solids, and nitrogen forms and will not pose a
pollution threat to the Hols ton Pdver.
Air Pollution
There are four main sources of air pollution in Area B. These are:
1. Nitric-acid producers;
2. Nitric-acid concentration;
3. Open burning of trash; and
4. Steam production.
The nitric-acid producers, at full capacity, release about 17,000 lb
of NO /day to the atmosphere. The level of NO in the general area is
X X
greater than 5 ppm, the maximum level recommended for personnel.
The nitric-acid concentrators, at full production, contribute about
5,200 lb of NO^/day.
About 13 tons of refuse and explosive wastes are burned each day by
open burning techniques. It is estimated that this operation adds
1,410 lb of contaminants to the atmosphere each day.
The six coal-fired and the three natural-gas or oil-fired boilers
release about 28,000 lb of particulates and 11,000 lb of sulfur oxides
to the atmosphere each day.
Refuse disposal is to be handled by sanitary landfill or by incin-
eration with wet scrubbing of the stack gas. Design criteria are avail-
able for an explosives incinerator.
Consideration is being given to the use of electrostatic precipi-
tators or wet scrubbers to renove particulate matter fi*om the boiler-
building stack gas.
-------
E-142
The control of SO and NO from the incinerators and steam genera-
X X
tors has not been given much consideration. Use of low-sulfur coal may
solve the SO problem, and NO can be reduced by control of combustion
X X
temperatures, by catalytic reducers, or by molecular sieves.
Little consideration has been given to the volatile orp.anic wastes
released to the atmosphere from the various manufacturing operations in
Area B. These materials include cyclohexanone, toluene, acetone, acetic
acid, and methyl nitrate, a by-product of the nitration operation.
Studies should be undertaken to determine the extent of pollution from
these sources and, as required, control measures should be developed
and installed.
In all pollution-control operations, care should be taken to assure
that the pollution is not transferred from water to the atmosphere or
vice versa.
-------
APPENDIX F
CITY OF KIHCSPORT, TENNESSEE
INDUSTRIAL WASTE OpvDr NANCE KO. 1539
-------
F-l
ORDINANCE NO. 1539
An ordinance regulaLing the use of public and private sewers in the
City of Kingcport, Tennessee, providing for trcatiaent of domestic sewage
and the discharge* of waters and such industrial wastes Into the public
sewers, as may be remitted hereby and repeal all ordinances or parts of
ordinances in conflict, with the provisions of this ordinance, and to fix
a penalty for the violation thereof.
BE IT ORDAII'TD BY THE CITY OF KIKCSP0T1T, AS FOLLOWS:
Article 1
Section 1. The general purposes of this ordinance arc:
(a) To establish control of the contribution of domestic sewage,
industrial wastes, or oth-Er wastes ''bich ir.ay be permitted to
be discharged into the public seiners or into any natural
outlet within the jurisdiction of the City of Kingsport.
(b) To prohibit the contribution of oewage or industrial waste
to the public sewers which may cause undue maintenance or
operiti onil difficulties In the ss "age \ or'-s .
(c) To prohibi t the discharge into public sewers of all wastes
which contain sufficient polluting inaLcrial ns nay create
A hazard to hunans or animals and/or as nay be deemed now
or in the future undue pollution to uric receiving streams.
(d) To provide by special agvecmont wi ch the City for the dis-
charge of wastes to the public sewers which are sub |ect to
a sewer service charge. In general, the sewer service charge
will be based on excessive treatnent cost and the origin of
waters carrying waste frora sources oLner tiian the public
water sunnly.
Section 2. Unless the context specifically indicates otherwise, the
meaning of the terns in this ordinance shall lie as follows:
(a) "City" shall mean the City of Kingsport, Tennessee, or an
authorised agent or agents actinp for t.he City of Kingsport.
(b) "Sewage" shall pean the combination of the water-carried
wastes from residences, business buildings, institutions,
and industrial establishments, together ui th such giound,
surface, and storm waLers as raay be present.
-------
"Public Sewer" shall mean a sewer controlled or maintained by
the City.
"Sanitary Sewer" shall mean a .sewer which carries sewage and
to which storm, surface, ground and unpolluted waters are not
intentionally admitted.
"Storm Sewer" shall mean a sewer which carries "Storm and sur-
face waters and drainage, but excludes sewage and do]luted
industrial wastes.
"Combined Sewer" shall mean a sewer which receives both surface
runoff and sewage.
"Building Sewer" shall mean the extension from Lhe building
drain to the public sewer or other place of disposal.
"Sewage Works" shall mean all facilities for collecting,
pumping, treating, and disposing of sewage.
"Natural Outlet" shall mean any outlet into a watercourse,
pond, lake, ditch, or other surface or ground water.
"Industrial Wastes" shall mean any wastes from industrial pro-
cesses as distinct from domestic sewage.
"Person" shall rean any individual, firm, company, association,
society, corporation, or group.
"Biochemical Oxygen Demand" shall moan the quantity of oxygen
utilized in the biochemical oxidation of organic matter under
standard laboratory procedure in 5 days at ?0 degrees centi-
grade, exnressed in parts per million by weight.
"pH" shall mean the logarithm of the reciprocal of the weight
of hydrogen ions in grams per liter of solution.
"Properly Shreddpd Garbage" shall mean the wastes from the
preparation, cooking, and dispensing of food that has been
shredded to such degree that all particles wi 11 be carried
freely under flow conditions normally prevailing in public
sewers wjth no particles greater than 1/2 inch in any
dimension.
"Suspended Solids" shall mean solids that either float on the
surface of, or are Ln suspension in, water, scwape, or other
liquids; and which arc removable by laboratory filtering.
-------
F-3
Article II
Use of Public Sewers Required
Section 3. It shall be unlawful for any person to deposit or cause to
be deposited in an insanitary manner upon public or private property
within the jurisdiction of the City of Kingsport any fecal matter or
other objectionable waste.
Section 4. It shall be unlavjful to discharge to any natural outlet
within the jurisdiction of the City of Kingsport any sanitary sewage,
industrial waste or other polluted waters except where such waters
have been treated in a suitable treatment works, or unless the dis-
charge to the natural outlet Is permitted by the Division of Sanitary
Engineering of the State of Tennessee Department of Public Health.
Section 5. Except as hereinafter provided, or as Is provided in thp(
"Plumbing Ordinances of the City of Kingsport", it shall be unlawful
to construct, or maintain any privy, private vault, septic tank, or
other facility intended or used for the disposal of sewage.
Section 6. The owner of all houses, buildings, or structures used for
human occupancy, employment, recreation, or other purposes, including
property where people are regularly assembled, situated within the City
an a -»r.~ ---- ?llcy or right-of~;ray in which there is a
public sanitary or combined sewer is hereby required at his expense to
install and maintain suitable toilet facilities therein, and to connect
such facilities directly with the public sewer in accordance with the
provisions of this ordinance and the plumbing ordinance of the City of
Kingsport within 30 days after date of official notice to do so, pro-
vided that said sewer is within 200 feet of the structure and of such
elevation as to serve the structure, or property.
Section 7. At such times as a public sewer becomes available to a
property served by a private disposal system, as provided in Section 6,
a direct connection shall be made to the public sewer; and any septic
tank, or similar private disposal facility, shall be abandoned and
filled with material approved by the £ity.
Article III
Use of Public Sewers
Section 8. No person shall discharge or cause to be discharged any
storm water, surface water, ground water, roof runoff, subsurface drain-
age, cooling water, or unpolluted industrial process waters to any
sanitary sewer.
-------
F-4
Section 9. Storm Water and all other unpolluted drainage shall be dis-
charged to such sewers as are specifically designated as combined sewers
or storm sewers, or to a natural outlet approved by authorities having
jurisdiction.
Section 10. Except as herein provided, no person shall discharge or
cause to be discharged to any public sewer any of the following des-
cribed wastes:
(a) Any ashes, cinders, sand, mud, line slurry, lime residue, straw,
shavings, metal, glass, rags, feathers, tar, plastics, woods,
paunch manure, paraffin, or any other substance capable of
causing obstructions to flows in sewers or interfering with the
operation of the sewage works.
(b) Any waters or wastes containing a toxic or poisonous substance
in sufficient quantity to injure or interfere with any sewage
treatment process, constitute a hazard to humans or animals
or create any hazard in the receiving waters of the sewage
treatment plant.
Materials such as iron, lead, copper, zinc, chromium, and
similar toxic substances shall be limited in quantity so that
the total contribution will not cause interference in any
normal operation of sewage treatment.
(c) Any gasoline, benzine, naptha, fuel oil, mineral oil, or
other flammable or explosive liquid, gas, or solid.
(d) Any waters or wastes which may contain more than 100 parts
per million by weight, of fat, oil, and/or grease.
(e) Any liquid or vapor having a temperature higher than 150 de-
grees fahrenheit.
(f) Any waste having a pH lower than 5.5 or higher than 9.0, or
having any other corrosive property capable of causing damage
or hazard to structures, equipment, or personnel of the sewage
works.
(g) Any waters or wastes containing suspended solids of such
character and quantity that unusual provision, attention,
or expense is required to handle such material at the sewage
treatment plant.
(h) Any garbage that has not been properly shredded.
(i) Any noxious or malodorous gas or substance capable of creating
a public nuisance or hazard.
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F-5
(j) No polluted industrial waste from any source shall be permit-
ted to be discharged into any sanitary sewer without the per-
mission of the City, it being necessary to control the quantity
and quality of industrial wastes thus discharged, since the
primary function of the treatment plant is to provide for the
treatment of domestic sewage.
Section 11. That the admission to the public sewers of any waters or
wastes having a 5 day biochemical oxygen demand greater than 300 parts
per million by weight, or containing more than 350 pans per million by
weight of suspended solids, or containing any quantity of substance
having the characteristics of those listed in Section 10 shall be sub-
ject to review and approval by the City. Where necessary, in the opinion
of the City, the contributor shall provide at hi3 expense approved pre-
liminary treatment to reduce the biochemical oxygen demand, and/or
suspended solids to the preceding limits, or reduce objectionable char-
acteristics to within acceptable limits.
Section 12. Plans, specifications, and other pertinent data relating
to proposed preliminary treatment facilities as mentioned in Section 11
shall be submitted for approval of the City and/or the Division of Sani-
tary Engineering of the State of Tennessee Health Department: and no
construction of such facilities shall be commenced until said approvals
are obtained in writing.
Section 13. That the discharge of waters and wastes to public sewers
having discharge characteristics which require unusual provision, atten-
tion, or expense in any part of the sewage works, shall be subject to
reivew and approva'l of the City. When necessary, in the opinion of the
City, provisions shall be made to control rates of discharge by the
contributor.
Section 14. Grease, oil, and sand removal facilities shall be provided
by the producer when in the opinion of the City they are necessary for
the proper handling of liquid wastes containing grease in excessive
amounts, or any flammable wastes, sand, and/or other harmful ingredients.
All interceptors shall be of a type and capacity approved by the City,
and shall be located as to be readily and easily accessible for cleaning
and inspection.
Where installed, all removal facilities shall be maintained
by the owner, at his expense, in continuous efficient operation at all
times.
Section 15. When requested by the City, the owner of any property served
by the public sewer carrying industrial waste shall install an approved
control manhole in the buidling sewer, to facilitate observing, sampling,
and measuring the wastes. Such control manhole, when required, shall be
-------
F-6
accessible at all times to the City, safely located, and shall be con-
structed in accordance with plans approved by the City. The manhole
shall be installed and maintained by the owner at his expense and shall
be safe and accessible at all times.
Section 16. All tests and analyses of the characteristics of waters and
wastes to which reference has been made in this ordinance shall be deter-
mined in accordance with the latest edition of "Standard Methods for the
Examination of Water and Sewage" and shall be determined on samples taken
from the control manhole provided in Section 15. In the event that no
control manhole has been required, the control manhole shall be considered
to be the nearest manhole downstream or other sampling place approved by
the City.
Section 17. Highly colored wastes or waters which are of unusual volume,
concentration of solids, or composition which may or may not pass through
the sewage works unchanged are subject to review by the City for the
approval of admission to public sewers, or modification or pretreatment
at the point of origin to permit admission.
Section 18. Within 30 days after passage of this ordinance, all users
of the public sewers who discharge industrial wastes to the public sewer
shall file with their request for a permit from the City a statement
relative to their industrial wastes, vhich statement shall furnish al]
pertinent data including quantity of flow and a representative analysis
of the waters discharged to the public sewers and any other information
that may be required by the City or the Tennessee State Health Department.
Section 19. Within 30 days after passage of this ordinance, all users
of public sewers whose wastes are admissible to the sewers, but because
of above normal concentrations as compared to normal domestic sewage
and/or waste due to water not purchased from the public water supply
shall be subject to a sever service charge, and shall enter into an
agreement with the City for the disposal of wastes subject to condi-
tions as may be determined.
Section 20. The volume sewer service charge for customers inside the
corporate limits of the City of Kingsport for wastes due to water not
purchased from the Kingsport Water Department shall be as follows:
Gallons Per Thousand
First 2,500 $ .30
Next 22,500 .15
Next 50,000 .10
Next 125,000 .075
All over 200,000 .05
Minimum Charge of $0.75 per month.
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F -7
The City may require that the customer provide at his expense approved
metering facilities to determine the amount of waste subject to the
volume sewer service charge. Such metering facilities shall be acces-
sible to the City during working hours. The customer shall bear the
cost of maintaining, repairing, and testing of such metering facilities
as the City directs. In lieu of approved metering facilities, the cus-
tomer shall present data acceptable to the City whereby a representative
sewer charge may be made. The data shall include the average daily
amount of waste and the maximum daily amount which may be anticipated.
The City reserves the right to have the customer conduct such surveys or
to conduct such surveys itself as the City elects, to verify the data.
Such surveys are to be conducted at least once a year by the customer
and at other times as the City directs. The City reserves the right to
have the customer install approved metering facilities in order to
determine and control the volume of discharges into the public sewer.
Section 21. No statement contained in Section 20 of this ordinance ^hall
be construed as preventing any agreement or arrangement between the iiity
and any person whereby a waste of unusual strength or character may be
accepted by the City for treatment, upon the payment by the person of an
addition charge for such service.
Section 22. The City shall, after due notice, have the right to refuse
sewer service to a person if it is found that a particular wa3te whose
character, compopition or volume ?s such that the sewage system fails
in the performance of the prime function for which it was intended,
(Same being the treatment of domestic sewage) even though the City has
previously approved or accepted the waste for treatment.
Article IV
Powers and Authority of Inspectors
Section 23. Duly authorized agents of the City bearing proper identifi-
cation shall be permitted to enter upon such properties as may be necessary
for the purpose of inspecting, observing, measuring, sampling, and testing,
in accordance with the provisions of this ordinance, during reasonable
working hours.
Article V
Penalties
Section 24. Any person violating any of the provisions of this ordinance
shall be liable to the City for any and all expenses, losses, or damages
resulting to the public or the sewage treatment plant of the City, by
reason of such violation.
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F-8
Section 25. Any person violating any provision of this ordinance shall
be guilty of a misdemeanor, and upon conviction thereof, shall be fined
not less than one dollar and not more than fifty dollars; and each day's
violation thereof shall constitute and be deemed a distinct and separate
offense.
Section 26. The City is hereby granted authority to discontinue city
water and/or sewer service to any person who violates any of the pro-
visions of this ordinance or who fails to make sewer service charge
payments when due.
Article VI
Validity
Section 27. If any part, section, subsection, sentence, clause, or
phrase of this ordinance is for any reason declared to be unconstitutional
or invalid such decision shall not affect the validity of the remaining
portions of this ordinance.
Article VII
Ordinance in Force
Section 28. Be it further ordained by the City of Kingsport, that this
ordinance shall take effect from the after the date of final passage
and publication, as the law directs, the public welfare of the City of
Kingsport, Tennessee, requiring it.
Mayor
ATTEST:
City Recorder
Passed on 1st Reading
Passed on 2nd Reading
Passed on 3rd Reading
Approved as to form and correctness:
City Attorney
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APPENDIX G
BIOASSAY METHODS
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G-l
BIOASSAY METHODS
During the period 28 November through 17 December 3 972, personnel
from the National Field Investigations Centers-Cincinnati and Denver
conducted static and flow-through fish bioassays on effluents
discharged to the Holston River and the South Fork of the Holston
River by three industries in Kingsport, Tennessee. Fish bioassays t
were performed to determine the toxicity of waste pollutants dis-
charged into these waters.
Samples of effluents used in the bioassays were obtained from
rive discharges at the Holston Army Ammunition Plant Area A (HAAP
"A"), four discharges at the Holston Army Ammunition riant Area B
(EAAP "B"), and five discharges at the Tennessee Eastman Corporation
Plant (TEC). Effluent samples from each discharge were assigned
station numbers which are described in Appendix C of this report.
An initial grab sample was collected for use in a 24-hr screen-
ing bioassay test. A subsequent composite sample was collected
during a 24-hr period for use in the full-scale bioassay. The amount
of sample composited depended on whether a static bioassay or both
static and flow-through bioassays were to be conducted. Ten gal. were
composited in two five-gal. polyethylene carboys for a single static
bioassay; 220 gal. were composited in four 55-gal. epoxy-Jined
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raetal drums for both static and floi^-through bioassays.. During the
compositing of each sample, portions of the effluent were distrxbuted
equally between the containers to ensure uniformity in al] containers
Dilution water was obtained periodically during the study from
the reservoir upstream of Fort Patrick Henry DAm located on the South
Fork of the Hols ton River. This reservoir was upstream of all
major sources of industrial and municipal discharge.
The bioassays were conducted in the NFTC mobile laboratory teinpor
arily located at the Kingsport municipal Wastewater Treatment Plant.
All effluents were tested for toxicity according to standard fish
bioassay procedures.—''
Fathead minnows {Piwepkales promelas) were used in the bioassays
of all effluents. A duplicate set of static bioassays were conducted
on two effluents (17 and 23) employing bluegill (Lepomis macrochivus)
to further define toxicity.
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