National Enforcement Investigations Center, Denver
CHARACTERIZATION AND EVALUATION OF WASTEWATER SOURCES
UNITED STATES STEEL CORPORATION
CLAIRTON WORKS
PITTSBURGH, PENNSYLVANIA
k January 28-31, 1976
U.S. Environmental Protection
- I., i..
Office of Enforcement
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Environmental Protection Agency
Office of Enforcement
CHARACTERIZATION AND EVALUATION OF WASTEWATER SOURCES
UNITED STATES STEEL CORPORATION
CLAIRTON WORKS
PITTSBURGH, PENNSYLVANIA
January 28-31, 1976
May 1976
National Enforcement Investigations Center - Denver, Colorado
and
Region III - Philadelphia, Pennsylvania
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CONTENTS
I INTRODUCTION 4
II SUMMARY 10
III MONITORING PROCEDURES 18
IV FINDINGS OF IN-PLANT MONITORING .... 21
OUTFALL 001 23
OUTFALL 002 32
OUTFALL 003 34
OUTFALL 004 36
OUTFALL 005 . 38
OUTFALL 006 39
OUTFALL 007 40
OUTFALL 008 41
OUTFALL 010 41
OUTFALLS Oil and 012 42
OUTFALL 013 44
OUTFALL 014 44
OUTFALLS 015 and 115 45
OUTFALL 016 46
OUTFALL 017 47
OUTFALL 018 * 48
AIR COMPRESSOR DISCHARGE 48
OUTFALL 020 49
OUTFALLS 21 to 44 53
STEEL WORKS PLANT WATER INTAKE .... 54
COKE WORKS PLANT WATER INTAKE 55
RESULTS OF ORGANIC ANALYSIS 56
WASTE LOADS DISCHARGED PER UNIT OF
PRODUCTION 56
V MONITORING REQUIREMENTS 60
REFERENCES 66
APPENDIX
A RECONNAISSANCE REPORT 68
B STUDY METHODS 122
C ANALYTICAL PROCEDURES AND
QUALITY CONTROL 126
D CHAIN OF CUSTODY PROCEDURES ... 129
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TABLES
1 Description of Monitoring Stations ... 19
2 Sampling Schematic 20
3 Production 22
4 Summary of Field Measurements and
Analytical Data 24
5 Summary of Oil/Grease and Phenol
Analyses 26
6 Summary of Total and Hexavalent
Chromium Data 29
7 Summary of Self-Monitoring Data .... 30
8 USSC Proposed Limitations 33
9 Organic Chemical Pollutants 57
10 Load Discharged per Unit of Production . 59
11 Recommended Monitoring Requirements . . 62
FIGURES
1 Location Map - USSC Clairton Works ... 5
2 Flow Schematic - USSC Clairton Works . . 8
3 Flow Schematic - USSC Clairton Works . . 9
4 Flow Diagram for Contaminated
Wastewater Treatment Plant 52
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I. INTRODUCTION
The United States Steel Corporation (USSC) Clairton Works consists
of a coke plant, chemical plant and steel plant [Fig. 1], The facility
is in the city of Clairton on the Monongahela River, about 29 km (18 mi)
upstream of the confluence of the Ohio, Monongahela and Allegheny Rivers.
The major activity at Clairton is the coking of coal and subsequent
recovery of chemicals. The coke and chemical plants, operating since
1918, produce 18,200 to 21,800 m. tons (20,000 to 24,000 tons)/day of
coke* from 20 batteries containing a total of 1,375 ovens. Gases from
the coking operation are processed to produce: coke oven gas (used for
fuel at all the USSC Monongahela Valley Works); benzene; xylene; toluene;
solvent naphtha; pyridene; alpha, beta and gamma picolene; phenols;
ortho- and meta-para cresols; cresylic acid blends; naphthalene; creosote;
pitch; ammonium sulfate; anhydrous ammonia; and sulfur.
The steel plant includes a blast furnace** for either basic iron or
ferromanganese (FeMn) production and four steel finishing mills (14-,
18-, 21- and 22-inch***). The mills, built from 1905-1908, process
steel slabs from the USSC Duquesne Works into angles, bulb angles,
channels, beams, elevator tee bars, zee bars, other bars, plates, floor
plates and special sections. Production is about 2,180 m. tons (2,400
tons)/day finished steel products, and 820 m. tons (900 tons)/day basic
Iron or 450 m. tons (500 tons)/day ferromanganese production.
* From 27,200 to 31,800 m. tons (20,000 to 35,000 tons)/day of coat
is used to produce this coke.
** The blast furnace has not operated since January 1975.
*** Metric equivalents: 35.6-, 45.7-, 53.3-, 55.9-cm
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The capacity1 during 1976 for each operating area is listed below:
Process
m.tons/mo
Capacity
tons/mo
FeMn
Iron
22-inch mill
18-inch mill
14-inch mill
21-inch mill
Coal charged to ovens
Furnace coke produced
Sulfur produced
Ammonia recovered from
coke oven gas
Ammonia recovered from water
Syn ammonia produced
Slag
Light oil products
Tar products
0
0
5,347
8,192
4,585
5,357
732,700
509,600
2,106
1,046
528
18,081
0 3
13,000 m~/mo
28,000 m /mo
0
0
5,889
9,022
5,050
5,900
806,900
561,200
2,319
1,152
581
19,913
0
3,442,000 gal/mo
7,384,000 gal/mo
t Capacity given is base volume for 1976 which is predicted
performance of the various producing sectors at Clairton
Works.
Two intake stations on the Monongahela River supply process and
f
cooling water for this facility. The steel plant pumphouse* has five
Wilson-Snyder pumps with a pumping capacity of 300,000 m /day (79.5
mgd). Pumps 1-4 are rated at 45 m /min (11,800 gpm) and pump 5 at 30
3
m /min (8,000 gpm). Some of the water is treated by lime softening and
filtration for the blast furnace boiler makeup.
The coke plant pumphouse** has six Wilson-Snyder centrifugal pumps
with capacities as follows:
* This pumphouse supplies water for processes which discharge waste-
waters through outfalls 001, 002 and 003.
** This pumphouse supplies water for processes which discharge waste-
waters through outfalls 004, 005, 006, 007, 008, 010, Oily 012,
013, 014, 015, 115, 016, 017, 018 and 020.
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Pump Capacity
m3/day mgd
1
132,000
35
2
121,000
32
3
87,000
23
4
159,000
42
5
159,000
42
6
159,000
42
A portion of this water is treated for use in the benzene boiler house,
the No. 2 coke works boiler house and the "Keystone" complex cooling
tower.
Wastewater is discharged daily into the Monongahela River through
outfalls 001, 002, 003, 013, 014, 015, 115, 015, 017 and 018* [Figs. 2, 3].
The remaining outfalls (i.e., 004, 005, 006, 007, 008, 010, 011, 012 and
020) discharge into Peters Creek, a tributary of the Monongahela River.
A dye study was conducted on outfalls 003, 004, 008 and 020 by NEIC
personnel December 15-18, 1975 to determine if the USSC sampling locations
are representative. These stations reportedly contain about 75% of the
total wastewater flow discharged from the Clairton Works. Results show
that the sampling locations on outfalls 004, 008 and 020 were repre-
sentative. Wastewaters from the steel rolling mills (outfall 003)
combine at the manhole where USSC collects samples. Access to this
wastewater is possible at the river during low stages; however, at the
time of the dye study the outfall was surcharged. Therefore, the repre-
sentativeness of 003 could not be determined.
In-plant monitoring was conducted during January 28-31, 1976. This
report summarizes the survey results.
* Outfall numbers designated, on the National Pollutant Discharge
Elimination System (NPDES) permits.
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Figurt 2. flow Schematic - USSC Cloirlon Works
Co
CO
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u>
00
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II. SUMMARY
1. Wastewater discharges from all outfalls and water intakes were
monitored January 28-31, 1976. Flows, measured at outfalls 003,
004 and 008 using the dilution techniques, were in accord with
values reported in USSC self-monitoring data. Company-installed
flow measurement devices were used to obtain the contaminated
wastewater treatment facility and water intake flows. Twenty-four-
hour flow-weighted composites were collected from outfalls 003,
004, 020 and the contaminated wastewater treatment plant. Grab
samples were collected from outfalls 001, 002, 005, 006, 007, 008,
010, 011, 012, 013, 014, 015, 016, 017 and 018.
2. The blast furnace was banked.* The steel finishing mills which
process steel slabs from the Duquesne works were operating at a
combined production of 527 to 1,181 m. tons (581 to 1,301 tons)/day,
66 to 159% of the average production [795 m. tons (876 tons)/day]
reported for the period January-October 1975. Coke production
averaged 16,423 m. tons (18,087 tons)/day, similar to the average
production reported for January-October 1975.
3. Outfall 001 primarily contains blast furnace cooling water, barometric
condenser water, sand filter backwash and boiler blowdown. Daily
maximum oil/grease concentrations were low, ranging from <1 to 3
mg/1, which are in accord with values reported in USSC self-
monitoring data (1.8 to 5.7 mg/1). USSC has proposed a daily
* A banked furnace, although not in production, is maintained at lower
than operating temperature so it can be efficiently brought back
into production when necessary.
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maximum net oil/grease limitation for this outfall of 30 mg/1,
which is ten times the maximum gross concentration observed during
the survey.
Effluents from the blast furnace clarifier and slag settling basin
and cooling water are discharged through outfall 002. The Company
samples each effluent separately because a point does not exist
where the combined discharge can be sampled. As discussed earlier,
the blast furnace was banked; therefore, only cooling water was
being discharged. Grab samples of cooling water contained net
concentrations ranging from 0 to 8 mg/1 total suspended solids
(TSS); 0 to 0.03 mg/1 total cyanide [CN(T)]; and 0.01 to 0.03 mg/1
ammonia (NH^-N). USSC self-monitoring data show that TSS, total
cyanide and ammonia net concentrations ranged from 0 to 597; 0.01
to 1.54; and 0 to 1.3 mg/1, respectively.
USSC has proposed the following daily maximum gross limitations for
outfall 002:
Parameter
kg/day
lb/day
TSS
7,148
15,720
Ammonia
486
1,068
Cyanide
57
126
Phenol
14.7
32.4
2
Based on the Company-estimated flow of 36,000 m /day (9.6 mgd) and
self-monitoring data, the proposed TSS and cyanide limitations have
been exceeded.
Outfall 003 discharges process and cooling waters from the four
steel finishing mills. Flows through this outfall ranged from
79,800 to 98,000 m /day (21.1 to 25.9 mgd) compared to Company-
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estimated flows of 16,700 to 117,000 m^/day (4.4 to 30.8 mgd). The
USSC has proposed limitations for TSS and oil/grease (0/G). These
limitations are compared below with survey findings:
Parameter
USSC Proposed Limitations
NEIC Survey Data
Daily Average Daily Maximum
kg/day lb/day kg/day lb/day
Dail^y Average Daily Maximum
kg/day lb/day kg/day lb/day
TSS (Net)
18,681 41,099 56,200 123,297
0 0 0 0
0/G
2,185 4,810 6,560 14,430
570 1,250 670 1,470
Based on a flow of 130,500 m /day (34.5 mgd), the maximum flow
observed during the survey, the net TSS concentration would have to
exceed 430 mg/1 before a violation of daily maximum criteria would
occur.
6. Outfall 004, the main industrial sewer for the Clairton Works,
contains cooling tower blowdown, boiler blowdown, steam condensate,
barometric condenser water and primary cooler water. The discharge
ranged from 226,900 to 232,800 m^/day (60.0 to 61.5 mgd). The
Company estimates that this flow ranges from 183,000 to 392,000
m^/day (48.4 to 103.5 mgd).
During the survey, large TSS, total cyanide, ammonia and total
chromium loads were discharged into Peters Creek through outfall
004. The maximum loads (net) discharged were 12,500 kg (27,600
lb)/day TSS; 170 kg (375 lb)/day total cyanide; 1,500 kg (3,300
lb)/day ammonia; and 60 kg (132 lb)/day total chromium. USSC
proposes only to measure the flow and temperature without any
numerical limitations.
7. Outfall 005 contains benzene plant cooling water, ash pit effluent,
boiler blowdown and treatment plant backwash water. The Company
collects samples from a manhole where, in addition to the main
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sewer, five drains/sewers terminate. Representative sampling and
flow measurement at this location is impossible. The Company
estimates that the flow varies from 8,700 to 12,100 m^/day (2.3 to
3.2 mgd).
Grab samples collected from this discharge contained 390 mg/1 of
TSS.
USSC has proposed TSS limitations for outfall 005 as follows:
Parameter (kg/day) (lb/day)
Daily average 5,010 11,025
Daily maximum 15,030 33,075
o
Based on a flow of 12,100 m /day (3.2 mgd), the TSS concentration
of a representative sample would have to exceed 1,240 mg/1 (more
than three times the concentration observed during the survey)
before the daily maximum limitation would be exceeded.
The 006 discharge is cooling water from the pitch coolers. Outfall
007 contains cooling water from the tar stills, strainer building
and electrode pitch factory. These outfalls terminate at common
drop manholes which empty directly into Peters Creek. More than
one discharge enters each manhole, precluding the collection of
representative samples and flow measurements.
USSC proposes that outfall 006 be monitored for temperature and pH
with the flow to be estimated. Survey results showed that the
samples collected contained from 1 to 8 mg/1 of oil/grease, in-
dicating the necessity for monitoring oil/grease.
The Company has proposed a 30 mg/1 daily maximum oil/grease limita-
tion for outfall 007. During the survey, the maximum oil/grease
concentration (2 mg/1) was one-fifteenth of the proposed limitation.
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9. Outfall 008 contains cooling, seal and condenser waters from the
No. 1 powerhouse. Flows through this outfall ranged from
35,600 to 43,100 m /day {9.4 to 11.4 mgd) lower than the Company-
estimated flows of 45,000 to 90,500 m^/day (11.9 to 23.9 mgd).
During the survey, oil/grease and phenol concentrations were low
(<1 to 3 mg/1 and <0.005 mg/1, respectively), similar to values
reported by the USSC. USSC proposes to measure flow, temperature
and pH of outfall 008.
10. Outfall 010 contains cooling tower blowdown, cooling waters and
condensate. USSC estimates that from 3,000 to 4,200 m3/day (0.78
to 1.10 mgd) of wastewater is discharged into Peters Creek. The
USSC has proposed a daily maximum oil/grease limitation of 30 mg/1
for this discharge. During the survey, the maximum oil/grease
concentration was 5 mg/1, considerably less than the proposed
1 imitation.
11. Outfalls 011 and 012 both contain contact cooling water from prill
3
pitch units. Estimated flow through each outfall is 2,100 m /day
(0.568 mgd). USSC has proposed the following limitations for each
outfall.
Parameter
Daily Average
Daily Maximum
kg/day lb/day
kg/day lb/day
TSS
1,330 2,925
3,990 8,775
0/G
910 2,000
2,730 6,000
Phenol
0.15 0.32
0.45 0.96
Based on the Company-estimated flow, the TSS, 0/G and phenol con-
centrations must exceed 1,850, 1,270 and 0.20 mg/1, respectively,
before the daily maximum values are violated. The above concentrations
are 3, 70 and 3 times greater than the maximum values observed
during the survey.
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12. Discharge 013 contains blowdown from the flash evaporator and
cooling tower. USSC proposes to monitor this outfall for only
flow, temperature and pH. Daily total cyanide concentrations
ranged from 0.03 to 0.18 mg/1. The results indicate the necessity
for monitoring total cyanide.
13. Outfall 014 contains cooling tower blowdown, cooling water and
condensate. The Company currently samples this outfall at two
locations (designated by them as 014 and 114) and has proposed to
monitor only flow, temperature and pH.
Survey results showed that phenol concentrations for the combined
discharge ranged from 0.616 to 0.882 mg/1 which greatly exceeds
self-monitoring data (range of 0 to 0.158 mg/1).
14. Outfalls 015 and 115 each contain cooling water and blowdown from
the No. 2 coke works boiler house. Each outfall is normally submerged
during a portion of the year. Daily maximum oil/grease concen-
trations were negligible (1 to 3 mg/1).
USSC has proposed no effluent limitations for outfalls 015 and 115.
The Company plans only to estimate flow and measure the temperature
and pH.
15. Outfall 016 contains backwash water from a continuous backwash
strainer. TSS concentrations of the discharge were equal to or
less than intake water concentrations. Again, USSC plans only to
estimate flow and measure pH and temperature on this discharge.
16. Outfall 017 contains wastewaters originating in the Road Tar
Terminal area. Daily oil/grease concentrations ranged from 1 to 24
mg/1. USSC proposes only to estimate flow and measure the pH and
temperature. The survey results indicate the necessity for monitoring
this outfall for oil/grease.
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17. Discharge 018 contains cooling water, blowdown and condensates from
the No. 2 powerhouse. USSC proposes to measure pH and temperature
and estimate the flow. Oil/grease concentrations in this discharge
were low (1 to 3 mg/1).
18. Air compressor cooling water is discharged into the Monongahela
River through an outfall designated by USSC as 023. Oil/grease
concentrations were high (maximum of 26 mg/1), indicating con-
tamination from the air compressor. Since this was not an NPDES-
designated outfall, USSC has not proposed any limitations.
19. Outfall 020 contains the effluent from the contaminated wastewater
treatment plant and No. 2 primary cooler water. During the survey,
the efficiency of the treatment plant was 95% or greater for total
and amenable cyanide [CN(A)], ammonia, oil/grease and phenol. The
TSS effluent concentrations were from 4 to 8 times greater than the
influent concentrations. During the survey the flow through the
sand filters was erratic, which could possibly have caused the high
TSS effluent concentrations.
The USSC has proposed effluent limitations for outfall 020. The
waste loads found during the survey and those proposed are compared
below:
Parameter USSC Proposed Limitations NEIC Survey Data
Daily Average Daily Maximum Daily Average Daily Maximum
kg/day lb/day kg/day lb/day mg/1 kg/day lb/day kg/day lb/day mg/1
TSS
730
1,606
2,190
4,818
NA+
1,540
3,390
1,830
4,040
63
nh3-n
2,727
6,000
8,181
18,000
NA
225
500
465
1,030
16
CN(A)
2.7
6.0
8.1
18
0.5
33
70
49
110
1
Phenol
8.3
18.4
24.9
55
NA
1.9
4.0
2.5
5.4
0.116
0/G
218
480
654
1,440
30
37
80
70
150
3
t Sot Applicable
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On all three monitoring days, the USSC-proposed daily maximum waste
load 1 imitations for cyanide were exceeded. The daily average load
limitations for cyanide and TSS exceeded the USSC-proposed daily
limitations by 400 and 200%, respectively, during the three-day
monitoring period.
Flows from outfalls 002, 003, 004 and 020 should be continuously
measured and recorded. Flows from outfalls 001, 102, 202, 005,
006, 007, 008, 010, 011, 012, 013, 014 and 017 should be measured
the same day samples are collected.
Representative samples were collected where possible. Represen-
tative sample collection and/or accurate flow measurements cannot
be made at the present monitoring locations for outfalls 005, 006,
007, 011 and 012. Wastewaters from the 14- and 22-inch mills join
with the 18- and 21-inch mills in the manhole where outfall 003 is
sampled.
Since no other point existed to sample this outfall, the represen-
tativeness could not be determined. Outfalls 015, 115 and 018 are
monitored at the river. Since sample containers scrape the river
wall during sample collection, sample contamination is highly
probable. Modification of present outfall configuration is necessary
before accurate flow measurements and representative sampling can
be conducted.
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III. MONITORING PROCEDURES
During August 26-28, 1975 a reconnaissance visit was conducted at
the Clairton Works to observe process operations, waste treatment systems
and sampling locations [Appendix A].
The amount of intake water is measured at both the steel and coke
pumphouses. According to Company officials, these meters are calibrated
every six months. The amount of wastewater discharged is estimated
monthly by Company personnel based on intake flows. The exact procedures
used by USSC for estimating flows were not provided.
In conducting self-monitoring, Company personnel collect time-
weighted 24-hour composite samples comprised of three aliquots taken
once per shift. Grab samples are normally collected during the daylight
shift (0800 to 1600 hours).
In-plant monitoring was conducted at selected stations [Table 1 and
Figs. 2, 3] during January 28-31, 1976. The parameters monitored and
the sample type for each station are shown in Table 2. Details on the
sampling procedures and flow measurement techniques, analytical procedures
and quality control, and chain of custody procedures are contained in
Appendices B, C and D, respectively.
Effluent flows at outfalls 003, 004 and 008 were obtained using the
dye dilution technique [Appendix B]. Influent and effluent flows for
the contaminated wastewater treatment plant and the two water intake
flows were obtained from Company-installed meters. According to Company
representatives, these meters were checked in September 1975 and found
to be accurate. Procedures used to check the meters were not provided.
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Tabla 1
DESCRIPTION OF MONITORING STATIONS
USSC CLAIRTON WORKS
Station*
Description
Reported Flow
mJ/dav mgd
x 10*
001
Untreated cooling water (barometric condenser) from
blast furnace
53
14
002
Treated effluent and cooling water from blast furnace
36
9.6
102
Treated effluent from the blast furnace clarlfler
-
-
202
Treated effluent from the blast furnace slag pit
-
-
003
Process effluents and cooling waters from 14-, 18-,
21- and 22-inch rolling mills. Process wastewaters
flow through their respective scale pits.
36
9.4
004
or
009
Untreated cooling waters primarily from coke oven gas
coolers and recovery facilities are normally discharged
into Peters Creek (004) but can be discharged into the
Monongahela River (009)
269
71.1
005
Cooling waters from benzene plant, sludge from sediment
tanks, and process wastewater from No. 2 "boiler house
ash pit
19
5
006
Cooling water from tar pitch coolers
0.8
0.1
007
Cooling water from tar still, downstream electrode
pitch factory, tar stills, and strainer building
6.4
1.7
008
Barometric condenser water from No. 1 powerhouse
3.8
16
010
Cooling waters from tar and naphthalene plants
6.8
1.8
Oil
Untreated contact cooling water from No. 1 prill pitch
unit
2.8
0.75
012
Untreated contact cooling water from No. 2 prill pitch
unit
2.8
0.75
013
Blowdown from flash evaporator
5.3
1.4
014
Cooling tower blowdown, condensate and cooling water
from BTX processing area
0.19
0.05
114
Condensate and cooling water from BTX processing area
-
-
015
Cooling water and blowdown from No. 2 coke works boiler
house
3.94
1.04
115
Cooling water from No. 2 coke works boiler house
0.98
0.26
016
Strainer backwash
0.4
0.1
017
Miscellaneous flows from road tar terminal and loading
facilities
0.4
0.1
018
Cooling water and blowdown from No. 2 powerhouse
1.9
0.5
020
Effluent from bioplant and primary cooling water from
No. 2 unit
-
-
A.C.
Cooling water from air compressor
-
-
SWRPH
Steel works (water intake) river pumphouse
-
-
CWRPH
Coke works (water intake) river pumphouse
-
-
t Figs. 2, 3 ehou outfall location; numbers are the NPDES pemit outfall
designation.
ft Bmzene-toluene-xylene
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Table 2
SAMPLING SCHEDULE
USSC CLAIRTOU WORKS
Station
Type of Sample
Parameter*
Outfall 001, 018,
and air compressor
cooling water discharge
Grab
0/G
Outfall 002
Grab
TSS; CN(A) and CN(T); NH^-N
Outfall 003
24-hr composite
TSS
Grab
0/G;++ organics*
Outfall 004
24-hr composite
TSS; CN(T) and CN(A); NH.-N;
total and hexavalent Cr
Grab
0/G;++ phenol;t+ organics*
Outfall 005
Grab
0/G; phenol; TSS; CN(T) and CN(A)
Outfalls 006, 007,
015 and 017
Grab
0/G; phenol
Outfall 008
Grab
0/G;++ phenol++
Outfall 010
Grab
0/G; phenol; CN(T) and CN(A);
NH3-N; total and hexavalent Cr
Outfalls 011, 012
Grab
0/G; phenol; TSS
Outfall 013
Grab
CN(T) and CN(A); total and
hexavalent Cr
Outfall 014
(includes 114)
Grab
Phenol; total and hexavalent Cr
Outfall 016
Grab
TSS
Influent to bioplant 24-hr composite
and effluent from bioplant g ^
TSS; CN(T) and CN(A); NH-j-N
0/G;++ phenol++
Outfall 020
24-hr composite
Grab
TSS; CN(T) and CN(A); NH,-N
+ + + +
0/G; phenol; organics*
SWRPH and CWRPH**
24-hr composite
TSS; CN(T) and CN(A); NH3-N;
total and hexavalent Cr
Grab
0/G;++ phenol;++ organics*
+ Temperature and pH were measured, periodically at all stations
ft Grdb samples collected 3 times each day for this parameter
* Organics were sampled twice during the survey
** SWRPH: Steel Works Fiver Pumphouse; CWRPH: Coke Works River Pumphouse
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IV. FINDINGS OF IN-PLANT MONITORING
During the survey, the blast furnace was banked;* therefore, there
was no granulated slag or iron production. The rolling mills operated
on the following schedule:
Mill
Turn+
12-8 8-4 4-12
14-inch
X
18-inch
X X
21-inch
X X
22-inch
X X
t Work shift
Finished steel production during the survey was:
Mill
Product2
1/29
1/30
1/31
m.tons tons
m.tons tons
m.tons tons
14-inch
18-inch
21-inch
22-inch
53.38 58.79
266.32 293.31
294.62 324.47
272.58 300.20
91.01 100.23
226.35 249.28
334.46 368.35
529.37 583.01
61.33 67.54
94.67 104.26
131.68 145.02
238.54 262.71
+ Production corresponds to sampling day (0600-0300
hours).
The above production ranged from 66 to 159% of the average production
[795 m. tons (876 tons)/day] reported for the period January-October
1975 data [Table 3].
Coke production during the survey ranged from 16,401 to 16,455
m. tons (18,063 to 18,122 tons) which was equal to the average weekly
production reported for 1975 [Table 3].
* Cooling water is circulated to keep the heat level dam.
21 of
-------
Table 3
PRODUCTION*
USSC CLAIRTON WORKS
January-October 1975
Process Minimum Average Maximum
week month week month week month
tons/day
FeMn
0
0
0
0
0
0
Iron
0
0
142.6
146.5
988.3
784.8
22-1nch mill
0
92.1
239.8
241.8
404.7
323.1
18-inch mill
0
66.4
253.4
255.0
572.2
461.1
l4-1nch mill
0
30.8
129.8
130.4
284.8
211.8
21-inch mill
0
58.5
252.5
254.7
478.9
389.7
Coal.charged
20,950
26,969
26,970
27,262
29,265
27,930
Coke
15,221
17,072
18,299
18,543
19,136
18,923
Sulfur
2.0
40.0
58.9
60.4
82.4
72.3
NH, Recov. COG
21.3
35.3
38.1
39.2
43.8
41.9
Nh£ Recov. HpO
0
0
1.2
1.3
15.7
8.8
Syn NH, *
0
0
680.0
699.1
1,084.3
1,013.6
Slag 3
0
0
45.9
47.6
337.5
241.9
qallons/day
Light Oil Refining
Benzene
0
75,322
93,279
95,766
138,857
126,733
Toluene
0
11,000
14,834
15,230
24,714
19,433
Xylene
0
1,100
2,477
2,543
7,285
3,225
Crude No. 2
0
734
2,280
2,341
6,641
3,734
Bz. Naph.
0
4,293
6,435
6,607
12,268
9,253
Raffinate
0
2,032
3,639
3,736
7,714
5,433
Sundries
0
1,751
3,659
3,757
16,914
6,032
Tar Refining
Wax Oil
0
0
90
92
1,506
351
Creosote
29,874
78,024
89,986
92,385
150,637
106,453
Naph.
0
15,637
34,427
35,345
67,553
59,052
Naph. Sundries
0
4,750
11,631
11,941
25,574
21,029
Tar Acids
0
0
1,066
1,095
7,774
2,697
Pitch (bbl/day)
19,275
102,848
129,955
133,420
202,567
151,789
Prills T (tons/day)
0
107
241
248
464
442
t Information provided by USSC in letter dated January 19, 1976 with attach-
ments from Mr. James L. Hamilton, III, Manager Environmental Control Water,
United States Steel Corporation to Mr. Stephen R. Wassersug, Director,
Enforcement Division, U. S. Environmental Protection Agency, Region HI.
ft Quantities listed are furnace coke, not total coke.
ttt Prills are produced from the pitch quantities listed.
22 of
-------
In addition to the steel and coke, USSC reported the following production
figures for the survey:2
Product
Unit
1/29
1/30
1/31
Oxygen
mscf
3.596
3.340
3.808
Nitrogen
mscf
26.414
26.344
27.653
Phosam
m.ton
51
51
54
ton
56
56
59
Synam
m.ton
915
917
916
ton
1,008
1,010
1,009
Hydrogen
mscf
0.532
0.535
0.538
Sulfur
m.ton
40.86
38.29
63.25
ton
45.00
42.17
69.66
Distillates
m3
1,137
689
1,102
gal
300,305
181,949
291 ,054
Desulfurized
252
281
258
Naphthalene
gal
66,691
74,300
68,152
Pitch Prills
m.ton
418
372
418
ton
460
410
460
Monitoring results are tabulated by sampling location [Tables 4, 5,
6 and Figs. 2, 3] and discussed by individual outfalls. Waste loads
discharged per unit of production have also been calculated.
OUTFALL 001
Company officials stated that outfall 001 contains cooling waters
from the blast furnace and air compressor, barometric condenser water
from turbine-driven pumps, exhaust steam from feedwater treatment, sand
filter backwash from the treatment plant and boiler blowdown. The
Company has reported this flow to be 53,000 m /day (14 mgd). According
to self-monitoring data [Table 7] the flow is considerably lower, ranging
from 4,200 to 14,000 m /day (1.1 to 3.7 mgd). This is partly due to the
blast furnace not being in operation since January 1975.
23 of
-------
Table 4
SUMMARY OP FIELD MEASUREMENTS AND ANALYTICAL DATA
USSC CLAIRTON WORKS
January 28-31, 1976
Station
Description
Date
Flow
mJ/dav mgd
x 10*
PH
Range
Temp.
Range
(°C)
TSS
mg/1 kg/day lb/day
CN(T)
mg/1 kg/day lb/day
CN(A)
May
nh3-n
mg/1 kg/day lb/day mg/1 kg/day lb/day
Outfall
002° 1/28
7.2
2
44
0.03
<0.01
0.20
1/29
6.9
4
33
0.05
0.03
0.17
1/30
7.3
3
28
0.01
<0.01
0.17
3-day average
35
0.03
0.01
0.18
Outfall
003 1/29
98.0
25.9
6.4-6.9
9-24
25
2,450
5,400
1/30
83.2
22.0
5.8-8.1
9-20
18
1,500
3,300
1/31
79.8
21.1
6.3-7.3
10-45
15
1,200
2,600
3-day average
87.0
23.0
19
1,700
3,800
Steel works 1/29
129.8
34.3
6.5-6.9
4-5
36
4,700
10,300
0.01
1.3
2.9
<0.01
0.19
25
54
water intake 1/30
126.4
33.4
6.0-7.4
3-7
33
4,200
9,200
0.02
2.5
5.6
<0.01
0.15
19
42
1/31
105.6
27.9
6.5-7.3
4-5
24
2,500
5,600
0.01
1.1
2.3
<0.01
0.14
15
33
3-day average
120.6
31.9
31
3,800
8,400
0.01
1.6
3.6
<0.01
0.16
20
43
Outfall
004 1/29
226.9
60. Oc
6.3-8.6
17-23
100
22,700
50,000
0.04
9
20
<0.01
1.9
430
950
1/31&
229.6
60.7
6.5-7.5
16-22
16
3,700
8,100
0.75
170
380
0.25
55
125
7.0
1,600 3.500
l/31d
232.8
61.5
7.3-8.1
18-19
68
15,900
34,900
0.20
45
100
<0.01
1.9
440
970
3-day average
229.6
60.7
61
14,100
31,000
0.33
75
165
0.08
18
40
3.6
820
1,800
Outfall
005a 1/30
8.5
37
390
0.01
<0.01
Outfall
010® 1/28
7.5
9
<0.01
<0.01
0.23
1/29
6.9
11
0.02
<0.01
0.21
1/30
7.1
9
1.0
0.98
0.18
3-day average
0.34
0.33
0.21
Outfal 1
01 la 1/28
7.0
12
120
1/29
7.2
11
190
1/30
7.2
9
320
3-day average
210
Outfall
012a 1/28
6.9
12
560
1/29
7.0
10
260
1/30
7.2
9
480
3-day average
430
Outfall
013a 1/28
9.0
42
0.03
0.02
1/29
9.5
41
0.18
0.16
1/30
9.1
41
0.10
0.08
3-day average
0.10
0.09
-------
Table 4 (Continued)
SUMMARY OF FIELD MEASUREMENTS AND ANALYTICAL DATA
Station
Flow
PH
Range
Temp.
Range
(°c)
TSS
CN(T)
CN(A)
nh3-n
Description Date
mJ/day
x 10*
mgd
mg/1 kg/day lb/day
mg/1 kg/day lb/day
mg/1 kg/day lb/day
mg/1 kg/day lb/day
Outfall 016a 1/28
7.3
3
31
1/29
7.0
3
41
1/30
7.3
3
20
3-day average
31
Influent to 1/29
7.2
1.9
8.3-8.7
53-62
12
85
190
e
e
1,700
12,200
26,900
bloplant 1/30
9.5
2.5
8.2-8.8
47-58
21
200
440
500
4,700
10,400
460
4,400
9,600
2,000
19,000
41,700
1/31
9.5
2.5
8.4-9.0
50-61
13
125
270
550
5,200
11,500
520
4,900 10,800
2,000
19,000
41,700
3-day average
8.7
2.3
15
135
300
525
5,000
11,000
490
4,600
10,200
1,900
16,700
36,800
Effluent from 1/29
16.3
4.3
6.8-8.9
26-30
87
1,420
3,120
10
165
360
3
49
110
6.7
110
240
bloplant 1/30
15.9
4.2
6.6-8.0
25-36
86
1,370
3,010
9
145
315
2
32
70
6.7
105
235
1/31
16.7
4.4
6.5-7.8
27-31
110
1,830
4,040
8
135
295
1
17
37
28
465
1,030
3-day average
16.3
4.3
94
1,540
3,390
9
150
325
2
33
70
13.8
2 25
500
Outfall 020' 1/29
6.9-7.4
29-44
57
5.5
0.10
1.0
1/30
6.6-7.9
31-47
63
4
1
6.7
1/31
6.7-7.8
31-41
54
4
<0.01
16
3-day average
58
4.5
0.37
7.9
Coke works 1/29
344
91
6.5-6.9
3-4
45 15,500 34,200
0.01
3.4
7.5
<0.01
0.23
80
175
water Intake 1/30
340
90
6.3-7.3
3-5
40
13,600
30,000
0.02
6.8
15
<0.01
0.18
60
135
1/31
340
90
6.4-7.2
3-5
33
11,300 24,800
0.01
3.4
7.5
<0.01
0.48
165
360
3-day average
340
90
39
13,500
29,700
0.01
4.5
10
<0.01
0.30
100
225
a One grab sample uas collected, daily from this discharge. Flaw was not measured,
b Composite sample collected from 0600, 1/30 to 0300, 1/31.
c Dye pump did not operate continuously on this date. Therefore the average flou for 0600 1/29 to 0300 1/31 is used,
d Composite sample collected from 1200, 1/30 to 0900, 1/31
c Sample contained gross interferences.
t Loads discharged through outfall 020 are equal to or greater than those discharged from the treatment plant.
-------
Table S
SUMWT OF OIL AND CREASE AND PHENOL ANALYSES8
USSC CLAIRTOn WORKS
January 28-ZO, 1976
Instantaneous
Station Date Time of Flow6 Oil/Grease° Phenol
(Jan.) Collection mJ/day mgd mg/1 kg/day 16/day mg/1 kg/day lb/day
x 103
SWRPH 28
29
30
Outfall 001 28
29
30
Outfall 003 28
CWRPH
Daily average'
29
Daily average'
30
Daily average
28
29
1705
2035
2330
0510
1625
2235
0125
1610
2210
1230
1220
1220
1545
1825
2115
,d
0307
1505
2110
30
Outfall 004 28
Daily average
29
Daily average
30
Daily average'
0001
1455
2105
d
1730
1947
2243
0540
1635
2200
0055
1630
2200
1545
1840
2132
0322
1536
2120
d
0012
1510
2133
d
112.0
29.6
<1
<0.005
110.5
29.2
<1
<0.005
129.8
34.3
1
130
285
<0.005
126.8
33.5
<1
<0.005
130.6
34.5
<1
<0.005
107.1
28.3
<1
<0.005
132.4
35.0
1
130
290
<0.005
106.0
28.0
1
105
235
<0.005
60.6
16.0
3
181
400
<0.005
<1
<1
3
98.8
26.T
9
890
1,960
84.0
22.2
9
760
1,670
103.9
27.4
3
310
690
98.0
25.9
7
650
1,440
94.1
24.9
10
940
2,070
76.0
20.1
7
530
1,170
75.5
20.0
7
530
1,170
130.5
34.5
5
670
1,470
97.8
25.8
4
390
860
84.0
22.2
6
500
1,110
86.4
22.8
3
260
570
79.8
21.1
5
380
845
340
90
<1
348
92
<1
<0.005
337
89
2
670
1,480
<0.005
340
90
<1
<0.005
340
90
<1
<0.005
340
90
<1
<0.005
340
90
1
340
750
<0.005
340
90
<1
<0.005
340
90
3
1,020
2,250
<0.005
237.5
62.8e
1
240
520
0.026
6
14
237.5
62.8e
6
1,430
3,140
0.036
9
19
237.5
62.8e
2
480
1,050
0.085
20
45
237.5
62.8
3
720
1,570
0.049
12
26
171.7
45.4
2
340
760
0.033
6
12
213.4
56.4
4
860
1,880
0.068
15
32
233.9
61.8
1
235
520
0.041
10
21
229.6
60.7
2
480
1,050
0.043
10
22
230.2
60.8
2
460
1,010
0.040
9
20
224.1
59.2
3
670
1,480
0.047
11
23
224.1
59.2
4
900
1,980
0.033
7
16
232.8
61.5
3
680
1,490
0.039
9
20
26 of 138
-------
Table 5 (Continued)
SUMMARY OF OIL AND GREASE AND PHENOL ANALYSES8
Instantaneous
Station Date Time of Flow" 011/Grease6 Phenol
(Jan.) Collection mJ/day mgd mg/1 kg/day lb/day mg/1 kg/day lb/day
x 103
Outfall 005 30
1515
<0.005
Outfall 006 28
1435
1
<0.005
29
1410
6
<0.005
30
1425
8
<0.005
Outfall 007 28
1505
2
0.007
29
1415
2
0.024
30
1420
<1
0.011
Outfall 008 28
1630
34.0
9.0
<1
<0.005
2005
36.0
9.5
<1
<0.005
2230
33.4
8.8
1
33
74
<0.005
Daily
average''
35.6
9.4
0.3
11
25
<0.005
29
0445
33.0
8.7
<1
<0.005
1600
48.8
12.9
1
49
110
<0.005
2150
45.0
11.9
<1
<0.005
Daily
average**
43.1
11.4
0.4
16
37
<0.005
30
0042
43.6
11.5
1
45
100
<0.005
1540
43.2
11.4
2
85
190
<0.005
2150
39.4
10.4
3
120
260
<0.005
Daily
average**
41.3
10.9
2
85
185
<0.005
Outfall 010 28
1450
<1
<0.005
29
1355
4
<0.005
30
1405
5
<0.005
Outfall Oil 28
1540
15
0.020
29
1425
7
0.025
30
1440
7
0.032
Outfall 012 28
1550
14
0.051
29
1435
15
0.051
30
1445
18
0.054
Outfall 014 28
1350
0.882
(includes 29
1300
0.900
114) 30
1335
0.616
Outfall 015 29
1505
1
<0.005
30
1310
3
<0.005
Outfall 017 28
1415
1
0.011
29
1340
21
<0.005
30
1345
4
<0.005
Outfall 018 28
1615
2
29
1455
3
30
1305
1
Influent to 28
1605
8.17
2.16
110
900
1,980
1,000
bioplant
1900
6.54
1.73
150
980
2,160
0.133
2155
6.32
1.67
210
1,330
2,920
810
Daily
average4*
7.2
1.9
149
1,070
2,350
616
29
0325
6.28
1.66
190
1,200
2,630
880
1535
9.31
2.46
220
2,050
4,510
1,100
2135
9.38
2.48
180
1,700
3,720
1.100
Daily
average1*
9.5
2.5
174
1,650
3,620
920
8,200 18,000
1 2
5,100 11,300
4,430 9,770
5,500 12,200-
8,700 19,200
27 of 138
-------
Table S (Continued)
SUMMARY OF OIL AND GREASE AND PHENOL ANALYSES3
Station Date Time of
(Jan.) Collection
Instantaneous
Flow6
011/Grease0
Phenol
m-Vday
x 103
mgd
mg/l
kg/day
lb/day
mg/l
kg/day
lb/day
Influent to 30
0025
9.38
2.48
200
1,880
4,140
1,200
11,300
24,800
bloplant
1520
9.42
2.49
180
1,700
3,740
650
6,100
13,500
(continued)
2124
9.50
2.51
55
520
1,150
B10
7,700
17,000
Dally average"
9.5
2.5
144
1,370
3,010
884
8,370
18,400
Effluent 28
1610
16.01
4.23
2
32
70
0.106
1.7
3.7
from bioplant
1915
19
5
<1
'
-
2145
16.19
4.28
2
32
70
0.127
2.1
4.5
Dally average1
¦}
16.3
4.3
1
21
45
0.076
1.3
2.7
29
0337
15.82
4.18
1
16
35
0.100
1.6
3.5
1540
16.01
4.23
<1
0.130
2.1
4.6
2130
15.82
4.18
3
48
105
0.101
1.6
3.5
Dally average**
15.9
4.2
1
21
45
0.111
1.8
3.9
30
0020
16.19
4.28
3
49
105
0.138
2.3
5.0
1525
14.87
3.93
3
45
100
0.149
2.2
4.9
2119
18.13
4.79
6
110
240
0.156
2.9
6.4
Dally average®
16.3
4.3
4
70
150
0.151
2.5
5.4
Discharge 28
1545
<1
0.072
020'
1929
1
0.049
2215
<1
0.078
Dally average
0.4
0.067
29
0352
<1
0.079
1530
<1
0.104
2140
2
0.067
Dally average
0.7
0.083
30
0035
1
0.084
1510
3
0.116
2137
1
0.095
Dally average
2
0.098
Air 28
1315
1
Compressor 29
1325
26
Discharge 30
1255
<1
a All data based on grab samples,
b Loads were calculated using instantaneous flous.
c Freon extractable material
d Daily average flew is calculated from total of all flow measurement for day (i.e., 0600, Jan. 28,
to 0300, Jan. 29). The daily average load is the arithmetic average of instantaneous loads. The
• daily average concentration, mg/l, was calculated from daily average load and daily average flotD.
9 Mean of daily flous as instantaneous flows not available.
( The loads discharged from outfall 020 are equal to or greater than those discharged fzvm the
treatment plant.
28 of 138
-------
Table 6
SUMMARY OF TOTAL AND HEXAVALENT CHROMIUM DATA
USSC CLAIRTON PLANT
January 28-313 1976
Station
Date
Flow
Total
Cr
Hexavalent
; Cr
Description
m-Vdav
x lO5
mgd
mg/1
kg/day lb/day
mg/1
kg/day lb/day
Outfall 004
1/29
226.9
60.0
0.26
60
130
0.04
9
20
1/31+
229.6
60.7
0.10
23
50
0.03
7
15
1/31++
232.8
61.5
0.19
45
100
0.06
14
32
Outfall 010+++
1/28
1/29
1/30
0.01
<0.01
<0.01
<0.01
<0.01
<0.01
Outfall 013+++
1/28
1/29
1/30
<0.01
<0.01
0.03
<0.01
<0.01
<0.01
Outfall 014+++
(includes
114)
1/28
1/29
1/30
0.02
0.02
<0.01
<0.01
<0.01
<0.01
Coke works
water intake
1/29
1/30
1/31
<0.01
<0.01
<0.01
<0.01
<0.01
<0.01
t Composite sample collected from 0600 1/30 to 0300 1/31
tt Composite sample collected from 1200 1/30 to 0900 1/31
ttt One grab sample was collected daily from this discharge. Flow was not
measured.
29 of 138
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Table ?
SUMMARY OF SELF-MONITORING DATA
USSC CLAIRTON WORK§
January-September
Station
Flow
mgd
.tt
Temperature pH++ TSS
0/G
NH,-N
mg/1
CN(T)
Phenol
Outfall 001
Range (gross)
Measurements
Outfall 002
Range (net)
Measurements
Outfall 003
Range (net)
Measurements
Outfall 004
Range (net)
Measurements
Outfall 005
Range (net)
Measurements
Outfall 006
Range
Measurements
Outfall 007
Range (gross)
Measurements
Outfall 008
Range (gross)
Measurements
Outfall 010
Range
Measurements
Outfall Oil
Range (net)
Measurements
Outfall 012
Range (net)
Measurements
Outfall 013
Range
Measurements
1.1-3.7
6
0.9-3.7
5
4.4-30.8
18
48.4-103.5
32
2.3-3.2
8
0.3-1.0
2
2.07-2.95
8
11.9-23.9
32
0.78-1.10
10
0.558
10
t+t
ttt
0.568
12
0.97-1.50
8
79-92
6
49-92
5
47-88
16
52-100
31
93-150
8
83-102
2
60-110
8
51-112
32
42-94
9
48-66
8
42-97
10
108-120
8
7.6-9.6
5
1.8-5.7
5
7.3-8.6 0-597 0.2-51.1
5 5 5
tt
tt
6.6-8.1 0-2,647 0.96-268.7
16 16
4.3-9.4
32
9.2-11.2 0-404 0.6-20.5+t
8 8 8
7.2-7.9
2
2.6-7.7
8
5.1-8.2
26
7.0-7.7
7
0-4.2
8
0-2.9
8
0.1-7.6
8
6.8-7.6 11-511 0-21.5
6 6 6
6.7-8.0 16-839 0-11.5
12 11 9
7.0-9.4
8
0-1.3
5
0.01-1.54
5
0-0.06
8
0-0.066
5
0-0.218
9
0-0.074
8
0.008-0.125 0-0.409
8 8
0.005-0.016 0.005-0.409
8 8
0-0.064
6
0-0.105
11
-------
Table 7
SUMMARY OF SELF-MONITORING DATA
USSC CLAIFTON WORK£
January-September
Station
Flow
mgd
tt
Temperature
°F
PH
+t
TSS
0/G
nh3-n
mg/1
CN(T)
Phenol
Outfall 014
Range (net)
Measurements
Outfall 015
Range
Measurements
Outfall 016
Range
Measurements
Outfall 017
Range
Measurements
Outfall 018
Range
Measurements
Outfall 020
Range (net)
Measurements
0.20-0.27
6
0.87-1.14
8
0.075
2
0.060
2
ttt
,+tt
0.49-0.59
3
3.5-4.6
12
Steelworks Pumphouse
Range (gross) 6.1-38.8
Measurements Continuous
Coke Works Pumphouse
Range (gross) 78.4-125.6
Measurements Continuous
82-94
7
52-112
8
49-84
2
58-88
2
64-92
3
118-146
13
42-93
22
40-97
34
7.1-8.1
6
7.2-10.3
8
7.2-7.7
2
8.6-8.9
2
7.6-8.6
3
5.6-8.0 0-123
10 12
6.2-8.6 0-128
21 23
6.5-8.0 1-563
30 22
0-5
12
0-10
24
0-47.8
11
0-2.2
8
•0-0.158
7
0-50.7 0.009-0.86
25 10
0.007-0.357 0-1.73
10 12
0.006-0.02 0-0.014
9 9
0.002-0.061 0-0.124
19 27
t Data for June 1975 waa not available. All negative valuee reported by the Company are considered to be 0.
++ These are gross values.
ttt All values were the same.
-------
During NEIC monitoring, grab samples were collected daily for
oil/grease analyses and field measurements. The analytical results
[Table 5] show gross oil/grease concentrations of <1 to 3 mg/1 which are
the same as those concentrations observed in the intake water. The
temperature ranged from 4 to 18 °C (39.2 to 64.4 °F), and pH ranged from
9.6 to 9.8 °C (49.3 to 49.6 °F). Self-monitoring data for 1975 show
that the oil/grease concentrations ranged from 1.8 to 5.7 mg/1. USSC
has proposed a daily maximum net oil/grease concentration of 30 mg/1 for
this discharge [Table 8] or ten times the maximum gross concentration
observed during the survey.
The present monitoring location for outfall 001 is satisfactory.
Flows are currently estimated by USSC, but they can be measured either
by tracer techniques or conventional devices, such as a flume or weir.
OUTFALL 002
The 002 discharge contains wastewater originating from blast furnace
operations. Slag from the blast furnace is sprayed with water in the
granulating pit; the overflow from the pit is pumped into a settling
basin, about 25 m long x 10 m wide (80 x 33 ft), and then it is discharged
through outfall 202. Water, 4.5 m /min (1,200 gpm), is used to scrub
blast furnace gas in a venturi. The wastewater is treated in a Dorr
thickener, 34 m (110 ft) in diameter, and recycled, discharging 0.2
m /min (50 gpm) through outfall 102. Water used to cool the blast
furnace is also discharged (002). All three of the above wastewater
discharges (102, 202, 002) enter a City storm sewer in which evidence of
domestic sewage was observed. The combined flow enters the Monongahela
River. The Company samples all three discharges, estimates flow, and
sums the loading to obtain pollutant load. Since Janaury 1975 the blast
furnace has been banked; therefore, only cooling water is discharged
through 002.
32 of 138
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Table 8
USSC PROPOSED EFFLUENT LIMITATIONS
USSC CLAIRTON WORKS
/ USSC Proposed Limitations
Parameter Gross/Net pal1y Averaoe+t Daily Maximum
' kg/day lb/day kg/day lb/day mg/1
001
0/G
N
NA+t+ NA
NA
NA
30
Duration of permit
002*
TSS
G
2,376
5,240
7,148
15,720
NA
Effective date
0/G
G
NA
NA
NA
NA
NA
to 6/30/77
NHrN
G
162
356
486
1,068
NA
CN(T)
G
19
42
57
126
NA
Phenol
G
4.9
10.8
14.7
32.4
NA
003
TSS
N
18,681
41,099
56,200 123,297
NA
Effective date
0/G
G
2,185
4,810
6,560
14,430
NA
to 6/30/77
004 or 009
Phenol
N
NA
NA
NA
Duration of permit
005
TSS
G
5,010
11,025
15,030
33,075
NA
Duration of
0/G
G
NA
NA
NA
NA
NA
permit
CN(T)
G
NA
NA
NA
NA
NA
Phenol
G
NA
NA
NA
NA
NA
007
0/G
G
NA
NA
NA
NA
30
Duration of permit
008
0/G
NS**
NA
NA
NA
NA
NA
Duration of
CN(T)
NS
NA
NA
NA
NA
NA
permit
Phenol
NS
NA
NA
NA
NA
NA
010
CN(T)
NS
NA
NA
NA
NA
NA
Duration of
Phenol
NS
NA
NA
NA
NA
NA
permit
0/G
G
NA
NA
NA
NA
30
011
TSS
G
1,330
2,925
3,990
8,775
NA
Effective date
0/G
G
910
2,000
2,730
6,000
NA
to 6/30/77
Phenol
G
0.15
0.32
0.45
0.96
NA
012
TSS
G
1,330
2,925
3,990
8,775
NA
Effective date
0/G
G
910
2,000
2,730
6,000
NA
to 6/30/77
Phenol
G
0.15
0.32
0.45
0.96
NA
014
Phenol
N
NA
NA
NA
NA
NA
Duration of permit
020
TSS
G
730
1,606
2,190
4,818
NA
Startup of
nh,-n
G
2,727
6,000
8,181
18,000
NA
bioplant***
CN(A)
G
2.7
6.0
8.1
18
0.5
to expiration
Phenol
G
8.3
18.4
24.9
55
NA
0/G
G
218
480
654
1,440
30
+ Flou and temperature parameters were listed as NA for all limitations. The
proposed pH limitation for all outfalls is 6.0 minimum and NA maximum. The
Company thought outfalls 006, 013, 015, 115, 016, 017 and 018 should only be
monitored for pR.
tt Daily average in mg/l not applicable.
+++ Not applicable
* Limitations also proposed for 102 and 202. Rouever, during the survey there uere
no flous from these tuo intermediate locations.
** Not specified
*** Prior to startup of bioplant USSC proposes no limitations for outfall 020.
33 of 138
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Grab samples were collected for three days from the blast furnace
cooling water (002) for TSS, total and amenable cyanide and ammonia.
Results [Table 4] show that the discharge contained net concentrations
ranging from 0 to 8 mg/1 TSS; 0 to 0.03 mg/1 total cyanide; and 0.01 to
0.03 mg/1 ammonia.
Self-monitoring data [Table 7] for January-October 1975 show that
the net TSS, total cyanide, and anmonia concentrations ranged from 0 to
597; 0.01 to 1.54; and 0 to 1.3 mg/1, respectively, similar to the
values observed during the survey. USSC has proposed the following
daily maximum limitations for this discharge [Table 8].
Parameter
kg/day
lb/day
TSS
7,148
15,720
CN(T)
57
126
Phenol
14.7
32.4
nh3-n
486
1,068
Based on Company-estimated flows of 36,000 m /day (9.5 mgd) [Table 1], the
daily TSS, ammonia and cyanide concentrations would have to exceed 196,
13 and 0.4 mg/1, respectively, before violations of USSC-proposed maximum
criteria would occur. The self-monitoring data show that USSC-proposed
TSS and cyanide criteria have been exceeded.
Representative samples of all waste sources (102, 202 and 002) can
be collected at the sampling points. Flows presently estimated by USSC
can be measured by installing flow measuring devices and/or using tracer
techniques.
OUTFALL 003
This outfall contains scale pit effluents and cooling waters from
the four hot form rolling mills. An average 1,111 m. tons (1,225 tons)/mo
of scale is removed from the scale pits and trucked either to Carrie
34 of 138
-------
Blast Furnace or Saxonburg. Scale and/or other solids were also observed
where outfall 003 enters the Monongahela River [Appendix A].
The rolling mills are a major user of oils and greases. According
to Company data, monthly usage figures are:
Area 0/G Type Monthly Usage
metric English
All mills Van Talgar 10 455 kg 1,000 lb
block grease
18-inch mill Atlantic 0.8 m^ 4 bbl
vertical Premium 1,000 oil
rolls
Steam engines NLS 1000 10,200 2,700
at 14-, 18-, liters gal
21-inch mills
Penoil §6 10,200 2,700
liters gal
t It is assumed that these barrels are 55-gal drums
Company officials do not know the amount of oil/grease discharged into
the Monongahela River.1
Composite samples were collected for three days and analyzed for
TSS. Grab samples for oil/grease analyses were collected three times
each day [Table 2]. During the survey, 79,800 to 98,000 m^/day (21.1 to
25.9 mgd) of wastewater was discharged through outfall 003. Results
[Table 4] show that the effluent contained TSS loads ranging from 1,200
to 2,450 kg (2,600 to 5,400 lb)/day. Net loads for all three days were
zero (the intake TSS concentrations were greater than the effluent
concentrations on all three days of the survey). The oil/grease concen-
trations [Table 5] ranged from 3 to 10 mg/1, resulting in daily loads
of 380 to 670 kg (845 to 1,470 lb)/day.
Self-monitoring data [Table 7] for January-October 1975 show that
the net TSS concentrations ranged from 0 to 2,647 mg/1 and oil/grease
35 of 138
-------
concentrations ranged from 0.96 to 268.7 mg/1. Survey data is within
the ranges reported by the Company. The Company-estimated flows ranged
from 16,700 to 117,000 m^/day (4.4 to 30.8 mgd). The maximum flow
recorded during the survey (130,500 m /day to 34.5 mgd) is within
15% of the maximum value reported in the self-monitoring data.
USSC has proposed effluent limitations for TSS and oil/grease
[Table 8]. The daily maximum load limitations are 56,200 kg (123,297
lb) for TSS (net) and 6,560 kg (14,430 lb) for oil/grease. Based on the
maximum flow observed during the survey (130,500 m /day), the net TSS
concentrations would have to exceed 430 mg/1 before a daily maximum
violation would exist. The oil/grease loads were 10% of the proposed
daily maximum limitations.
Samples are collected using a pump permanently installed in the
manhole. Wastewater from the 14- and 22-inch mills join with the
wastewaters from the 18- and 21-inch mills in this manhole. A dye
study was conducted December 15-18, 1975 to determine if samples
collected from the pump were representative of the total discharge.
However, the surcharged condition of the outfall due to the high river
stage precluded this determination. USSC personnel should conduct
a study of this sampling point to insure representativeness or provide
an alternate sampling location. Flow can be measured using tracer
techniques.
OUTFALL 004
Outfall 004, the main industrial sewer at the Clairton Works,
extends from south to north through the major portion of the coke works
and terminates at Peters Creek. The Company has the option of discharg-
ing this wastewater directly into the Monongahela River (outfall 009) by
36 of
-------
opening a control gate. According to USSC, outfall 004 contains the
following wastewater sources:1
Source Flow
m3/day
gpm
#2 Unit Tar Storage
tank heater steam condensate
545
100
Keystone Cooling Tower
blowdown from tower
4,360
800
Phosam Plant
barometric condenser
8,175
1,500
Ammonia Plant
barometric condenser
109,000
20,000
#1 Unit Tar Storage
tank heater steam condensate
1,640
300
#1 Unit Primary Coolers
indirect cooling water
54,500
10,000
#1 Unit Exhauster House
barometric condenser
38,150
7,000
Sulfur Recovery Plant
indirect heat exchangers
10,900
2,000
Keystone waste heat
boilers blowdown
380
70
Company self-monitoring data for January-September 1975 indicate
that from 183,000 to 392,000 m^/day (48.4 to 103.5 mgd) of wastewater is
discharged to Peters Creek through outfall 004. Survey flows varied
from 226,900 to 232,800 m^/day (60.0 to 61.5 mgd). USSC proposes only
flow and temperature measurements without any numerical limitations.
Composite samples for TSS, total and amenable cyanide, and total
and hexavalent chromium analyses were collected for three days. Grab
samples for oil/grease and phenol analyses were collected three times
daily [Table 2], Results [Tables 4, 6] show that the discharge con-
tained large amounts of TSS, total cyanide, ammonia and total chromium
(maximum net loads of 12,500, 170, 1,500 and 60 kg/day, respectively).
37 of 138
-------
Self-monitoring data [Table 7] show that the net phenol concen-
trations ranged from 0 to 0.218 mg/1, similar to the survey data (0.026
to 0.085 mg/1).
The Company samples outfall 004 using a submersible pump permanent-
ly installed in a manhole. A dye study conducted December 15-18, 1975
showed that this sampling location is representative of the wastewater
discharged into Peters Creek. Flow can be measured using tracer techniques.
OUTFALL 005
This outfall reportedly contains: benzene plant cooling water; No.
2 boiler house ash pit effluent; backwash from the benzene boiler
feedwater treatment plant; and blowdown from the benzene boiler house.
The total flow is estimated at 18,900 m /day (5 mgd). The Company
samples this outfall using a pump permanently installed in a manhole.
According to Company officials, no other point exists to sample this
outfall before it is discharged into the enclosed section of Peters
Creek. Representative sample collection from this manhole is impossible
because in addition to the main 36-inch sewer, five smaller drains/sewers
discharge at different elevations. Flow measurement is not possible.
During the first two days of the survey, samples could not be
collected from this discharge because USSC personnel were unable to
operate the pump. Grab samples were collected the third day and ana-
lyzed for TSS, total and amenable cyanide, oil/grease and phenol [Table
2]. Results* [Tables 4, 5] show that the sample collected contained 390
mg/1 TSS and 4 mg/1 of oil/grease. Self-monitoring data [Table 7] show
that the concentrations of parameters measured by USSC are similar in
magnitude to those obtained during the survey. Flow was reported to
* Temperature and pH were 37°C (98.6°F) and 8.5, respectively.
38 of 138
-------
vary from 8,700 to 12,100 m^/day (2.3 to 3.2 mgd) which is less than
2
previously reported (18,900 m /day; 5 mgd).
USSC has proposed the following TSS limitations for the duration of
the permit [Table 8].
Parameter
kg/day
1b/day
Daily average
5,010
11,025
Daily maximum
15,030
33,075
The flow is to be measured. However, as indicated earlier, flow measure-
ment is not possible with the present configuration of multiple discharges
into one manhole. Moreover, representative collection is impossible.
OUTFALL 006
Outfall 006 contains cooling water from the pitch coolers. Two
separate lines discharge into a vertical manhole directly over Peters
Creek. Samples are collected through a pipe which extends from the
manhole cover to the ground surface, which precludes sampling each
discharge separately. Therefore, the samples collected are not repre-
sentative unless the concentration of pollutants is the same in each.
Flow measurement is not possible.
Grab samples* were collected for three days and analyzed for oil/
grease and phenol to determine if the cooling water was being contaminated
by the process. Results [Table 5] show that the oil/grease concentration
of wastewater ranged from 1 to 8 mg/1, more than twice the maximum
concentration of the intake water (3 mg/1), indicating contamination of
the cooling water.
* These samples were collected the scone way that USSC personnel collect
samples and are not considered representative of the discharge.
39 of 138
-------
USSC currently monitors this discharge for temperature and pH
[Table 7]. Accordingly, the Company has proposed that for the duration
of the permit only the above parameters be monitored, with only pH being
1imited.
OUTFALL 007
This outfall contains cooling waters originating from the tar
stills, strainer building and electrode pitch factory. Three lines
enter a manhole also located over Peters Creek. Samples are collected
through a pipe which extends from the manhole cover to the ground surface
without knowing the source (wastewater from one or all three lines is
collected in a sampling container lowered into the manhole). Samples
collected in this manner are not representative.
q
According to Company self-monitoring data, 7,800 to 11,200 m /day
(2.07 to 2.95 mgd) of wastewater was discharged from this outfall during
January-September 1975 [Table 7]. Under the present configuration flow
measurement is not possible. Therefore, the Company flow figures are
questionable.
Grab samples* for oil/grease and phenol analyses were collected for
three days [Table 2], to determine if the cooling water was being
contaminated by the process. Monitoring results** [Table 5] show that
the samples contained oil/grease and phenol concentrations ranging from
<1 to 2 and 0.007 to 0.024 mg/1, respectively. The phenol concentrations
are higher than the intake values, indicating contamination of the
cooling water.
* Grab samples were collected the same way that USSC personnel collect
samples and are not considered to be representative.
** The temperature ranged from 21 to 26°C (69.8 to 78.8 °F) and pH
ranged from 7.0 to 7.4.
40 of 138
-------
Self-monitoring data [Table 7] were similar for oil/grease, ranging
from 0 to 4.2 mg/1. The Company does not monitor for phenol. USSC has
proposed a daily maximum oil/grease limitation for the duration of the
NPDES permit of 30 mg/1 [Table 8]. This limitation is 15 times greater
than the maximum concentration (2 mg/1) observed during the survey.
OUTFALL 008
Powerhouse No. 1 cooling, seal and condenser waters are discharged
into Peters Creek through outfall 008. Company officials estimate that
from 45,000 to 90,500 m^/day (11.9 to 23.9 mgd) of wastewater is discharged
through this outfall [Table 7]. Actual flows varied from 35,600 to
3
43,100 m /day (9.4 to 11.4 mgd), lower than the reported flow.
Grab samples for oil/grease and phenol analyses were collected
three times per day for three days [Table 2]. During the survey, oil/grease
concentrations ranged from <1 to 3 mg/1. Phenol concentrations were
<0.005 mg/1. These values are similar to those reported in USSC's self-
monitoring data [Table 7].
A dye study conducted December 15-18, 1975 showed that the Company
sampling location is representative of the wastewater discharged. Flow
can be measured using tracer techniques. USSC proposes to measure the
flow, temperature and pH of outfall 008, with pH being limited [Table 8].
OUTFALL 010
Outfall 010 originates in the tar and naphthalene plant. Waste-
water contributions include naphthalene cooling tower blowdown, cooling
water from tar acid distillation (includes compressor and pump cooling
waters) and condensate from tank heating. The wastewater is discharged
through a manhole into Peters Creek. Company officials reported that
41 of 138
-------
o
from 3,000 to 4,200 m /day (0.78 to 1.10 mgd) was discharged through
outfall 010 during January-September 1975 [Table 7].
Grab samples were collected three days for oil/grease, phenol,
total and amenable cyanide, ammonia and total and hexavalent chromium
analyses [Table 2]. Results [Tables 4, 5, 6] show that the effluent
concentrations were similar to water intake concentrations for all
samples except total and amenable cyanide on the third day. The total
and amenable cyanide concentrations of 1.0 and 0.98 mg/1, respectively,
were considerably higher than intake values (0.01 and <0.01 mg/1). The
cause for the cyanide concentration increase is not known.
Self-monitoring data [Table 7] were similar for oil/grease and
phenol, but considerably less for total cyanide. Company data show a
maximum total cyanide concentration of 0.016 mg/1, while the maximum
survey concentration was 1.0 mg/1.
USSC has proposed a daily maximum oil/grease limitation of 30 mg/1
[Table 8] with the flow to be estimated. Results [Table 5] show that
the oil/grease concentration ranged from <1 to 5 mg/1, considerably less
than the proposed limitation. The monitoring location for outfall 010
is satisfactory. Flow measurement can be accomplished using tracer
techniques.
OUTFALLS 011 and 012
Outfalls 011 and 012 both contain contact cooling water from prill
3
pitch units.* Company officials reported that 2,100 m /day (0.568 mgd)
of wastewater is discharged into Peters Creek through each outfall
[Table 7].
No. 1 prill pitch unit discharges through outfall 011 and No. 2 unit
through 012.
42 of
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Outfall Oil is sampled from a manhole adjacent to the No. 1 prill
pitch building. In addition to the contact cooling water, condensate
and wastewater from an unknown source are also discharged into this
manhole. The shallow flow makes the collection of representative
samples doubtful. Flow measurement could possibly be accomplished by a
weir or similar device.
Outfall 012 is sampled from the recycle holding tank in the No. 2
prill pitch building. While representative wastewater samples can be
collected, flow measurements are not possible with the existing con-
figuration.
Grab samples were collected from each outfall for three days and
analyzed for TSS, phenol and oil/grease analyses [Table 2]. Samples
collected from each outfall contained black solids (prills). Results
[Table 4] show that the TSS concentrations ranged from 120 to 320 mg/1
and 260 to 560 mg/1, respectively, for outfalls 011 and 012. The lower
TSS concentrations in outfall 011 are probably due to the unsatisfactory
sampling location (the shallow flow precluded collection of a represen-
tative sample). Similarly, oil/grease and phenol concentrations were
lower in otufall 011 [Table 5].
USSC has proposed the following effluent limitations (effective
until June 30, 1977) for each of the outfalls [Table 8] with the flow to
be estimated.
Parameter
Daily Average
Daily Maximum
kg/day lb/day
kg/day lb/day
TSS
1,330 2,925
3,990 8,775
0/G
910 2,000
2,730 6,000
Phenol
0.15 0.32
0.45 0.96
43 of
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3
Based on the Company flow of 2,100 m /day, the daily maximum TSS, oil/grease
and phenol concentrations would have to exceed 1,850, 1,270 and 0.20
mg/1, respectively, before a violation occurs. These concentrations are
about 3, 70 and 3 times greater than the maximum TSS, oil/grease and
phenol concentrations observed during the survey.
The Company self-monitoring data [Table 7] for January-September
1975 are similar to NEIC results.
OUTFALL 013
This discharge contains blowdown from the flash evaporator and
cooling tower. The ratio of blowdown to recycle is 1:1. The Company
measures the total flow with an orifice plate, and from this outfall the
discharge is calculated. Reported flows ranged from 3,700 to 5,700
m /day (0.97 to 1.5 mgd) [Table 7]. The Company sampling point is
adequate to obtain representative samples.
USSC has proposed measuring the flow, temperature and pH with only
pH being limited. Grab samples were collected for three days and analyzed
for total and amenable cyanide and total and hexavalent chromium [Table
2]. During the survey, total and amenable cyanide concentrations ranged
from 0.03 to 0.18 mg/1 and 0.02 to 0.16 mg/1, respectively. These
concentrations are higher than those observed in the intake water (0.01
to 0.02 mg/1 total cyanide and <0.01 mg/1 amenable cyanide) [Table 4],
Total chromium concentrations were insignificant, ranging from <0.01 to
0.03 mg/1 [Table 6].
OUTFALL 014
Outfall 014 contains benzene plant cooling tower blowdown and
condensate and cooling water from the benzene-toluene-xylene (BTX)
44 of 138
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processing area. The Company samples the benzene plant cooling tower
blowdown and the wastewater from the BTX area separately, designating
the two points as 014 and 114 respectively. Representative samples can
be collected from the combined discharge, and flow is possible by installing
a conventional flow structure (weir, flume, etc.). USSC has reported
that the flow varies from 760 to 1,000 m^/day (0.20 to 0.27 mgd)* [Table 7].
Grab samples** were collected three days from the total discharge
(014 plus 114) for phenol and total and hexavalent chromium analyses
[Table 2]. During the survey, the phenol concentrations were high,
ranging from 0.616 to 0.882 mg/1 [Table 5]. These concentrations exceed
those reported in the Company self-monitoring data (0 to 0.158 mg/1).
Company officials indicated that chromium is used in the cooling
towers. The grab samples collected from outfall 014 indicate that ex-
cessive amounts of chromium are not being used in the towers. The total
chromium concentration ranged from <0.01 to 0.02 mg/1.
The Company proposes to measure flow, temperature and pH with only
pH being limited (minimum of 6.0). As ntoed earlier, flow can be measured
by installing a conventional flow device.
OUTFALLS 015 and 115
These outfalls each contain cooling water and blowdown from the No.
2 coke works boiler house. Outfalls 015 and 115 reportedly discharge
3,900 m3/day (1.04 mgd) and 1,000 m^/day (0.26 mgd) of wastewater,
* Self-monitoring reports the flow for outfall 014 and does not
indicate whether this includes the flow from outfall 114.
** The temperature of the wastewater was 27°C (80.6°F). The pH
ranged from 7.1 to 7.5.
45 of 138
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respectively. At high river stages, generally in the springtime, each
outfall is submerged.
Grab samples were collected for two days from outfall 015 and
analyzed for oil/grease and phenols [Table 2]. Survey results showed
the effluent contained no phenol (<0.005 mg/1) and only 1 to 3 mg/1
oil/grease.
USSC proposes to estimate flow and measure temperature and pH for
outfalls 015 and 115. Only the pH has numerical limitations (minimum of
6.0). The self-monitoring data contains only flow (estimated), tempera-
ture and pH values.
Outfalls 015 and 115 are monitored at the river. A sample con-
tainer lowered over the river wall scrapes the wall during sample col-
lection, thus sample contamination is highly probable. As noted earlier,
these stations are also submerged during high river stages. An alternate
sampling location should be established so flow can be measured and
representative samples can be collected at all times.
OUTFALL 016
Outfall 016 contains backwash water from a continuous basket
strainer. Product water is used for BTX cooling tower makeup. Company
3
officials estimate that 280 m /day (0.075 mgd) of wastewater enters the
Monongahela River through this outfall [Table 7].
Grab samples for TSS analyses were collected three days [Table 2].
Results [Table 4] show that the TSS concentrations in outfall 016 were
equal to or less than intake concentrations (net discharge of TSS was
zero).
46 of 138
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USSC proposes to estimate flow and measure temperature and pH of
outfall 016 for the duration of the permit, with only pH being limited
(6.0 minimum) [Table 8]. Self-monitoring data includes flow (estimated),
temperature, and pH [Table 7].
The present monitoring location for outfall 016 is satisfactory
except for obtaining accurate flow measurements. Modifications are
necessary to provide accurate measurement.
OUTFALL 017
This outfall contains miscellaneous wastewater, primarily tank
heating condensate, originating from the Road Tar Terminal area.
Company officials estimate that 230 m /day (0.06 mgd) of wastewater is
discharged to the Monongahela River through outfall 017 [Table 7].
USSC proposes flow estimation, pH and temperature measurements,
limiting only pH (6.0 minimum) [Table 8]. Self-monitoring data [Table
7] includes flow, pH and temperature values.
Grab samples were collected three days for oil/grease and phenol
analyses [Table 2], During the survey,* oil/grease and phenol concen-
trations ranged from 1 to 24 mg/1 and from <0.005 to 0.011 mg/1, respectively
[Table 5].
The monitoring location for outfall 017 is satisfactory. Flow can
be measured using conventional flow techniques (weir, flume, etc.).
* The temperature ranged from 11 to 13°C (51.8 to 55.4 °F) and
pH ranged from 7.1 to 8.5.
47 of 138
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OUTFALL 018
Outfall 018 contains cooling water, blowdown and condensate originat-
ing from the No. 2 powerhouse. USSC currently estimates flow and measures
temperature and pH [Table 7]. Accordingly, the Company has proposed
that for the duration of the permit only the above parameters be monitored,
with only pH limited [Table 8].
Grab samples were collected for three days for oil/grease analyses*
[Table 2]. During the survey, oil/grease concentrations ranged from 1
to 3 mg/1. These concentrations are similar to oil/grease concentrations
of the intake water (<1 to 3 mg/1) [Table 5].
Samples are collected by lowering a sample container over the river
wall. A steel plate has been positioned over the outfall to prevent the
wastewater from being discharged into barges; the plate interferes with
sample collection. In addition, the sample container scrapes the river
wall, causing contamination of the sample. An alternate sampling location
must be provided for this discharge. Flow can be measured using tracer
techniques.
AIR COMPRESSOR DISCHARGE
Air compressor cooling water is discharged to the Monongahela River
through outfall 023.** This discharge apparently was not identified in
the NPDES permit application; therefore, no monitoring requirements were
established and the Company has not provided the results of their monitoring.
* The temperature and pH ranged from 22 to 30°C (71.6 to 86.0°F)
and from 7.1 to 7.4, respectively.
** The NPDES permit designates outfall 022 as a 1-1/2-inch condensate
drain from the No. 1 transfer tower.
48 of 138
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Grab samples were collected for three days and analyzed for oil/grease*
[Table 2]. The oil/grease concentrations ranged from <1 to 26 mg/1
[Table 5]. The high oil/grease concentrations (26 mg/1) indicate a
possible oil leak from the compressor into the cooling water system.
The monitoring location for this discharge is satisfactory. Flow
can be measured using tracer techniques.
OUTFALL 020
Outfall 020 contains the effluent from the contaminated wastewater
treatment plant and No. 2 primary cooler water. Company officials
reported the flow at 13,200 to 17,400 m^/day (3.5 to 4.6 mgd) [Table 7].
The Company samples this outfall using a submersible pump permanently
installed in a manhole. A dye study conducted December 15-18, 1975
showed that this sampling location is representative of the wastewater
discharged into Peters Creek.
During the survey, dye was injected in outfall 020 upstream of the
contaminated wastewater treatment plant effluent to determine the total
flow in outfall 020. However, clouds of water vapor rising from the
manhole (dye injection point) made it impossible to see into the manhole.
Flow measurement by dye dilution proved impractical because NEIC survey
results show that the dye was not directly entering the wastewater as
required to obtain continuous flow results. The dye results are not
reported, and it is assumed that the loads discharged in outfall 020
were the same as discharged from the treatment plant. The loads reported
are lower than actual; that is, actual loads would be greater due to any
load contributions from the No. 2 primary cooler.
* The temperature and pH ranged from 9 to 11°C (48.2 to 51.8°F) and
from 7.3 to 8.4, respectively.
49 of 138
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Composite samples for TSS, total and amenable cyanide and ammonia
analyses were collected for three days from outfall 020. Grab samples
were collected three times each day for oil/grease and phenol analyses
[Table 2]. During the survey, net TSS, total cyanide and ammonia con-
centrations ranged from 54 to 63 mg/1, 4 to 5.5 mg/1, and 1.0 to 16
mg/1, respectively [Table 4], The phenol concentrations [Table 5]
ranged from 0.049 to 0.116 mg/1 (daily average: 0.067 to 0.098 mg/1).
Self-monitoring data [Table 7] for January-September 1975 were
similar for TSS, ammonia, oil/grease and phenol, but considerably less
for total cyanide. Company data show that the total cyanide concen-
trations ranged from 0.007 to 0.357 mg/1 [Table 7], while the survey
concentrations ranged from 4.0 to 5.5 mg/1.
USSC has proposed the following limitations from treatment plant
startup until the permit expiration:
Parameter Daily Average Daily Maximum
kg/day lb/day kg/day lb/day mg/1
TSS
730
1,606
2,190
4,818
NA
nh3-n
2,727
6,000
8,181
18,000
NA
CN(A)
2.7
6.0
8.1
18
0.5
Phenol
8.3
18.4
24.9
55
NA
0/G
218
480
654
1,440
30
Flow
Measured
A comparison of survey data [Tables 4,,5] to these proposed limita-
tions show that the daily average TSS and the daily average and daily
maximum amenable cyanide limitations were exceeded by more than 2, 11
and 6 times, respectively. In addition, the daily maximum amenable
cyanide concentration limitation (0.5 mg/1) was exceeded on the second
day of the survey.
50 of
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The contaminated wastewater treatment plant [Fig. 4] treats ammonia
and phenolic-laden wastes from the primary coolers, final coolers,
phosam distillation, light oil refinery and tar distillation plant.
These wastewaters were previously used in the quench towers. Major
treatment units consist of four 380 m (100,000 gal) separator tanks
(tar and oil removal), free and fixed stills (ammonia removal), aeration
basins, clarifiers and sand filtration. Because the wastewater is toxic
to biological treatment, approximately 30 m /min (1,350 gpm) dilution
water* is added to the wastewater as it enters the aeration basins.
According to Company personnel, treatment plant water is diverted to the
quench water system when operational problems develop.1
The plant is equipped with flow measurement devices which permit
flow monitoring at the influent, effluent and intermediate points.
Information on the type of devices used and calibration procedures was
not provided. During the survey, the effluent flow meter was inoperative.
Therefore, the meter which measures the amount of wastewater applied to
the filtration unit (sand filters), an intermediate point, was used to
obtain flow.
Company officials collect influent samples upstream of the stills
(after tar and oil removal). Effluent samples are collected following
the sand filters. Composite samples were collected from these two
points for three days for TSS, total and amenable cyanide, and ammonia
analyses. Grab samples were collected three times daily for oil/grease
and phenol analyses. Results [Table 4] show that TSS concentrations
were greater in the effluent than the influent. As a result, 1,370 to
1,830 kg/day (3,010 to 4,040 lb/day) of TSS were discharged to outfall
020. During the survey, the flow through the sand filters was erratic,
O O
varying from 15,800 m /day (2,900 gpm) to more than 19,100 m /day
(3,500 gpm) within a few seconds. This is a possible cause for the TSS
* This dilution water is obtained from the Monongahela River.
51 of 138
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(
STEAM
0 4 m<)d \
AS COMOENSATE I
DILUTION WATER
(1 7 mgd ^
2 5 ngd
OIL AND TAR
SEPARATOR
POL THlR
FEED
3.000.000
GALLON
STORAGE
TAUK
FREE
STILL
2 9 mtid
FIXED
STILL
CLARIFIER
COOL INC
FACILITIES
3.000.000
GALLON
STORAGE
TANK
SLUDGE
THICKE"ER
AERATION
BASINS
CLARiriERS
FILTRATION
FACILITIES
4 6 mod
/ "
^ _| RECYCLED SLUDGE J
EFFLUENT TO '
hOliOI.GAHELA
RIVER
VACUUM
FILTER
OIL AMD TAR
TO DECANTER
TANK
SLUDGE TO
DISPOSAL
BY TRUCK
- LEGEND -
PROCESS HATER
SLUDGE
OIL 1 TAR
Figure 4. flew Diagram for Conlcminoted Wadtwolar Traalmanf Plant'
in
ro
Co
CO
-------
effluent loads exceeding the influent loads. On February 3, 1976, NEIC
personnel observed that the sand filters were being bypassed and clari-
fier effluent was being discharged directly to outfall 020. Company
officials indicated that the bypass was necessary for pump repair.
The removal efficiency* of the wastewater treatment plant for total
and amenable cyanide, ammonia, oil/grease and phenol was 95% or more on
all three days of the survey.
The sampling stations for the treatment plant (influent and effluent)
and outfall 020 are satisfactory. Flow measurement in the treatment plant
is satisfactory, provided that the devices are calibrated periodically
and the continuous flow recorders are operational. Flow in outfall 020
can be measured using tracer techniques, provided the upstream injection
point can be located to insure that dye enters the waste stream.
OUTFALLS 21 to 44
Outfalls 21 to 44 reportedly contain only steam condensate. A
description of each follows:
Outfall Description
021 Two 3/4-in. condensate drains from temporary change house
022 Two 2-in. and one 1-1/2-in. condensate drains from waste oil
storage area and fuel oil tank
023 One 1-1/2-in. condensate drain from No. 1 transfer tower
024 Two 3/4-in. condensate drains from No. 1 sample building
025 One 1/2-in., one 4-in. and one 2-in. condensate drains from
surge bin area
026 One 2-in. condensate from sanitary station
027 One 1-1/2-in. condensate from machinery house
028 One 4-in. and one 1-1/2-in. condensate drains
* These efficiencies do not include any materials removed in the tar and
oil treatment units.
53 of 138
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Outfall
Description
029 One 1-1/2-in. condensate from transformer station
030 Two 2-in. and one 3-in. condensate and area drains from coal
hoppers
031 Two 1/2-in. condensate drains from coke works river pumphouse
032 Two 3/4-in., one 1-in. and one 2-in. condensate drains from
clarifier and pumphouse
033 One 2-in. condensate drain from surge bin area
034 One 2-in. condensate drain from No. 2 sample building
035 One 3/4-in. condensate from No. 3 transfer tower
036 One 1-in. and one 3/4-in. condensate from No. 3 coal hoist
037 One 3/4-in. and two 1-in. condensate from oil house and sanitary
station
038 Two 3/4-in. and one 2-in. condensate drains from No. 4 coal
hoist
039 One 1-in. condensate from No. 2 boiler house
040 Condensate from water treating plant
041 One 1-in. condensate at evaporator
042 Two 1-1/2-in. condensate drains from recirculating pumphouse
043 Four 1-in. and two 3/4-in. condensate drains from creosote and
naphthalene line tracers
044 One 3/4-in. condensate drain from lime slurry storage tank and
one 8-in. compressor cooling water
Monitoring these outfalls is not required either in the NPDES
permit or USSC-amended adjudicatory hearing request. These stations
were not monitored during the survey.
STEEL WORKS PLANT WATER INTAKE
The steel plant water intake structure contains a wide-spaced bar
screen followed by a traveling screen. The pumphouse has five pumps
3
with a 300 m /day (79.5 mgd) pumping capacity. Intake volumes are
measured using Bailey continuous flow meters. These meters were cali-
brated in September 1975 and found to be within +2% at full-scale range.
Maximum intake water volumes for January-October 1975 ranged from
40,500 to 147,000 m^/day (10.7 to 38.8 mgd).1 During the NEIC survey,
54 of
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the intake volume ranged from 105,600 to 129,800 m^/day (27.9 to 34.3
mgd) [Table 4]. The steel plant intake supplies water for processes
from which wastewater discharges to outfalls 001, 002 and 003.
Total and amenable cyanide, ammonia, oil/grease and phenol con-
centrations were low and remained constant during the survey [Tables 4,
5]. TSS concentrations varied daily ranging from 24 to 36 mg/1 [Table
4]. Self-monitoring data [Table 7] are similar to those obtained during
the survey.
Intake water samples are collected from the pump seal water supply
line ahead of the filter. This monitoring location is adequate to
collect representative samples.
Flow measurement is adequate, providing that USSC continues to
calibrate the existing flow devices on a regular schedule (every 4 to 6
months).
COKE WORKS PLANT WATER INTAKE
The coke plant water intake structure is downstream from the steel
works outfalls 001, 002 and 003. The pumphouse has six centrifugal
pumps with a total pumping capacity of 817,000 m /day (216 mgd). Intake
volumes are measured with two Foxboro DP #12-A Venturi meter tubes.
These meters are calibrated at least every six months. USSC last cali-
brated the meters in September 1975 with a meter error of +2% at full-
scale range.
Maximum intake volumes for January-October 1975 ranged from 379,000
to 473,000 m^/day (100 to 125 mgd).1 During the survey, daily intake
•3
volumes were lower, ranging from 340,000 to 344,000 m /day (90 to 91
mgd) [Table 4]. This intake supplies process and cooling waters which
discharge to outfalls 004 through 020.
55 of 138
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During the survey, total and amenable cyanide, oil/grease, phenol
and total and hexavalent chromium concentrations were low and remained
constant [Tables 4, 5, 6]. Ammonia and TSS concentrations ranged from
0.18 to 0.48 mg/1 and 33 to 45 mg/1, respectively [Table 4]. These con-
centrations are similar to those reported in the USSC self-monitoring
data [Table 7].
Intake samples are collected from screen backflush water ahead of
the strainer; it is the same water that is pumped into the coke works.
The monitoring location and flow measurement procedures are adequate.
RESULTS OF ORGANIC ANALYSIS
Outfalls 003, 004, 020, steel works water intake, and coke works
water intake were grab-sampled for organic analyses twice during the
survey (January 30 and February 3, 1976). Results [Table 9] show that
organic chemical pollutants were present in detectable levels in outfalls
003 and 004. Pollutants were present in both samples from outfall 004
and in a sample from outfall 001.
WASTE LOADS DISCHARGED PER UNIT OF PRODUCTION
Finished steel and coke production for the survey period are listed
below:
Product
Quantity of Product2
1/29
1/30
1/31
m.tons tons
m.tons tons
m.tons tons
Finished
steel
887 977
1,181 1,301
527 580
Coke
16,412 18,075
16,401 18,063
16,455 18,122
56 of
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Table 9
ORGANIC CHEMICAL POLLUTANTS
USSC CLA IETON WORKS
January 30 and February 3, 1976
Location and Date
Compound Outfall 003 Outfall 004 Outfall 004
2/3/76 1/30/76 2/3/76
ug/1
yg/i
yg/1
Ethyl benzene
32
NDf
375
Cumene
5
ND
NO
Ethylmethylbenzene
14
5
ND
Trimethylbenzene
6
4
ND
p-Cymene
6
ND
ND
m or p-Diethyl benzene
18
2
ND
m or o-Cymene
41
18
ND
m or p-Diethylbenzene
6
8
ND
Naphthalene
14
ND
ND
1,2,3,4-Tetrahydronaphthalene
ND
ND
12
1,2,4,5-Tetramethylbenzene
<30
*35
ND
Dimethyl-Iso-Propylbenzene
*10
*10
ND
Subs, Alkane
*10
ND
ND
t Not detected
57 of 138
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Using the above production rates, the waste loads discharged per
unit of production were computed [Table 10]. Results show that for the
steel mills, the TSS and oil/grease loads ranged from 1.999 to 2.764 and
0.565 to 0.737 kg/kkg. If credit is given for intake TSS concentrations,
waste loads per unit of production are zero.
Loads per unit of production for the coke works were calculated by
summing the waste loads contained in the effluent from the contaminated
wastewater treatment plant and the net load discharged through outfall
004. The January 30, 1976 data is based only on treatment plant waste
loads because the composite from outfall 004 was spilled during com-
positing. During the survey, the TSS unit loads ranged from 0.083 to
0.847 kg/kkg of coke produced [Table 10]. Ammonia, total cyanide,
oil/grease and phenol loads per unit of production were low.
58 of 138
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Table 10
LOADS DISCHARGED PER UNIT OF PRODUCTION
USSC CLAIRTON WORKS
January 29-31, 1976
Process
Parameter
Load Discharged/Unit of Production
January 29
kg/kkg
January 30
kg/kkg
January 31
kg/kkg
Rolling mills
TSSf
2.764
1.999
0/G
0.737
0.565
"f* "f"
Coke works
TSS
0.847
0.083+++
0.112
nh3-n
0.030
0.007+++
0.120
CN(T)
0.010
0.009+++
0.019
0/G
0.045
0.001+++
0.045
Phenol
0.001
0.0001+++
0.001
t Actual load discharged based on gross values,
tt Actual load discharged based on pollutants contained in the dis-
charge from contaminated wastewater treatment plant (gross) and
in outfall 004 (net except for oil/grease which is gross).
ttt Number includes only loadings from treatment plant. Sample from
outfall 004 for this date was lost.
59 of 138
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V. MONITORING REQUIREMENTS
USSC personnel collect time-weighted composite samples comprised of
three aliquots, one collected each 8-hour shift. Grab samples are
collected during the daylight shift. Flows are estimated* except for
water intakes, the contaminated wastewater treatment plant and outfall 013.
During the survey, the dye dilution technique was used to measure
wastewater flows from outfalls 003, 004 and 008 because these points are
not amenable to flow measurement using conventional techniques (flumes,
flow meters, weirs, etc.). The installation of the latter flow measure-
ment devices will require modification of the existing outfalls. Company-
installed measurement devices were used to obtain intake and wastewater
treatment plant flows.
The dye tracer technique could be used to measure and record flow
on a continuous basis. The method requires an upstream dye injection
point, and a sampling point downstream at which all wastewater sources
are adequately mixed. The majority of the outfalls from the USSC Clairton
Works are suited for the tracer technique. This method of continuous
flow measurement, however, is costly and time consuming. The wastewater
must be pumped through a fluorometer with the results continuously
recorded. Each outfall would require a metering pump for controlled dye
injection, sampling pump, fluorometer and recorder. These items would
cost from $2,700 to $3,000.** In addition, a suitable tracer such as
O
Rhodamine WT dye would cost about $2 per day per 3,785 m /day (1 mgd)
* The exact procedures used by USSC for estimating flows were not provided.
** These oosts do not include maintenance3 extra parts, manpower, protective
structures or power to operate the pumpss fluorometer and recorder.
60 of 138
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of flow measured. Conventional flow measurement devices may be preferable
due to the lower cost, reduced maintenance requirement and ease of
operation.
The flows from outfalls 002, 003, 004 and 020 should be continuously
measured and recorded. This can be accomplished by either modifying
existing outfall lines to allow installation of flow structures or in-
stalling in-line meters. Flows through outfalls 001, 102, 202, 005,
006, 007, 008, 010, 011, 012, 013, 014 and 017 should be measured the
same day samples are collected. Outfalls for which net limitations
apply should be sampled the same day the intake water is sampled.
Recommended monitoring requirements are -listed in Table 11. Signifi-
cant parameters for process wastes are from the EPA Guidelines for Iron
and Steel Manufacturing.3^ Measurement frequency was established on
the basis of EPA Permit Program Guidance.5
As discussed previously, outfall 002 only contains cooling water
from the blast furnace. A new outfall line should be constructed such
that this cooling water, the settling basin effluent (102), and the
clarifier effluent (202) can be sampled at a common point (designated in
the NPDES permit as 002).
Representative samples cannot be collected from outfalls 005, 006,
007 and 011. In addition, the representativeness of samples from outfalls
003, 015, 115 and 018 is questionable. The present discharge configurations
of outfalls 005, 006, 007 and 012 preclude representative flow measurements.
Modifications will be required at these locations to allow accurate flow
measurement and the collection of representative samples.
USSC presently samples both 014 and 114 instead of the combined
discharge as required. Representative samples and accurate flow
measurement can be accomplished after the two discharges combine.
61 of 138
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Table 11
RECOMMENDED MONITORING REQUIREMENTS
USSC CLARITON WORKS
Outfall
Effluent
Measurement
Sample Type
Number
Parameter
Frequency
001
Oil/grease
1/month
3 grabs/24 hr
pH
1/month
3 grabs/24 hr
Temperature
1/month
3 grabs/24 hr
Flow
1/month
Minimum of 8 instantaneous
measurements over 24 hr
002+
TSS
1/week
24-hr flow-weighted composite
Amnion i a
1/week
24-hr flow-weighted composite
Total Cyanide
1/week
24-hr flow-weighted composite
Amenable Cyanide
1/week
24-hr flow-weighted composite
Total Zinc
1/week
24-hr flow-weighted composite
Total Iron
1/week
24-hr flow-weighted composite
Manganese
1/week
24-hr flow-weighted composite
Oil/grease
1/week
3 grabs/24 hr
Phenol
1/week
3 grabs/24 hr
PH
1/week
3 grabs/24 hr
Temperature
1/week
3 grabs/24.hr
Flow
Continuous
Measured
102*
TSS
1/week
24-hr flow-weighted composite
Amnion i a
1/week
24-hr flow-weighted composite
Amenable Cyanide
1/week
24-hr flow-weighted composite
Total Iron
1/week
24-hr flow-weighted composite
Total Zinc
1/week
24-hr flow-weighted composite
Manganese
1/week
24-hr flow-weighted composite
Phenol
1/week
3 grabs/24 hr
pH
1/week
3 grabs/24 hr
Temperature
1/week
3 grabs/24 hr
Flow
1/week
Minimum of 8 instantaneous
measurements over 24 hr
202*
TSS
1/week
24-hr flow-weighted composite
Ammonia
1/week
24-hr flow-weighted composite
Total Iron
1/week
24-hr flow-weighted composite
Total Zinc
1/week
24-hr flow-weighted composite
Manganese
1/week
24-hr flow-weighted composite
Phenol
1/week
24-hr flow-weighted composite
pH
1/week
3 grabs/24 hr
Temperature
1/week
3 grabs/24 hr
Flow
1/week
Minimum of 8 instantaneous
measurements over 24 hr
62 of
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Table 11 (Continued)
RECOMMENDED MONITORING REQUIREMENTS
Outfall Effluent Measurement Sample Type
Number Parameter Frequency
003
TSS
2/week
24-hr flow-weighted composite
Oil/grease
2/week
3 grabs/24 hr
pH
2/week
3 grabs/24 hr
Temperature
2/week
3 grabs/24 hr
Flow
Continuous
Measured
004
TSS
2/week
24-hr flow-weighted composite
or
Ammon i a
2/week
24-hr flow-weighted composite
009
Total Cyanide
2/week
24-hr flow-weighted composite
Phenol
2/week
3 grabs/24 hr
pH
2/week
3 grabs/24 hr
Temperature
2/week
3 grabs/24 hr
Flow
Continuous
Measured'
005
TSS
1/month
24-hr flow-weighted composite
Oil/grease
1/month
3 grabs/24 hr
PH
1/month
3 grabs/24 hr
Temperature
1/month
3 grabs/24 hr
Flow
1/month
Minimum of 8 instantaneous
measurements over 24 hr
006
Oil/grease
1/month
3 grabs/24 hr
PH
1/month
3 grabs/24 hr
Temperature
1/month
3 grabs/24 hr
Flow
1/month
Instantaneous measurements at
the time samples are collected
007
Oil/grease
1/month
3 grabs/24 hr
PH
1/month
3 grabs/24 hr
Temperature
1/month
3 grabs/24 hr
Flow
1/month
Instantaneous measurements at
the time samples are collected
008
Oil/grease
1/week
3 grabs/24 hr
PH
1/week
3 grabs/24 hr
Temperature
1/week
3 grabs/24 hr
Flow
1/week
Minimum of 8 instantaneous
measurements over 24 hr
010
Total Cyanide
1/month
24-hr flow-weighted composite
Amenable Cyanide
1/month
24-hr flow-weighted composite
Oil/grease
1/month
3 grabs/24 hr
Phenol
1/month
3 grabs/24 hr
pH
1/month
3 grabs/24 hr
Temperature
1/month
3 grabs/24 hr
Flow
1/month
Minimum of 8 instantaneous
measurements over 24 hr
63 of
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Table 11 (Continued)
RECOMMENDED MONITORING REQUIREMENTS
Outfall
Effluent
Measurement
Sample Type
Number
Parameter
Frequency
Oil
TSS
2/month
24-hr flow-weighted composite
Oil/grease
2/month
3 grabs/24 hr
Phenol
2/month
3 grabs/24 hr
pH
2/month
3 grabs/24 hr
Temperature
2/month
3 grabs/24 hr
Flow
2/month
Minimum of 8 instantaneous
measurements over 24 hr
012
TSS
2/month
24-hr flow-weighted composite
Oil/grease
2/month
3 grabs/24 hr
Phenol
2/month
3 grabs/24 hr
PH
2/month
3 grabs/24 hr
Temperature
2/month
3 grabs/24 hr
Flow
2/month
Minimum of 8 instantaneous
measurements over 24 hr
013
Total Cyanide
1/month
Grab
PH
1/month
Grab
Temperature
1/month
Grab
Flow
1/month
Instantaneous
014
Phenol
1/month
3 grabs/24 hr
pH
1/month
3 grabs/24 hr
Temperature
1/month
3 grabs/24 hr
Flow
1/month
Instantaneous measurements at
the time samples are collected
015
PH
1/month
Grab
Temperature
1/month
Grab
Flow
1/month
Estimated
115
PH
1/month
Grab
Temperature
1/month
Grab
Flow
1/month
Estimated
016
PH
1/quarter
Grab
Temperature
1/quarter
Grab
Flow
1/quarter
Estimated
017
Oil/grease
PH
Temperature
Flow
/month 3 grabs/24 hr
/month 3 grabs/24 hr
/month 3 grabs/24 hr
/month Instantaneous measurement at
the time samples are collected
64 of 138
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Table 11 (Continued)
RECOMMENDED MONITORING REQUIREMENTS
Outfall
Effluent
Measurement
Sample Type
Number
Parameter
Frequency
018
pH
1/quarter
Grab
Temperature
1/quarter
Grab
Flow
1/quarter
Estimated
A.C.**
Oil/grease
1/month
3 grabs/day
pH
1/month
3 grabs/day
Temperature
1/month
3 grabs/day
Flow
1/month
Estimated
020
TSS
2/week
24-hr flow-weighted
composite
Ammonia
2/week
24-hr flow-weighted
composite
Total Cyanide
2/week
24-hr flow-weighted
composite
Amenable Cyanide
2/week
24-hr flow-weighted
composite
Oil/grease
2/week
3 grabs/24 hr
Phenol
2/week
3 grabs/24 hr
pH
2/week
3 grabs/24 hr
Temperature
2/week
3 grabs/24 hr
Flow
Continuous
Measured
021-044
None
NA
NA
t Outfall 002 should be sampled at a location which includes all waste-
water from the blast furnace operation (i.e., 1023 202 and cooling
water).
tt 24-hr flow-weighted composite samples shall consist of a minimum
of 8 sample portions collected at equally spaced intervals.
ttt Flow measurement to consist of a minimum of 8 readings equally
spaced over each day.
* Outfalls 102 and 202 are to be sampled the same day that outfall 002
is sampled.
** The air compressor discharge has not been assigned an NPDES
designation.
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REFERENCES
1. Letter - January 19, 1976 with attachments from Mr. James L.
Hamilton III, Manager, Environmental Control - Water, USSC, to Mr.
Stephen R. Wassersug, Director, Enforcement Division, USEPA, Region
III.
2. Letter - March 11, 1976 with attachments from Mr. James L. Hamilton
III, Manager, Environmental Control - Water, USSC, to Mr. Stephen
R. Wassersug, Director, Enforcement Division, USEPA, Region III.
3. Development Document for the Steel Making Segment of the Iron and
Steel Manufacturing Point Source Category, Feb. 1974, USEPA Effluent
Guidelines Division, Washington, D.C. and Guidelines published in
Federal Register, Phase I, June 28, 1974.
4. Development Document for the Hot Forming and Cold Finishing Segment
of the Iron and Steel Manufacturing Point Source Category, Aug.
1975, USEPA Effluent Guidelines Division, Washington, D.C. and
Guidelines published in Federal Register, Phase II, Mar. 29, 1976.
5. Permit Program Guidance for Self-Monitoring and Reporting Require-
ments, Apr. 30, 1975, USEPA, Office of'Permit Programs, Washington,
D.C.
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APPENDICES
A Reconnaissance Report
B Study Methods
C Analytical Procedures, Quality Control
D Chain of Custody Procedures
67 of 138
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APPENDIX A
Reconnaissance Report
68 of 138
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SUMMARY - RECONNAISSANCE RFPORT FOR USSC, CLAIRTON WORKS
MADE AUGUST 1975 BY EPA, NEIC AND REGION III
An EPA field reconnaissance was made to the Clairton, Pennsylvania, Coke
and By Products Chemical Works of U. S. Steel on August 26-28, 1975,
in order to prepare for an intensive NEIC field sampling survey tentatively
scheduled for Clairton December 1975. Clairton is a complex facility
including 20 coke batteries having up to 1 ,375 ovens, a Blast f-urnace
producing basic iron and/or ferromanganese, four steel finishing mills,
two power plants, three boiler houses, and cryogenic processing (i.e.,
ultra low temperature) and conventional distillation -fractionation
of the coke oven gases in turn consisting of tar product distillation,
tar acid refining, benzene toluene-xylene processing, light oil refining
and the Claus-carbonate process for desulfurization of fuel gas and
production of sulfur, More than two dozen products are made at Clairton,
the two most important being metallurgical coke and coke oven or fuel gas
piped as fuel supply to the other USSC iron/steel mills in the Monongahela
Valley. Tar and pitch constitute additional chief products.
The Clairton complex occupies about 2.5 miles of waterfront and is about
1/3
-------
In the quenching of coke, USSC reports about 160 gallons of water used
per ton coke. "Stage charging" of the coke batteries is extensively
employed at Clairton. At this plant, the 20 batteries and support equip-
ment and processing are basically divided into two operational Units
physically separated by the Keystone {gas processing) operations. USSC
recovers ammonia uniquely by the Phosam process, employing phosphoric
acid. This process aids in recovering additional light oils in conjunc-
tion with cryogenic gas separation and processing. Both synthetic ammonia
and ammonia from coke oven gas are produced. Hydrogen, nitrogen and
oxygen constitute additional products. A physical-biological waste treat-
ment plant receiving heavily-laden ammonia-phenolics contaminated waste-
water is nearly ready for operation as of September 1975.
Storm sewers can impact upon Clairton Outfalls 002, 003 and 008 and
possibly others including municipal storm lines on the northerly and
southerly USSC plant boundaries and miscellaneous runoff that can enter
Peters Creek.
The Blast Furnace and slag handling operations are served by Outfalls
001 and 002. A Dorr Thickener with appreciable recycling is available
on the venturi scrub effluent from the Blast Furnace. The steel finishing
mills all drain into Outfall 003. Outfall 004 has been cited above. It
serves a very extensive portion of the Clairton property. Discharge 005
emanates from the BTX and Water Treatment Sector entering into Peters
Creek; Outfalls 006, 007, 010, 011, 012 and 019 are all considered
minor contributions to Peters Creek. The State Street storm sewer, i.e.,
008 must be sampled in detail to determine USSC loads, other possible
industrial loads, municipal loads and storm loads. Outfalls 018, 015-
115, 013, and 014-114-116 respectively serve the No. 2 Power House,
Boiler Houses Nos. 1 and 2, Flash Evaporator Building, and BTX Recircu-
lating Cooling Pump House, all located along the Monongahela River.
The Clairton plant has a high River Wall making sampling of outfalls
issuing forth via this Wall extremely difficult. Sampling within the
completely-enclosed section of the lower quarter-mile of Peters Creek
35-40 feet underground will be as difficult, if not more so, than the
Monongahela River waterfront. Outfall 017 is a small waste flow from a
road tar terminal. Outfall 009 has been discontinued'.
The NEIC reconnaissance report additionally provides a series of seven
figures on overall layout of the Clairton Works together with location
of buildings, outfalls, etc. Also included is a Table giving tentative
sampling locations for the NEIC future field study.
70 of
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REPORT ON. EPA RECONNAISSANCE/INSPECTION OF AUGUST 26-28, 1975 AND
PRELIMINARY EVALUATION OF AVAILABLE DATA RELATIVE TO NEIC PROPOSED FIELD
SAMPLING SURVEYt USSC, CLAIRTON, PA. COKE WORKS
Attendees during the EPA Reconnaissance of August 26-28, 1975:
Paul Morrison, USSC, Chief Environmental Officer, Clairton Works
Robert Dunham, USSC, Environmental Control, Corporate, Pittsburgh
William E. Snee, USSC, Clairton Works
Eric Hrivnak, USSC, Clairton Works
James Hatheway, EPA, NEIC
David L. Brooman, EPA, NEIC
Edmund Struzeski, Jr., EPA, NEIC
Peter Schaul, EPA, Region III
Matthew Miller, EPA, Region III
This document contains results of an EPA field reconnaissance and
inspection made to U. S. Steel's Clairton, Pa. Coke and Chemical Works
during August 26-28, 1975 together with a preliminary evaluation of
accompanying technical information on this plant obtained from various
sources.
The Report is essentially divided into history of the Clairton
Works; sampling locations specified in the 1974 NPDES draft permit;
process description and information; iron and steel making and Outfalls
001, 002 and 003; the steel Works and coke Works water Intakes; Outfalls
009, 013 through 016 and 018; BTX processing and Outfall 005; minor
discharges to Peters Creek; and Outfalls 008, 020 and 004. The latter
three outfalls were the largest and perhaps the most important from
Clairton - contributing almost 100 mgd to Peters Creek. These outfalls
are respectively described as the State Street sewer; effluent from the
physical/biological treatment works; and the Industrial Waste Sewer
capturing up to 71 mgd miscellaneous flows.
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I. HISTORY AND BACKGROUND
The Clairton Coke Works of United States Steel is located at Clairton,
Pa. about 18 miles upstream of Pittsburgh on the Monongahela River.
This facility is reported as the Nation's largest coke plant and producer
of chemicals from coal. By far and away, the major activities at Clairton
comprise the coking of coal and recovery of chemicals. However, the
Works also has a convertible basic iron and ferromanganese blast furnace
together with four old-type steel finishing/rolling mills. Coke was
first produced at Clairton in 1918. In the early days, byproduct chemicals
were limited to tar, ammonium sulfate, and benzene products. Coke is
used at the blast furnaces of other USSC mills principally in the Monongahela
River Valley. Coke oven gas is relied upon as a primary fuel for Clairton
and for the other USSC mills in the Valley. The list of products and
byproducts reported as produced today at Clairton include the following:
Steel. Bulb angles, angles - special/equal/unequal/other, channels,
beams, H-beams, I-beam Lok, cold drawn flats, elevator tee, plates,
round edge flat bars and other bars, floor plates, and special sections.
Coal Products and Chemicals. Coke oven gas, metallurgical coke,
domestic coke, coke breeze, benzene, xylene, toluene, solvent naphtha,
pyridine, alpha picoline, beta picoline, gamma picoline, phenols, ortho
and meta-para cresols, cresylic acid blends, naphthalene, creosote,
pitch, ammonium sulfate, anhydrous ammonia, sulfur, ferro-manganese, and
slag.
Other. Nitrogen, hydrogen, oxygen, roof tar, various forms of
pitch including pitch prill, fibre pitch, electrode pitch, roofing
pitch, enamel pitch, cathode pitch.
72 of 138
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The first steel rolling mills at Clairton were originally built by
the St. Clair Steel Co., a subsidiary of Crucible Steel Co. around 1901-
1902. The facilities were transferred to the Clairton Steel Co. in July
1902 and the first steel was rolled later the same year. Additional
works included 3-400 TPD blast furnaces and 12 open hearths. The original
rolling mills consisted of a 40-inch bloom mill and a 28-inch billet
mill. The overall facilities were purchased by USSC in 1904. Thereafter
the steel finishing mills were constructed. The first of these was the
22-inch (No. 1) structural shape rolling mill comprising 3-stands, 3-
high reversing rolling facilities. This mill on the westernmost side of
Clairton steelmaking sector was changed in the 1940's from steam-driven
to becoming fully electrified. The 18-inch mill, a 5-stand cross-
country mill, was built in 1905 principally for rolling merchant bars,
flats and tees. In 1907, the 14-inch mill, a 7-stand cross-country mill
was opened to roll small structurals and bar shapes. In 1909, the 22 or
21-inch (No. 2) structural shape rolling mill was completed. These
rolling mills continue to operate largely with "old" original equipment
and are steam-driven except for the 22-inch, No. 1 mill.
Operation of byproduct coke and chemical processing facilities
started in 1918. The first phase consisted of 12 batteries each having
64 ovens (768 total ovens). The second phase comprised 6 batteries
having 61 ovens each (366 total ovens). The third phase included 4
batteries of 87 ovens each (348 total ovens). In 1948, an additional
battery of 87 ovens was installed and later in 1964, 3 batteries totalling
192 ovens were removed to make way for the Keystone gas processing
facilities. Net facilities now consist of 20 batteries with a total of
1,375 ovens.
In 1921, the Marine Ways were built at Clairton to maintain and
repair USSC's navy. Coal pulverization was instituted around 1960 aimed
to yield coke with more uniform characteristics. Light oil purification,
naphthalene recovery and new tar distillation plants were all constructed
73 of 138
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in the early 1960's. Steel making was discontinued and blooms and
billets thereafter obtained from the Duquesne Plant of USSC by rail.
In the mid-1960's, construction started on the new coke oven gas
processing faciliites and the anhydrous ammonia plant which became known
as the Keystone Project. In 1964, Clairton's remaining blast furnace
was converted over to the production of ferromanganese. The Clairton Fe
Mn process casts the molten metal into beds; this procedure continues
today.
In 1965, a new 60-cycle power generation station and high-pressure
boiler were added. Facilities were also completed for making pitch
prills, and the road tar terminal was placed under construction. In
1968, molten sulfur and anhydrous ammonia were recovered. In 1969,
synthetic anhydrous ammonia was produced and the new naphthalene desulfurization
plant was put into operation. A simplified sketch of the processing
steps "From Coal to Chemicals at the Clairton Works" as of around the
early-1970's is given by the figure contained in Attachment I. It is
noted that cryogenic (intense cooling) is heavily relied upon at Clairton
in lieu of the more conventional distillation-fractionation means of
separating the various chemicals and gases.
The U. S. Steel Clairton Works extends over about 2.5 miles of
waterfront and varies from 1/4-1/2 mile wide plus a narrow strip of land
up Peters Creek to the Ravensburg Bridge or beyond. Clairton has 25
primary NPDES outfall or sampling NPDES points; plus 24 secondary, small
condensate discharges; plus two discharges which the Company has asked
be permitted but upon which no action has been yst taken by the EPA.
The Clairton Coke and Chemical Works operates 7 days a week, 24
hours a day for most processing. The main exceptions are the hot
rolling steel finishing mills which generally operate 4-5 days per week,
2 turns per day. Total employment is approximately 4,500 persons.
74 of 138
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Coking operations are roughtly divided about 30% on first turn (12:00
Midnight-8:00 A.M.), 35% on second turn (8:00 A.M.-4:00 P.M.) and 35% on
the third turn (4:00 P.M.-12:00 Midnight). Coking is reported heaviest
on the second turn. The rolling mills operate primarily during the
second and third turns. The maintenance force is relatively light
during the first turn. During the week of our reconnaissance, all four
steel finishing mills were operating 2 turns over 4 days. The
single (No. 1) blast furnace at Clairton has not operated since January
1975. Rather than shut down however this furnace has been banked with
cooling water continuously running through it. During most of 1974 the
blast furnace was producing only basic iron and no ferromanganese. The
NP0ES permit was written on basic iron production, not Fe Mn. We would
hope the Mo. 1 blast furnace would be started up prior to the NEIC
contemplated field sampling survey. However, Steel personnel stated of
all Company blast furnaces in the Valley, the Clairton unit may be the
last one up because of its small size. All sanitary sewage from the
Clairton Works is said to be pumped to the City of Clairton.
The draft NPDES permit and Fact Sheet of 1974 on the Clairton Works
gives production as follows: coke - 22,000 TPD; finished steel production
as a total for the four mills - 2,400 TPD; and blast furnace basic iron
production - 900 TPD or ferromanganese - 500 TPD. Basic iron when made
at Clairton is shipped in molten form generally to the National or E.
Thompson Works of USSC. The permit reports 108 mgd spent waters discharged
to the Monongahela River and some 25 mgd to Peter's Creek (total = 133
mgd). USSC personnel on August 26-28, 1975 indicated they could not
synthesize the figure of 2,400 TPD finished steel. Calculations leading
to this figure could not only be obtained from top management by very
careful scrutiny of past records. On the A.M. of August 26th (our first
day), plant officials stated production at Clairton was only running 30-
50% of capacity, probably 30-40%. Production of coke was estimated in
the range of 18,000 TPD during late August 1975. Bob Dunham stated most
75 of 138
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companies including USSC had developed their permits on the basis of
maximum month capacity over the most recent five years of record preceding
the NPDES permit preparation. This very probably was also the case for
the USSC Clairton permit.
II. SAMPLING/MONITORING LOCATIONS PROVIDED 'BY THE 1974 DRAFT NPDES
CLAIRTON PERMIT
The Fact Sheet and the Draft NPDES Permit describe the primary
outfalls at Clairton as follows. We note that current USSC sampling
points in a few instances are in different locations than specified by
the NPDES document.
001- Cooling water (barometric condenser) effluent from blast
furnace, untreated, 14.0 mgd to Monongahela River to be
sampled in 001 line "downstream of last addition point."
002- Treated effluent from blast furnace as "combined flow before
city of Clairton storm sewer discharging into Outfall 002."
Includes 9.2 mgd cooling water plus 0.4 mgd process waters,
treated.
102- Treated effluent from blast furnace at the discharge of the
blast furnace clarifier, to Outfall 002 (this point effective
after 7/1/77).
202- Treated effluent "at the discharge of the slag pit to Outfall
002"(this point effective after 7/1/77).
003- Combined treated process effluents plus untreated cooling
waters from hot form rolling mills, 9.4 mgd to Monongahela
River, Outfall 003 sampling apparently includes Shaw Av.
storm sewer addition.
103- Combined effluents from 21-inch (old No. 2) and 14-inch steel
finishing mills (the two mills closest to the River). This
sampling point in actual practice is inside and on the south
side of the 18-inch mill. Besides scale type wastes, it
includes barometric condenser waters from the combined
21- and 18-inch (steam driven) mills, but excludes coolinq
76 of 138
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waters from the reheat furnaces on the 21-inch mill (this
point effective only after 7/1/77). The permit defines this
point as containing the entire 21- and 14-inch mill flows
prior to entering the storm sewer.
203- Combined effluents from the 18-inch and 22-inch steel finish-
ing mills. This point is actually located between the 18-mch
and 22-inch mills and on the south side of the mills. The
Company likely has not yet established precise sampling
locations for 103 or 203 because the need for sampling these
points does not occur until mid-1977. USSC personnel believe
the 203 point although including scale pit effluent from the
18- and 22-inch mills does not pick up barometric condenser
water from the 18 inch (steam-driven) mill. The presence of
reheat furnace cooling water could not be ascertained (this
point effective only after 7/1/77). The permit defines this
point as containing the entire 18- and 22-inch mill flows
prior to entering the storm sewer.
004 or 009- "Miscellaneous" cooling waters before entering Peters
Creek (004) or the Monongahela River (009) - whichever is
discharging. Cooling waters, untreated, 71.1 mgd, reported to
be originating from miscellaneous coke oven gas coolers and
recovery facilities. Outfall 009 was reportedly used previous'
only during the relining of sewer 004, this project now
completed. 009 discharge should presently be zero. Other
data indicate spent waters mostly derive from barometric
condensers and primary coolers being released to 004 then to
the enclosed section of Peters Creek.
005- Reported to consist of 4.7 mgd cooling waters from benzene
plant and 0.3 mgd process flows from the No. 2 boiler house
ash pit. Total flow of 5.0 mgd enters into the enclosed
section of Peters Creek. Waste line runs between water treat-
ment plant and benzene boiler house via a 36-inch line which
converts to a 42-inch sewer line. VJaste sources are said to
include benzene refining, the benzene boiler house and feed
water treatment.
006- Approximately 0.1 mgd cooling waters, from compressors and/or
tar pumps entering into the completely enclosed section of
Peters Creek. Tar distillation facilities, tar stills and
tank yards are situated directly over Peters Creek in the
vicinity of this outfall to Peters Creek. Connection is via
48-inch diameter vertical drop MH into the concrete arch sewer
representing Peters Creek underground.
77 of
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007- Approximately 1.7 mgd cooling waters nominally originating
from tar still into enclosed portion of Peters Creek. Con-
nections include drain from electrode pitch factory, drains
from tar stills, and drain from strainer building all entering
48-inch diameter vertical drop MH into the concrete arch sewer
of Peters Creek.
008- State Street storm sewer entering open section of Peters Creek
receiving Power House No. 1 effluents, barometric condenser
•waters plus undefined miscellaneous. Power house effluents
reported as 16.0 mgd. Draft permit specifies that 008 shall
be monitored both at State Street storm sewer upstream of
power house discharge, and also at storm sewer discharge into
Peters Creek.
009- Given as "zero" discharge previously used as temporary dis-
charge while 004 sewer was under repair. If used, may contain
spent flows from "miscellaneous cooling water zone" or from
barometric condensers and primary coolers. Outfall is directed
to Monongahela River via submerged release immediately north
of water treatment clarifier tank.
010- Approximately 1.8 mgd of cooling waters from tar and napht-
halene plant(s) (intermittent flow) discharged into completely
enclosed section of Peters Creek. Sub-drains originating from
tar plant, phenolate storage area and naphthalene desulfurization
reported entering into 24-inch sewer in turn entering concrete
arch sewer representing Peters Creek.
011- Cooling waters from No. 1 Prill Pitch Unit, process and/or
cooling waters untreated, 0.75 mgd to enclosed portion of
Peters Creek. Drains originate from strainer building, prill
pitch building into 48-inch vertical drop MH entering concrete
arch sewer representing Peters Creek. Prill pitch, electrode
pitch facilities, strainer building, and tar storage tanks all
are more or less situated directly overhead of Peters Creek.
012- Cooling waters from No. 2 Prill Pitch Unit, untreated, 0.75
mgd process and/or cooling waters to enclosed portion of
Peters Creek. Drains originate from tar storage tanks and old
and new prill pitch buildings which more or less directly
overlay Peters Creek.
013- Reported principally as blowdown from flash evaporator and
cooling tov/er. Spent waters originate from area of pumphouse,
flash evaporator system and cooling tower, untreated, 1.4 mgd
to Monongahela River.
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014- Approximately 0.05 mgd from water recirculation pump house
adjacent to cooling tower both serving benzene, toluene, i.e.
BTX processing area. Discharge is untreated ta Monongahela
River. Company actually samples two separate flows from water
recirculation pump house which make up sewer 014.
016- Approximately 0.10 mgd from south side of water recirculation'
pump house. Discharge is untreated to Monongahela River.
Flow also reported to contain strainer backwash and cooling
tower sump drain water.
015- Spent cooling water plus blowdown from No. 2 Coke Works boiler
house; flow of 1.04 mgd untreated. Discharge to Monongahela
River, may be submerged a portion of the year.
115- Spent cooling water plus blowdown from Mo. 2 Coke Works boiler
house. Flow of 0.26 mgd untreated. Discharge to Monongahela
River may be submerged during a portion of the year.
017- Miscellaneous flows reported as 0.1 mgd intermittent to Monongahela
River from road tar terminal and loading facilities. Discharge
originates from area of road tar piles and loading, storage
tanks and BTX plant.
018- Some 0.5 mgd cooling waters, blowdowns, condensates, etc.
principally from No. 2 power house. Discharge to Monongahela
River.
019- Emergency overflow from sanitary pump station on Peters Creek.
Zero discharge reported. Company has withdrawn discharge
permit application. This point is in area of naphthalene
desulfurization facilities surmounting Peters Creek.
020- Described as final effluent from "Contaminated Waste Water
Physical/Biological Waste Treatment Works" entering into
completely enclosed sector of Peters Creek. Permit specifies
that outfall shall be measured at discharge point of the
wastewater treatment plant.
River mileage locations of the above permitted outfalls and/or
monitoring locations are tabulated in the following listing.
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USSC, CLAIRTON, PA. NPDES "PRIMARY" PERMITTED LOCATIONS
Outfal1
Discharging to
River Mile
001
Monongahcla River
21.66
002
Monongahela River
21.56
003
Monongahela River
21.13
004
Peters Creek
19.62/0.02
005
Peters Creek
19.62/0.08
006
Peters Creek
19.62/0.23
007
Peters Creek
19.62/0.25
008
Peters Creek
19.62/0.42
009
Monongahela River
20.16
010
Peters Creek
19.62/0.17
Oil
Peters Creek
19.62/0.27
012
Peters Creek
19.62/0.28
013
Monongahela River
19.58
014
Monongahela River
19.52
015
Monongahela River
19.59
115
Monongahela River
19.59
016
Monongahela River
19.54
017
Monongahela River
19.40
018
Monongahela River
19.65
019
Peters Creek
19.62/0.17
020
Peters Creek
19.62/0.06
Other outfalls, described as 021 through 044 are given in the
Clairton Draft NPDES Permit and reported as containing "steam condensate
only," and for which no monitoring was to have been required for the
duration of the permit. These "minor" outfalls most of which are highly
sporadic, are tabulated below for informational purposes. He note that
"old" Outfall Nos. 1-17 as condensate drains in USSC's permit application,
are now known as Outfalls 021 through 037, respectively. Old condensate
•drain outfalls 18 through 23 havp been changed to New Outfall Nos. 038-
043, respectively, and old Outfall No. 24 to new Outfall No. 044.
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CLAIRTON WORKS
CONDENSATE DRAINS
Outfall
No.
Description
021 Two 3/4" condensate drains from temporary change house
022 Two 2" and one 1-1/2" condensate drains from waste oil
storage area and fuel oil tank
023 One 1-1/2" condensate drain from No. 1 transfer tov/er
024 Two 3/4" condensate drains from No. 1 sample building
025 One 1/2", one 4" and one 2" condensate drains from surge
bin area
026 One 2" condensate from sanitary station
027 One 1-1/2" condensate from machinery house
028 One 4" and one 1-1/2" condensate drains
029 One 1-1/2" condensate from transformer station
030 Two 2" and one 3" condensate and area drains from coal hoppers
031 Two 1/2" condensate drains from coke works river pumphouse
032 Two 3/4", one 1", and one 2" condensate drains from clarifier
and pumphouse
033 One 2" condensate drain from surge bin area
034 One 2" condensate drain from No. 2 sample building
035 3/4" condensate from No. 3 transfer tower
036 One 1" and One 3/4" condensate from No. 3 coal hoist
037 One 3/4" and two 1" condensate from oil house and sanitary station
038 Two 3/4" and one 2" condensate drains from No. 4 coal hoist
039 1" condensate from No. 2 boiler hosue
040 Condensate from water treating plant
041 1" condensate at evaporator
042 Two 1-1/2" condensate drains from recirculating pumphouse
043 Four 1" and two 3/4" condensate drains from creosote and
naphthalene line tracers
044 One 3/4" condensate drain from lime slurry storage tank
and one 8"" compressor cooling v/ater
For purposes of NET load calculations, the SW (Steel Works) pump house
intake is to be sampled for coverage of Outfalls 001 through 003. The
CW (Coke Works) pump house intake will be sampled for coverage of the
remaining Outfalls, 004 through 020.
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III. GENERAL AND SPECIFIC PROCESSING
Coal is received from barges or the Clairton storage piles and off-
loaded into the Clairton Works at three points. The coal which has been
previously washed elsewhere is blended and hiixed with other coals,
pulverized, and conveyed into tall storage bunkers east of the coking
batteries near the River. Clairton is reported to have 1,375 coke
ovens where coal is heated in the absence of air for about
18 hours at 2,000-2,100 °F, yielding metallurgical coke, coke oven
gases, and various coke chemicals. Some 40-50% of the coke oven gas
(fuel gas) from the Clairton coking facilities is employed for underfiring
the flues in the refractory brick-lined ovens in the Clairton coke
batteries. The remainder is shipped to other USSC iron and steel Works
in the Monongahela Valley. Once the coking process is complete, the
contents of a single oven are pushed into a railroad quenching car. The
car is moved to one of 8 quench towers where the coke is cooled with
water and then discharged to coke v/harfs. Once completely cooled, the
coke is screened and either loaded into railroad cars for use at other
USSC mills, or stockpiled.
At Clairton, the 20 coke batteries are divided into two operating
units, i.e. in one unit is contained batteries 1, 2, 3, 7, 8, 9, 10, 11,
12 and 12A (10 batteries); and in the other unit is contained batteries
13, 14, 15, 16, 17, 18, 19, 20, 21 and 22 (also 10 batteries). The two
units are more or less physically divided by Keystone operations and by
oil and tar removal facilities.
In the coking process, coal volatiles are collected via overhead
mains running the length of each coke oven. These hot gases being
withdrawn under suction are initially cooled by spraying with ammonia or
flushing liquors. A large portion of the tar in the raw gas drops out
with this initial cooling. Condensed tar and the flushing liquor
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mixture travel down the suction main and into a decanter tank. The
partially cooled gas is then passed through primary coolers where the
gas temperature is further lowered. Condensate from primary cooling is
also sent to the above cited decanters.
In the decanters, separation is made into tars and flushing liquors,
the latter being recycled back to the coke ovens. Excess flushing
liquors are sent to storage. Gases after the primary coolers are
forwarded to exhausters and tar extractors both of which contribute
additional tar product. The excess flushing liquor is generally the
major single source of contaminated water from the coke plant.
Following the primary coolers of which there are two separate banks
at Clairton, the cooled gas is compressed to about 50 psi by compressors
each driven by a 3,000 hp motor. The gases pass to final coolers. In
the final coolers, water sprays dissolve soluble constituents and flush
out and condense insoluble naphthalene from the coke oven gases.
Separation is thusly made into tar, naphthalene, and ammonia. The final
cooler waters after separation of chemicals, are usually recycled
utilizing a cooling tower. If an efficient recycle system is not used
at this point, final cooler waters can constitute the largest wastewater
volume from the plant.
In most coke plants,'ammonia is recovered or absorbed between the
tar extractor and final coolers, but in the case of USSC, Clairton,
ammonia is recovered via the Phosam (phosphoric acid) Process, following
final coolers. In the Phosam process, ammonia is recovered through
'absorption in a recycled solution of ammonium phosphate. In a typical
absorption cycle, "lean" i.e. 40% phosphate solution is employed to
absorb the ammonia. The enriched phosphate solution is subsequently
reboiled in a distillation tower from which the ammonia vapor is recovered
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and the phosphate-type solution separated for reuse. The Phosam process
is said to substantially contribute to the overall Keystone operations
by producing additional light oils from the gases.
Regenerators at Clairton are employed for supercooling and the
cryogenic separation of gas into various components such as methane,
hydrogen, oxygen, nitrogen and light oils. The regenerators utilize
indirect cooling via extremely large quantities of coil exchangers.
USSC considers cryogenic separation of chemicals significantly more
efficient than conventional fractionation and distillation. Nevertheless
the latter operations are used in part. Oxygen is produced at the air
box. In the hydrogen plant, methane is separated out cryogenically but
importantly, ammonia is produced synthetically iro the SYN loop. Temperatures
of -300 °F or lower are achieved at Clairton. The synthetic ammonia is
commercially sold together with the ammonia produced from the Phosam
process.
The important tar products after recovery sre refined and reworked
generally via tar distillation, tar acid distinction and naphthalene
refining to give desirable cuts of products including various pitches
and tars, carbolic oils, methyl naphthalene, creosotes, naphthalene,
phenols, ortho cresol, meta para cresol, and xylenols. In most coking
operations the tars are refined using continuous type distillation with
multiple columns and reboilers. After naphthalene removal the phenols
and other tar acids are extracted from the middle* oil fraction with
caustic, neutralized and fractionally distilled.
The usual process after final coding is to remove the crude light
oils from the gases by absorbing onto wash oils aimd subsequently regenerating
and refining the light oils and wash oils. We nwtte, however, Clairton
employs cyrogenic separation in lieu of wash oil absorbing. In this
process line, the coke oven gases conveyed with ttHie light oils are
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additionally desulfurized via cryogenic facilities, the carbonate
plants and an old and new Claus plants. Elemental sulfur is produced
concurrently. The Claus process is currently undergoing considerable
expansion at Clairton.
Light oils are distilled and/or fractionated into benzene, toluene,
xylene and solvent naphthas in the extensive Clairton BTX process
sectors. Light oil recovery has recently become very profitable for
USSC. Steel even purchases outside light oil stocks to supplement
internal supply due to substantial process capacity. Hydrogen from the
hydrogen plant is employed for hydrogenation of light oils and their
components in the BTX plant. The No. 3 Still building is another important
facility in the BTX complex. The purification of pyridine and its
derivatives from light oils appears to have been discontinued at Clairton.
According to EPA Effluent Guidelines on the Iron and Steel In-
dustry, the more significant liquid wastes from overall coking and
chemical recovery are the excess ammonia liquor, final cooling water
overflow, light oil recovery wastes and indirect cooling waters. Additionally,
smaller volumes of wastewater may originate from coke wharf draiV
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IV. IRON AND STEEL MAKING: BLAST FURNACE AND STEEL FINISHING MILLS;
OUTFALLS 001, 002 and 003
The reconnaissance inspection was started in the iron making and
steel making areas located on the southernmost side of the Clapton
Works and covered by Outfalls 001, 002 and 003. Layout of this overall
sector is shown in enclosed sketches. During our visit the No. 1 Blast
Furnace and granulated slag processing were completely down. However,
the furnace was banked with continuous recirculating water through the
unit including the three accompanying stoves.
A. 002 Sewer System
Slag from the blast furnace (when occurring) is immersed into water
(i.e. slag enters under the water surface) in a small, three compartment
quench basin (for slag), and the overflow is pumped to a concrete-lined
slag settling basin, the latter approximately 80 ft long by 33 ft wide.
Sludges in the settling basin are removed via clamshell. Unrecoverable
or unusable slag is transported to a Peters Creek dump area for final
disposal (i.e. across the Creek from the Clairton STP and/or upstream.
Overflow from the settling basin leaves from the SE corner of the chamber,
crosses over or under the 001 sewer, and drains into the 002 Sewer. The
slag settling basin effluent is sampled at point 202 close to the settling
basin, but we did not determine its precise location. Also feeding the
002 sewer are: 1) a major city of Clairton storm sewer intersecting 002
at the west end of Steel's property in the vicinity of the railroad car
tipple; 2) Blast Furnace No. 1 cooling waters; and 3) effluent from a
110 ft diameter Dorr thickener serving the venturi scrubber off the
•Blast Furnace. Blast Furnace No. 1 is equipped with a dry dust catcher
and a venturi scrubber on the exhaust air discharges. The venturi scrub
effluent flows to the Dorr thickener.
The Company does not sample at the end of the 002 sewer but rather
at three intermediate points: 202, 102 and 002. This is because the
end of the 002 sewer below the river bank is difficult to access and
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because sanitary sewage from the city of Clairton is entering the top
end of the 002 line. Our observations of the end of the 002 sewer near
the river verified probable presence of organic matter, likely domestic
sewage, and hot temperatures. The 202 point, or the effluent from the
slag settling basin, has already been described. There is currently no
flow reported in the 202 sewer line.
The Dorr Thickener was dry during our visit. Under normal operation,
thickener effluent is largely recirculated back to the venturi scrubber.
The effluent flows into a box at the south side of the thickener. There
are two overflows from the box passing through the recirculation water
pump house. One is the recycle to the venturi scrubbing unit and the
other is the thickener bleedoff or blowdown to the 002 sewer through
sampling point 102. During Fe Mn blast furnace operation, USSC reports
no. discharge through 102. With basic iron blast furnace operation, the
Company reports an overflow of only about 50 gpm via sampling point 102.
The vacuum filter building serving thickener underflow was locked during
our inspection but regardless, the blast furnace and thickener were both
down. Filter cake is reported to be disposed of to Peters Creek dumping
grounds with the filtrate returning back to the thickener. Curiously we
noted oily water in a cistern below ground just east of the thickener
and filter house. We later learned this was previous exhaust from
vacuum pumps on the vacuum filters. Some of this oil was escaping onto
adjacent land surfaces. Immediately north of the 002 sev/er is located
the Fe Mn screening and casting operations; neither was in use during
our reconnaissance.
We inspected the upstream portion of the 002 sewer line for sampling
control on the city storm sewer feeding into the 002 line. This municipal
sewer seems to continuously convey sanitary sewage to the river and we
located a possible sampling location at the manhole next to the railroad
car tipple station just east and above the railraod tracks. Upon
raising the manhole cover, we observed reasonable flow in the sewer.
Subsequent inspection was made of the ore trench, the blast furnace
materials stockpile area, and the 30 and 54-inch storm sewers at the
southwest side of Steel property.
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The ore trench was mostly filled with water during our reconnaissance.
It appears to receive drainage from the materials stockpile area. We
noted at least two culverts leading off the stockpile sector to the ore
trench. Stockpiled materials running from north to south included iron
ore, ferromanganese ore, limestone and coke. Morrison indicated the ore
trench receives venturi scrub water bypassing the Dorr thickener when
the thickener is down for repair or for other reasons, and this bypass
is brought down into the south end of the ore trench. Flow is returned
to the thickener via a pump at the north end of the ore trench. USSC
personnel insisted there is no drainage from the materials stockpiles
into the trench nor from the trench to the 002 sewer. Nevertheless with
heavy and sustained rainfall the ore trench will overflow and it is
possible this excess runoff may find its way to the 002 sewer. There
may be a possible connection at the manhole next to the car tipple. All
three manholes on the upper end of the 30 and 54-inch storm sewers in
the railroad track area at the west side of Steel's property were
inspected and found to be almost completely dry. Morrison believes the
30-inch sewer may be clogged and presently is carrying no flow during
both wet and dry weather. USSC promised there was absolutely no process
water in either of these two storm sewers (possible unknown connections?).
Back on the 002 sewer, we visited USSC's 002 sampling point which
was directly east of Blast Furnace No. 1 and situated between the blast
furnace and the boiler house. The flow we observed at the raised manhole
representing the Company 002 location was reported to be entirely cooling
water coming from the banked blast furnace. Flow was estimated by
Morrison to be around 1.0 mgd. Sampling is conducted via a pump with a
solenoid valve. When the blast furnace is in normal operation, this
sampling point also receives slag settling basin overflow, i.e. discharge
from the 202 location. At this 002 location, it was reported that
little or no blowdown occurs with Fe Mn blast furnace operations.
However, considerable blowdown results with basic iron.
Within the "Pitch Bay" building (close to the slag settling basin)
pitch is poured in thin layers over the floor and allowed to harden as a
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black, amorphous , highly-brittle product. The pitch is broken into
more easily-handled pieces and loaded into outgoing railraod cars.
There appears to be no waste discharge from the Pitch Bay building. We
were told that the solid pitch is admixed with tar and creosote and used
in blast furnace operations at other USSC mills.
B. Upstream Storm Sewers
We viewed the site where the 30- and 54-inch storm sewers come
through the river bank and empty into the Monongahela River. From atop
the bluff we could see a reasonable discharge from one of the two lines
but could not tell which. The second outfall apparently was not flowing.
Our point of observation was approximately 130 ft upstream or south of
the "Pitch Bay" building.
C. 001 Sewer System
The 001 sewer is sampled by the Company at a manhole immediately to
the west of the railroad tracks next to the water purifying plant handling
boiler feed water. Immediately to the north side of the 001 Company
sampling point, is located the Steel Works Water Pump House and a tall
emergency standpipe. The Blowing Engine House (for the Blast Furnace)
is situated directly west of the water purifying plant. The power house
and turbogenerator house are directly west of the pump house. The
boiler house is also within this complex. Boiler water is treated by
the hot soda ash process (plus lime sometimes), followed by sand filtration.
The 001 sewer is reported as receiving cooling waters from the blast
furnace, barometric condenser waters from turbine-driven water
pump(s) in the water pump house, cooling waters and barometric condenser
waters from seven blowing engines in the blowing engine house, exhaust
steam from boiler feedwater treatment, air compressor cooling waters,
plus boiler blowdowns and sand filter backwashes. Boiler water treatment
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chemical sludges are likely discharged separately or with the sand
filter backwashes to the 001 sewer. The boilers are rated about 190,000
lb steam per hour with blowdown around 15%. We were told the boilers in
the Steel Viorks sector were not currently running. There was a relatively
small flow at the Company 001 sampling point because the blast furnace
and iron making complex were essentially down awaiting increased production
across the industry.
D. SW Water Intake
The Steel Works (SW) Water Intake Structure contains a wide-spaced
bar screen followed by a traveling screen. On the north side of the
pump house, tv/o pumps are functional and were running, with a third pump
in need of repair and non-functional. USSC indicates a single pump
could conceivably meet full demands of the steel-making portion of the
plant. One pump appeared to be steam-driven and the other electric-
driven. On the south side of the pump station are three more steam-
driven pumps not believed in use. Practically all readout gages are
located at the lowermost level of the pump station. The Company samples
for calculation of NET NPDES loads off the discharge side of the active
pump(s) at a convenient location on the main floor. This sampling
station is located at the southwest side of the pump house. Samples are
withdrawn from a spigot just downstream of a cartridge filter. Water
pressure was reading 43 lb during our visit. This water intake sampling
point on the main floor is directly next to the three steam-driven
standby pumps. We were told that the Steel Works Water intake is measured
via an orifice meter with continuous flow chart which in turn is planimetered.
However, we did not see this instrumentation. Further checking is in
order prior to the NEIC field survey. The Steel Works water intake was
said to be in the range of 20 to 30 mgd. However, it was later stated
that weekend intake is as low as 7 mgd running up to about 24 mgd.
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E. 003 Sewer System and the Steel Finishing Mills
The four steel finishing mills run in order from west to east: the
22-inch mill, 18-inch mill, the 14-inch mill and the 21-inch mill. All
four mills drain to the 003 sewer. Because of difficulty of access to
the end of the 003 sewer near the river, the company samples the combined
structural mill effluents at a point in the yards just east of the Guide
and Welding Shop and west of the southernmost ajrmonia storage tank. The
003 sampling point is an appreciable distance from the river - almost
500 ft. The 003 sample station is completely enclosed and has been
equipped with a pump and solenoid. The line must be sufficiently bled
before a proper sample can be taken. Because this manhole is completely
hidden from inspection and due to its proximity to the mills and reheat
furnaces, one must question if adequate mixing and a representative
sample is possible at this station. Each of the ammonia storage tanks
cited above is rated at 7.1 mg capacity. Liquid ammonia is stored in
the tanks at approximately -28°F and under minimum pressure. This
ammonia may originate from coke oven gas or represent ammonia specially
synthesized at Clairton.
We viewed what were described as sampling paints 103 and 203. The
103 point is located inside the 21-inch mill on the south side, the 203
point is between but outside the 22- and 18-indn mills and south of the
mills. The latter two points were previously described in our listing of
NPDES sampling points for Clairton. Station 103 is intended to pick up
all effluents from the 21- and 14-inch finishing mills whereas Station
203 is intended to pick up all effluent combined from the 18- and 22-
inch finishing mills. Neither station picks up all effluent intended to
be present at the respective points.
The four finishing mills are each equipped w.ith one or more scale
breakers. There are scale pits at each of the faur mills. There is no
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skimming nor specific removal of oils. Besides descaling and other
waters from underneath the rolling lines, other effluents originate as
furnace cooling waters, cooling waters on the saws and barometric condenser
waters. Two barometric condensers are available. One serves the combined
needs of the 21-inch (No. 2) and 14-inch steam-driven mills, and a
second barometric serves the 18-inch mill separately. Metal and sludge
from the scale pits are said to be recycled back for processing but
Steel was extremely unclear in this explanation. The scale pits are
said to remove the larger chunks. Smaller particles probably pass
through.
The 21-inch mill has a box-type scale pit approximately 6 ft x 16
ft. On the A.M. of August 27th in our tour of the 21-inch mill there was
3-5 inches of water over much of the floor on the south side of the
mill. The 14-inch mill appears to have the scale pit directly under the
mill stands, a few feet wide x many feet long. The 22-inch mill scale
pit is approximately 4 ft x 58 ft long. The 18-inch mill isfshown to
have both north and south scale pits respectively 4 ft x 12 ft and 11 ft
x 4 ft joined by a common channel (underrating) 4 ft x about 70 ft
which also contains the effluent pipe serving both scale pits.
A storm sewer is reported as contributing to the upstream end of
the 003 sewer. We were taken to a manhole just west of the 22-inch mill
which can serve as a possible wet weather sampling control on the 003
sewer. During our visit of the A.M. of August 27th,the sewer at this
location was running virtually dry.
The bottom end of the 003 sewer was free-flowing into the river as
was also the case for 002 (i.e. neither was submerged). The best way to
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sample both outfalls is believed to be by boat. Flow at the 003 outfall
was relatively large (20 to 25 ingd est.) and thought to be in excess of
NPDES figures. Velocity of the 003 flow is extremely fast issuing forth
from a 4 ft arch brick-lined sewer. A ladder was observed as available
down the side of the river bank in the vicinity of the Belle Bridge and
it may be possible although difficult, to get to the end of the 003
sewer by foot. Scale or other solids buildup was noted at the end of
the 003 outfall. This outfall is located directly to the rear of the
southernmost storage tank. It is also about 130 ft downstream of
the Belle Bridge. We noted a manhole on the bank just west of the end
of the 003 outfall. The Company reported this manhole is most probably
connected to a sanitary sewer line.
It is tentatively suggested on NEIC sampling of the Steel Works
outfalls that the 001, 002, 003 and the 54/30-inch (storm) sewers each
be sampled at their very end by boat, even though this will not be easy.
None of the outfalls should be submerged unless the river rises higher
than expected.
V. MISCELLANEOUS DISCUSSION ON CLAIRT0N OPERATIONS, MORNING OF
AUGUST 27, 1975
On the morning of August 27th, Paul Morrison was repeatedly called
out of our meeting because of a significant oil spill that had occurred
on the river adjacent and upstream of Peters Creek the night before.
The Oil spill was found by the USCG. Steel disclaimed any responsibility
for the incident. General discussion was held with USSC personnel
concerning the overall Works. We covered the Coke Works Water Intake,
number and function of various cooling towers throughout the chemical
operations, and use of contaminated waters in quenching coke. The
practice of using contaminated water in quenching was scheduled to be
terminated on July 1, 1975. Thereafter a physical/biological treatment
works would receive the contaminated waste stream.
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Coal is washed and sized before coming to Clairton. It is pulverized
after off-loading. A single barge bringing coal into Clairton runs from
900 to 1,200 tons in capacity and Clairton can handle 30-35 barges daily
through its coke ovens. USSC personnel insisted there are no wastewaters
originating from coking until the site of the primary coolers. Further
checking is necessary on this point. Clairton divides its 20 coke
batteries into two groups of ten batteries each. A list of cooling
towers was given us as follows: Cooling tower available at flash evaporator,
at the naphthalene refinery, at BTX (Benzene-Toluene) refinery, and at
the Keystone Process Center. Air conditioning at various locations
through the plant is additionally served by various small cooling towers.
VI. COKE WORKS WATER INTAKE AND OUTFALLS 022 and 023
The Coke Works Water Intake is located immediately east of Battery
No. 12 and upstream of the 009 discharge to the Monongahela River. Two
venturi meters are available on the intake which are calibrated regularly.
According to the NPDES Draft Permit, Coke Works Water Intake is in the
range of 90-120 mgd. Flows are recorded and the Company planimeters the
flow charts to obtain total volume. The pump station has six pumps, all
electric. During our visit of August 28, the two meters at the pump
house were reading 44 and 59 mgd respectively. USSC samples off the
pump discharge for calculation of NET NPDES permit loads. The sample is
actually collected at the southwest side of pump house. River water is
used throughout the Coke Works primarily for cooling. Needs were
reported to include coke oven gas cooling, primary coolers, various
shell and tube heat exchangers, makeup for cooling towers, boiler
Yeedwater (employing settling(?) - see below, hot process softening and
flash evaporation), supply for barometric condensers, etc. Besides
boiler water supply receiving special treatment, makeup for the large 5-
cell Keystone cooling tower (approximate recycle rate of 72,000 gpm) is
also treated. The latter receives clarification, addition of special
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flocculating agents and pH adjustment when necessary. The clarifier for
the Keystone cooling tower is located immediately north of the Coke
Works Pump House and adjacent to the 009 Outfall. Hexavalent chromium
is added to the recycle waters of the cooling tower. Cooling tower
makeup is estimated around 1200 gpm. Sludges from the clarifier are
taken to dumping grounds. Blowdowns from the large 72,000 gpm cooling
tower likely enter into the 004 sewer.
Outfall Nos. 022 and 023 are associated with the Coke Works water
intake pump station but we carefully note the numbers on these two
particular outfalls have been designated by Steel and not by the EPA.
USSC has applied for permits on these two outfalls but so far has not
received any approval, according to the Company. The above numbers are
confusing in the sense that there are a series of miscellaneous condensate
discharges in the Clairton draft NPDCS draft permit which are numbered
021 through 044 and which have received prior approval by the EPA. The
EPA approved condensate discharges 022 and 023 are different than the
Steel-designated outfalls 022 and 023 at the pump station. Morrison
reported that the 022 line is strainer backwash off the pumps, and 023
is essentially cooling water off an air compressor. These discharges to
the Monongahela River are thought to flow only intermittently. The
recommendation is made that NEIC sample these two discharges only for
one or two days; flow determinations are judged unnecessary.
VII. WASTE SEWER 009
This sewer and its discharge is reported no longer in use. It was
deployed in the last couple of years as a temporary measure while the
004 industrial waste sewer was undergoing relining and repair. This
sewer can conceivably be used - but only under emergency conditions.
The 009 sewer potentially can drain a rather expansive sector of the
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Clairton grounds including the coke ovens. The outfall is said to be
submerged intersecting the Monongahela River immediately north of the
Keystone cooling tower water treatment clarifier and Coke Works water
intake pump station. The upcoming NEIC survey should conclusively
verify the absence of flow in this sewer which was not done during the
August 1975 reconnaissance.
VIII. 018 OUTFALL FROM NO. 2 POWER HOUSE AT COKE WORKS
The Draft NPDES permit reports the 018 outfall as discharging about
0.5 mgd of condensates and blowdowns from the No. 2 power station to the
Monongahela River. USSC personnel indicated this outfall could additionally
contain some oil bearing cooling waters from pumps, etc. The 018 flow
emanates at the River wall from the base and approximate center of the
power house. Coal barges were lined up along the wall on the river side
making access from that side most difficult. The Company samples the
018 flow by drop bucket and this is likely our only means of sampling
the pov/er house effluent. The 018 water system is under pressure
probably negating use of the dye dispersion technique for flow measurement.
IX. OUTFALL 015 FROM COKE WORKS BOILER HOUSE NO. 1 AND OUTFALL 115
FROM BOILER HOUSE NO. 2 (EAST SIDE OF COKE WORKS)
Both outfalls 015 and 115 discharge to the Monongahela River and
may be submerged part of the year although they were not during our
reconnaissance. Both outfalls emanate from the River Wall which also
forms the side of the Boiler House building. Outfall 015 is the upstream
discharge located at the southeast corner of the building (immediately
downstream of Peters Creek) whereas 115 is about 1/3 from the northeast
corner of the building. Both discharges are a considerable vertical
distance down from the main level at the top of the River Wall and must
be sampled by drop bucket.
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.The Boiler House discharge comprises spent cooling waters and
condensates, cooling v/aters from a hydraulic system compressor, some air
conditioning waters, and boiler blowdowns. Blowdowns, principally from
the No. 2 Boiler House are carried over for use in the Flash Evaporator
House. This blowdown could be as high as 20%.
We were told the 015 outfall may receive storm drainage from
certain areas adjacent to the boiler house. Both the 015 and 115 water
drainage systems are reported under pressure, likely negating possible
use of the dye dispersion technique for determination of flow. The 015
discharge was observed as significantly churning up the river bottom at
the point of release. Flow may be appreciably higher than the 1.04 mgd
given in the draft permit.
X. FLASH EVAPORATOR BUILDING AND OUTFALL 013
The Flash Evaporator building is located between the main Coke
Works Boiler House (East Side) and the Water Recirculating BTX Pump
House. Outfall 013 discharges directly to the Monongahela River and is
reported to consist mainly of blowdowns from the flash evaporator and
accompanying cooling tower. We understand the flash evaporator system
serves to supply feed water to waste heat boilers in the Keystone
complex. The other boiler water treatment system is located across the
road and southeast of the flash evaporator building and consists of the
hot soda ash-lime process, filtering and zeolite softening. The latter
water treatment plant provides boiler supply for the main Coke Works
boilers and the Benzene Boiler House. The hot soda ash process situated
on the 005 waste line and the BTX area will be described later.
The Flash Evaporator is thought to provide makeup for the adjacent
cooling tower. The 013 Outfall is said to contain recycle blowdown from
the flash evaporators for the Keystone complex together with cooling
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tower blowdown. A 14-inch line originates from the northeast side of
the building and discharges to the Monongahela River as 013. USSC
records product flow; measurement is reported via an orifice plate,
calibrated periodically. This waste line is actually sampled inside the
evaporator building on the west side. Five sampling spigots are available
on a manifold. These five lines include boiler blowdown, recycle brine,
distillate, primary cooler and cooling tower water lines. Samples for
013 are taken from the first of these.
XI. THE 014, 114 AND 016 OUTFALLS FROM BTX (BENZENE-TOLUENE-XYLENE]_
RECIRCULATING COOLING PUMP HOUSE AND ADJACENT BTX COOLING TO'./R
The above three outfalls all discharge to the Monongahela River in
the area of the BTX cooling water recirculating pump house and accompanying
cooling tower. The BTX process area is located across the road generally
west of the subject facilities. The BTX processing covers considerable
area in the Clairton plant. The current sampling points of 014 and 114
presently used by the Company for monitoring, if added together, would
be equivalent to the older 014 sampling location described by the draft
NPDES permit. Physical layout of these points is depicted below.
Coolinh Tow
W/atcr Recirrf.
B>mp House
f^ricK JBIdy.)
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The 114 waste stream is carried in a pipe and sampled by USSC at
the end of the pipe. The 114 outfall cascades over the hill in an open
section. The Company samples both lines separately. The 114 flow is
relatively small (est. <0.10 mgd) but unmeasured by USSC. Besides
miscellaneous condensates, USSC indicates that the 114 drain may capture
storm waters from at least part of the BTX area. This was not mentioned
in the NPDES permit application nor the ensuing draft permit. Blowdowns
from the BTX cooling tower would appear to enter 114 although they are
reported going to 014.
The 014 line is sampled by USSC inside and at the northwest corner
of the water recirculating pump building on the main or upper floor of
the building. The point represents a takeoff from the cooling tov/er hot
well inside the building. Cooling tower blowdown is said to find its
way to the 014 waste line. USSC meters the makeup to the cooling tower.
It is tentatively recommended that NEIC in their upcoming survey sample
and gage the combined 014-114 effluent below their joining and just
before the river. Hov/ever safety in sampling must be carefully evaluated
for this point particularly for nighlime work. An alternative is to
come into this point via boat.
The 016 waste stream originates from the other side, i.e. the south
side of the recirculating cooling water pump house. Tnis stream is
described in the draft permit as comprising cooling tower sump drain
water plus strainer backwash. These sources were verified during the
reconnaissance. The actual sampling point used by the Company is located
inside, i.e. at the southeast corner and the lower level or bottom floor
of the recirculating pump house (adjacent to the strainer). The 016
stream seems to be mostly basket strainer backwash discharge. The
screened water is used for BTX cooling tower makeup. A flow estimate
may suffice for this secondary discharge.
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XII. BENZENE PROCESSING
AND OUTFALL 005
Outfall 005 serves the benzene or BTX process area situated on the
north side of Peters Creek. Within this complex is also located the hot
soda ash and lime water treatment works supplying feed water to the
majority of boilers within the Coke Works at Clairton. Besides cooling
waters, approximately 0.3 mgd continuous overflow from an ash settling
basin enters the 005 sewer. Ashes from stoker-fired boilers (east side
boiler house) are transformed in a slurry to ash bins then decanted to
the ash settling basin. The plant did not seem to be pumping ash-
carrying waters at the time of our observations. The 005 sewer also
captures sludge blowdowns off the hot process -water treatment chemical
mix and/or settling tanks, blowdowns off the Benzene Boiler House,
primary cooler operations (2nd Unit) excess water (to be taken out in
future), blowdowns from a small cooling tower together with evaporator,
excess cooling waters or blowdowns from a large BTX cooling tower, and
possibly some yard storm runoff. Outfall 005 is a reasonably-sized flow
described in the draft permit around 5.0 mgd.
Flow into the 005 manhole is judged quite warm. The 005 Company
sampling manhole is about 500 ft from Peters Creek which is the receiving
stream. This manhole is sandwiched inbetween the Feed Water Pump House
and the Benzene Boiler House and just south of the No. 3 Still Building.
The 005 manhole is completely enclosed and equipped with a pump to
obtain Company samples. There was a question whether this pump was
operable. This point is available for sampling by NEIC but the subject
of representative sampling prevails once again.
In the water treatment area, electrostatic precipitators are
available believed installed on the ash collection and storage tanks
directly west, of the Flash Evaporator Building. We observed fine ash
being off-loaded into a truck from one of the ash tanks. Unfortunately
the ultra-fine dust was dispersing in all directions much of it not
being captured into the truck.
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XIII. ADDITIONAL DATA ON COKE OVEN OPERATIONS
Clairton has 1,375 coke ovens contained in 20 batteries. The
batteries are supported by 8 quench towers and 0 coke wharfs. There are
two coke screening stations. One of these is equipped with three wet
Scrubbers and the second has a single wet scrubber (on one of 4 available
lines). Liquid scrubber effluents are sent to quenching or arc diverted
to the contaminated water sewer. Coke underdra/inage off the screening
stations is either reused internally at Clairton or shipped to sinter
plant(s) at other USSC locations. Clairton has been testing an experimental
coke shed device (with venturi scrubber) on Battery 17. In the quenching
of coke, USSC reports using about 160 gal water per ton coke quenchc
This compares to 350 gallons per ton coke cited in previous EPA Effluent
Guidelines. Morrison stated that more water can be evaporated in quenching
than they now use. They dilute flushing liquor with "good" water in
order to keep down the chloride content. Excess runoff from quench
towers is collected into a sump below each tower and either recycled for
additional quenching or pumped to the contaminated water system. Morrison
stated there is absolutely no extraneous wastewater from the coke batteries
and directly-associated operations. Coke wharf drainage if accumulating,
is collected into trenches and flows to the coke quench stations.
Plant personnel still visualize the 1 mg contaminated water mix
tank as being a central distribution point for supplying quench water to
the towers, putting out fires in the ovens, etc. It was indicated
whenever there may be trouble in the biological system that contaminated
waters will be returned to the contaminated water mix tank and/or to the
quench water system. Bypass capabilities back to the quench water
system probably will be maintained even after full connection is made to
biological treatment.
Large coke storage piles are maintained by USSC on the Peters Creek
watershed upstream of State Street and Outfall 008 all the way up to the
Ravensburg Bridge and even beyond. Granulated slag, ash, clinkers,
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stone and other discards are interdispersed among the coke piles in this
same area. Many small trickles representing subsoil or overland drainage
from this area were observed flowing into the lower stretch of Peters
Creek from USSC property.
XIV. SMALL WASTE SEWERS INTO PETERS CREEK - 006, 007, 010, Oil, 012
AND 019 OUTFALLS
We have previously described each of these six outfalls in general
terms. The draft NPDES permit describes the six discharges as totalling
a maximum of 5.1 mgd, mostly cooling waters from a number of sources.
The 005 manhole is reported as situated directly over Peters Creek.
Discharge comprises spent cooling waters from tar pitch coolers, cooling
water off tar still(s), and possible barometric condenser waters. A
number of spent streams enter directly into the 006 vertical manhole.
It will be near impossible to directly measure the 006 flow volume and
also very difficult to obtain representative samples at this location.
The 007 manhole also located more or less directly over Peters
Creek principally consists of cooler condenser waters on the overheads
from tar refining stills. Other cooling waters may also be present. At
least three streams are known to enter directly into the 007 vertical
manhole at various elevations. We see no possible way to accurately
determine flow into 007. Furthermore, from indications given us, we see
no way either the Company or ourselves can obtain any kind of representative
sampling at this particular location.
The 010 sewer mainly carries cooling waters from the tar and naphthalene
process plants into Peters Creek. The 010 manhole is above Peters Creek
immediately west of Coke Battery No. 22. During our visit, various sub-
flows to the 010 sewer were reported by USSC as including cooling waters
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from tar acid distillation, naphthalene cooling tower blowdowns, and
considerable condensates from tank heating and storage and process
tanks. It was also reported that strainer backwash off an industrial
cooling water line finds its way to the 010 sewer but we do not know
where this is located. Condensate sump drainage and other strong waste
waters off carbolic acid processing are said to be diverted from this
general plant sector over and into the contaminated water collection
system. This sewer manhole hopefully can be adequately sampled and flow
rated.
The two Prill Pitch process waste streams Oil and 012 are reported
by the Company to be nearly similar in waste flow and characteristics.
USSC samples 012 inside the Prill Pitch Bldg. No. 2 at the overflow end
of a small receiver box in an open section. This stream represents
cooling water in direct contact with the pitch prill. The contact
cooling waters are said to be partly recycled and partly bled off. The
No. 1 Pitch Prill building effluent is sampled at a box manhole directly
outside on the west side of the process building. It is recommended
that NEIC sample only 012 since it is relatively accessible and since
the two discharges are thought similar. Both flows appear to be extremely
warm. One or two samples could be taken of 011 and waste concentration
compared with 012.
Outfall 019 represents a potential emergency overflow, if and when
occurring, from a sanitary sewage pump station to Peters Creek. It is
not known if past discharge has occurred at 019. USSC, however, reports
they have never collected samples at this point. There are four main
sanitary pump stations serving the Clairton Works. These are in the
Marine Ways sector; the 019 pump station serving the benzene-tar-boiler
feedwater-coke sectors; the Maple Avenue sector, and the Steel Works
sector. The 019 pump station is the largest of the four. Previous
information supplied to the EPA had described this station as containing
only one pump and hence the need for a permitted discharge. Upon inspecting
the pump station we found two pumps with one reported as capable of
handling the entire sanitary flow together with dual power supply.
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XV. OUTFALL 008 - STATE STREET STORM STWER, CITY OF CLAIRTON,_POWER
HOUSE NO. 1 DISCHARGES, CLAIRTON STP, AND PETERS CREEK ABOVE AND
BELOW USSC PROPERTY
The State Street storm sewer drains the west side of the Clairton
Works and discharges into Peters Creek just below the city of Clairton
STP and immediately above the point where the Creek goes underground
through USSC property. Steel claims that only Power House No. 1 effluent
is released to the State Street sewer and accordingly the Company samples
internally within the plant on a sev/er line reportedly joining the storm
sewer southwest of Battery No. 19. EPA, Region III because of phenolics
found in the State St. storm sev/er from unknown sources, has recommended
in the permit that the Company sample at two locations, i.e. the very
end of the State Street storm sewer, and the storm sewer above the point
where the Power House No. 1 effluent enters this municipal sewer.
Apparently the State or others have conducted previous sampling upstream
on the storm system. The Company is presently sampling its internal
sewer southwest of Coke Battery No. 19 approximately 300 ft from State
Street and calling this point 008. The Company sampling access to its
manhole on 008 is only 4 inches in diameter. The flow inside was judged
very hot. There was some indication that dye had been previously dumped
at this manhole.
We located another manhole on the internal plant drain line but
farther downstream and only about 30 ft from State Street. This latter
point is recommended for one of the NEIC sampling points. We more or
less walked upstream on the internal sewer up to the Power Plant and
observed two barometric condensers on the west side of the Power Station
-reported to be connected to the top end of the sewer. Other spent flows
were said to include effluents from a pair of turbine generators and
cooling waters from an air compressor. Power Plant No. 1 pulls steam
from about 150-180 psi down to vacuum utilizing a barometric for condensing
steam. The other barometric is connected to a topping turbine. Additional
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information indicates the Clairton power plants are equipped with both
mechanical dust collectors and electrostatic precipitators; however, no
specific data was obtained.
On State Street in the city of Clairton we noted that both Hercules,
Inc. and Pico Chemicals (reported to be a subsidiary of Hercules)
maintain relatively small but complex processing/manufacturing operations.
These two companies may (or may not) be connected to the city storm
sewer; they are located upstream of USSC's power plant No. 1 discharge.
Sanitary and storm sewer lines run more or less parallel down the center
of State Street heading north. John Mitchell, Superintendent at the
Clairton STP indicated Pico and Hercules could possibly have extraneous
discharges to the storm sewer. He also thought that USSC could have a
series of discharges into the storm sewer. On Peters Creek immediately
upstream of the State Street storm sewer and also on the south side of
the Creek, we found a diversion structure with flap gate believed to be
a sanitary bypass off State Street. A short distance further upstream
but from the north side, the Clairton STP effluent also enters into
Peters Creek. .Closed J Sev/er ficyond,
A t H
dRirton StP
Ef-ftoani
£
te
£
^¦Sgni^rV F£>nriUa Diversion
_ Hillside Dr.?iVia«ja
ussc
Storage
Piles
We were unable to make contact with either Mr. Margard, City Engineer
or Mr. Pastor, Asst. City Engineer for Clairton, but Mitchell promised
to send us copies of maps of the storm sewers in the subject area by
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mail as soon as possible. The Clairton STP is a primary treatment works
with preaeration. Flow averages 1.7 mgd and plant capacity is 3.4 mgd.
They will be picking up 6 municipalities in the future and total sewage
flow is expected to increase to 9.0 mgd with provisions for a secondary
treatment works. Suggested NEIC sampling for the upcoming survey
covering 008, State Street and Peters Creek includes as follows:
1. State Street storm sewer immediately upstream of the USSC
sewer; the latter contains No. 1 power plant effluent.
2. USSC effluent at manhole approximately 40 ft from State St.
sewer
3. State Street storm sewer at point where it empties into Creek
4. Peters Creek at Ravensburg Bridge or possibly downstream, but
still above influence of USSC coke and slag piles and above
Clairton STP effluent
5. Clairton STP effluent.
6. Peters Creek at the mouth sampled from Monongahela River side
assuming there is no surcharge from the Monongahela River back
up into the underground sewer. Vie will attempt a mass balance
by means of the stipulated sampling on Peters Creek and waste
flows into it. Flow gaging and sampling at the lowermost end
of Peters Creek will be challenging. Velocity during the
reconnaissance was estimated around 6-9 fps. A double oil
boom was anchored in place at the mouth of the Creek. The
float and skirt on the boom were roughly estimated as 8 inches
and 15 inches respectively. Because of fast flows, the skirt
was almost horizontal a good part of the time. The flows
appeared surging back and forth. Appreciable oil was seen at
the mouth of the Creek and down and inbetween coal barges
moored on the upstream side of Peters Creek on the Monongahela
River. The oil boom was largely ineffective in holding back
oils and no collection provisions were evident.
XVI. PHYSICAL TREATMENT AND ACTIVATED SLUDGE TREATMENT SYSTEM FOR HIGH
NITROGEN AND PHENOLICS WASTES PREVIOUSLY USED AS COKE QUENCH
WATER: 020 SEWER ~
The activated sludge treatment works has been recently started up
at Clairton for handling ammonia and phenolics-laden wastewaters. These
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wastes consisting mainly of excess flushing liquors were previously
disposed of in coke quenching. During our visit the activated sludge
basins were in operation with 9 or 12 turbine aerators functioning
but the secondary settlers had not yet received any wastes. Con-
taminated wastes are collected into a mix-equalization tank just
north of the Claus process, then pass through a series of Tar Separation
Tanks (5 tanks at 100,000 gallons each), to a 3 mg feed tank just east
of the activated sludge basins, through free and fixed stills for removal
of ammonia, through another 3 mg equalization tank, the aeration basins
(in parallel) followed by 80 ft diameter secondary clarifiers in parallel,
then discharged. The final settlers are equipped with skimmers. Cooling
may or may not be available before feeding the activated sludge tanks.
Acid and/or antifoam may be present in an insulated tank next to the
final settlers. Upon walking over the top of the basins, wastewater
temperature at the head end of the activated sludge tanks was perceived
to be extremely warm. We were told that the ammonia stills will be
starting up around the first of September. Following the stills, flotation
cells are said to be present for handling lime sludges particularly
emanating from the fixed still. The sludge material is taken to a
thickener and solids sent to vacuum filters. Secondary sludges are also
destined to be forwarded to the vacuum filters. Ammonia off the stills
is scrubbed by the Phosam stripper and absorber sub-system.
USSC indicated they can achieve relatively low NH^N via the ammonia
stills but upon passing through the activated sludge aeration basins due
to thiocyanate breakdown, ammonia rises again to very high levels. This
treatment system was almost entirely designed and built by U.S. Steel
without outside consultation. A superstill is available somewhere
close to this circuit and we received two versions on role of the superstill.
The superstill is intended to recover ammonia from recirculating waters
and eventually from the streams leaving the free and fixed stills or, its
purpose is to control corrosion in the process waste lines. Secondary
settler effluent from the treatment works may (also) in the future
receive final polishing via sand filtration.
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Besides flushing liquors, the contaminated waste stream is thought
to contain spent process waters from the benzene refining plant, the tar
refining plant, spent streams from gas processing in turn consisting of
direct and primary cooling heat exchange waters and blowdowns (which
today are still going to the 004 sewer), tailwater off the Phosam
process, and various barometric condenser waters. Final cooler spent
flows consisting of contact cooler effluent, blowdown from recirculating
systems, and possibly some product water are thought to be routed to the
treatment works. Fractionater blowdown from the Phosam Process is
reported to be sent to the contaminated water collection system together
with undefined waters from tail gas operations on the Scot Unit and
other .streams from the Claus process. A number of these streams probably
have not yet been converted over from the 004 sewer into the treatment
works. Trench and contaminated yard waters from the coke battery sectors,
BTX and No. 3 Still areas are said by USSC to be picked up and either
sent to the quench water service tanks or to the contaminated water
treatment works. Flow into treatment approximates 1.5 mgd and with
added dilution water to the aeration basins will run about 2.5 to 3.0
mgd. Final effluent from this biological/ physical treatment system is
discharged to the 020 sewer. The Company intends to monitor close to
the final clarifiers on the west side. This point is a considerable
distance from Peters Creek, the receiving stream. The 020 sewer should
be sampled close to Peters Creek to check with the Company's upstream
sampling point and determine how much if any yard drainage could be
entering the 020 drain line from nearby coke batteries and other possible
sources. It is recommended NEIC in their upcoming survey sample 020 at
the downstream manhole 50-100 ft from Peters Creek. (Effluent characterization
data if available from the Company would be from the downstream manhole
but limited.) We note that the 004 sewer line passes almost directly
under the activated sludge treatment plant on its way to Peters Creek.
Inadvertently or otherwise, we did not have the opportunity to
inspect the building reportedly containing the free and fixed ammonia
stills, coolers, chemical feeders, etc. Further data on design and
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operational criteria/results are imperative from USSC on this treatment
works. We were told part of this data can only be obtained via a secrecy
agreement and is found only in Harrisburg. The Chemical Division is
responsible for maintenance and operation of the treatment plant. USSC
personnel indicated they had no idea of MLVSS in the aeration basins.
There was no specific knowledge whether flow instrumentation existed at
the treatment works-influent or effluent although USSC personnel had the
feeling there may be flow metering somewhere on the influent. Pilot
data is available in Harrisburg. On costs of the treatment system, we
were told this would necessarily have to be obtained in a 308 letter.
It is recommended that NEIC on its upcoming survey, sample both 020
locations and additionally the influent(s) to the treatment works.
XVII. THE 004 MAIN INDUSTRIAL SEWER AT CLAIRTON
The 004 waste drain extends through an extensive portion of the
Clairton Coke Works over three-quarters mile or longer as far south as
Coke Battery No. 1. It also serves the Keystone complex including
primary and final coolers on Unit 1, the main gas regenerators, tar
extractors and exhausters, both Claus plants and sulfur recovery, the
tar storage area, two areas of flushing liquor decanters, primary and
final coolers on Unit 2, compressor buildings. It passes under or near
the biological/physical waste treatment plant and finally terminates in
Peters Creek near Coke Battery No. 18. This drainage system termed by
the Clairton Works as the "Main Industrial Sewer," is described in the
draft NPDES permit as conveying 71 mgd of spent waters, and intercepts
Peters Creek very close to its mouth at R.M. 0.02. Previous descriptive
materials on sewer 004 categorize this flow as miscellaneous cooling
water. From the EPA reconnaissance of August 26-28, 1975, the following
list of known, reported, or inferred waste sources was prepared.
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Keystone Complex "large" cooling tower blowdowns. Blowdowns
from other undesignated cooling towers within the Keystone
complex.
"Ammonia recovery" barometric condensers. Two barometrics are
believed present, one on the synthetic ammonia (SYN) loop and
a second in the ammonia production building.
Effluents from HCN plant and from vacuum carbonate desul-
furization process (old and new Claus plants).
Cooling waters from sulfur recovery. We note sulfur is
shipped out from Clairton both in molten and solid (cast)
form.
Condenser waters from barometric on Ho. 2 Final Coolers. It
is noted that significant process water is recycled from sump
collection to the final coolers.
Condenser waters from barometric in Phosam sector (close to
009 waste 1 me)
Undefined boiler blowdowns
Cooling waters from No. 1 Primary Cooler operations, and
likely also from [Jo. 2 Primary Cooler facilities. On our
reconnaissance we observed heavy oil layers cn the ground in
the vicinity of certain primary cooler units and in and
around certain flushing liquor decanter units. Some of this
could find its way into the 004 sewer.
Air box cooling waters
Large barometric condenser, one of which was seen in the area
of the Primary Coolers
Various unknown drainages.
The Company sampling point on the 004 sewer is located about 1,100
ft from Peters Creek just north of the primary coolers and about 200 ft
south of the final clarifiers at the new biological treatment works.
This is a pumped station on a completely enclosed manhole. This manhole
is thought to be an exorbitant distance from Peters Creek. The next
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downstream manhole is located immediately north of the aeration basin at
the waste treatment works. This manhole is situated about 350 ft from
Peters Creek and is the preferred point for NEIC sampling. Peering down
this manhole we could not see the flowing stream but could perceive a
rather distinct odor off the manhole. Dye insertion hopefully can be
made at the upstream manhole and measured at the lower manhole. A
further downstream manhole is doubtful but should be searched for. It
is tentatively suggested both manholes be sampled by NEIC depending upon
where and how the dye may be added.
XVIII. ROAD TAR TERMINAL/LOADING AREA AND OUTFALL 017
This is a relatively small flow representing yard drainage and
probably condensates from out-of-doors tar and coal storage sectors.
Tank heating and yard tracing flows may also be integrated into this
sewer system. The Company sampling point for 017 is at a grated manhole
at the base of the railroad car load facilities just east of the tar
storage tanks and north of the BTX water recirculating cooling tower.
This stream can also be sampled just below the crest of the River bank
as an 11-inch ID pipe which terminates in an open section. The stream
then cascades down the hillside to the Monongahela River. Personal
preference is for sampling and gaging at the open section rather than
the manhole. During our visit, waste flow was estimated at 10 gpm, or
perhaps slightly more. Flow may be determinable by the bucket and
stopwatch method. The outfall may be subject to occasional spills by
the nature of adjacent facilities. The effluent was noted as fairly
•clear but possessing a slight yellowish tinge.
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XIX. COAL STORAGE AREAS
The Clairton coal storage piles are located directly north of the
road tar terminal station i.e. Outfall 017, extending about one half
mile downriver to the Marine Ways area. Coal reserves appeared low
probably due to the coal miners' strike which had started around mid-
August, 1975. Due to press of time we did not closely inspect this
area. Two main storm sewers cross under this area, one just north of
the Glassport Bridge and the other about 1,000 ft further downstream.
Vie will attempt to obtain further technical data on these sewers from
both the city of Clairton and USSC. Although sampling of sewers in the
coal yards is not planned, if new data indicates the need, revisions
will be made in the NEIC study plan. USSC personnel stated there is no
discharge from within this sector except possibly for storm runoff. No
drains are reported directly in the coal storage yards. Manholes are
present on the city sewers traversing this sector of which there are at
least three (sewers) according to Morrison although the maps only show
two such systems. We also need to obtain additional data on other storm
sewers as promised by Morrison, e. g. The Maple Street storm sewer
discharging to the Monongahela River almost directly east of the Keystone
Plant Office. In this same (Maple Street outfalTi) area along the River
we noted two waste oil storage tanks. Morrison stated each tank holds
roughly 87,000 gallons of waste oil. This oil is added to the pulverized
coal to impart better properties to the coal before entering the coke
batteries.
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TCNiAiw siircunri or -icic sahi'Uni. iocamons rns
USSC. CLftlinON cut E WINKS fACILITY, CLAIRTON, PA
Station Ho
or Description
Primary
Secondary
ConmentS
30/54-Inch storm
sewers at river
X
Only one sewer flowing
SW Uatcr Intake
X
001
X
002 Upstream
X
On storm sewer at car
tipple
002 (at river)
003 (upstream, storm sewer)
X
-
(Chk 10? Just prior to survey
To be sampled only if
necessaiy
003 (at river)
X
-
CU tater Intake
X
-
022 (USSC designated)
X
1-2 sampling days only, no
flow determination necessary
023 (USSC designated)
X
1-2 sampling days only, no
flow determination necessary
009
X
To be sampled only if flowing
018
X
flow messurcnent unlikely
015
X
now estimate only
115
X
Flow estimate only
013
X
013/114
X
Attempt to ser.ple and gage
the combined 011/114 dischg.
016
X
1-2 days sampling, flow
estimate nay suffice
005
X
To te sanplcd ? JSSC manhole
CCI'j. Major di sadvantage is
rcl long distance from
Peters treeV:
006
X
Rcec -lendation against smplg.
007
X
¦ ¦ •
010
X
Oil
X
1-2 days S2npling only. No
flow mcas. necessary
012
X
019
X
Recmrscndation against smplg
Mate St Storn
Sewer (Upstream of
USSC Power Plant
No. 1 Discharge)
X
State St Storm
Sewer at Peters Creek
X
OOS
X
Appro*. 40 ft from Stale St.
Peters Creek (upstream)
X
Near Rarcnsburg Br.
Peters Creel- at mouth
X
020 (downstream)
020 (USSC designated
monitoring point)
X
X
Appro*. 105 ft from Peters
Cr.
Appro». 350 ft from Peters
Cr.
Influent to Ireatucnt
Plant on 020
X
004 (downs trcani)
OM (USSC d- sl'inatcd
tionllorlmi/
sampling pt)
X
X
Approi. 350 ft from Peters
Cr.
Approj. 1.100 ft from Peters
Cr.
OU
x or
X
Preforwtt i-, for Ivation
Ju'.t l<-lu cri».t of Mil
113 of 138
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APPENDIX B
Study Methods
122 of 138
-------
STUDY METHODS
SAMPLING AND COMPOSITING TECHNIQUES
Information was obtained through interviews with plant officials on
water pollution control practices and in-plant surveys.
Influent water samples from the Monongahela River, collected from
the two pumphouses, were time-composited (i.e., equal portions from each
grab sample). Samples from outfall 003, 004, 020, influent to bioplant
and effluent from bioplant, were flow-composited according to instantaneous
flow readings obtained at the point of collection. Aliquots for the
composites were collected manually every three hours. Grab samples were
collected daily from all other discharges.
Samples for chemical analyses were collected in clean containers.
Each time a sample was collected field measurements of pH, temperature
and conductivity were made. Samples were delivered to the NEIC mobile
laboratory (McKeesport, Pennsylvania) and analyzed for selected parameters
(e.g., oil/grease and total suspended solids). Appropriate preserved
aliquots were shipped to the NEIC laboratory (Denver, Colorado) and
analyzed for total and amenable cyanide, heavy metals, ammonia, phenolic
materials and organics. All samples collected were split with USSC.
FLOW MEASUREMENT TECHNIQUES
Flow monitoring of discharges is specified in the NPDES permit
proposed by Region III, EPA. Flow measurements of selected discharge
points by NEIC personnel commenced January 28, 1976.
123 of 138
-------
Flow determinations were made using dye dilution with fluorometric
detection technique. In this procedure, a dye of known concentration is
injected at constant rate upstream of the sample site, an adequate
distance to insure mixing. Samples are collected and the dye concen-
tration is determined by a fluorometer. Knowing the dye injection rate,
initial dye concentration and concentration after the dye has mixed with
the wastewater flow, the flow can be calculated.
The G. K. Turner Model III fluorometer was used. Calibration of
the fluorometer was accomplished daily using dye standards prepared in
the NEIC laboratory. Rhodamine WT dye produced exclusively by duPont
DeNemours, E. I. and Company, was selected as the tracer because of its
low sorptive tendency and high stability to varying pH conditions.
Background investigations of all stations were conducted to determine
if any substances in the waste stream would fluoresce in the range that
could induce errors in flow determinations. Background samples were
taken each time samples for flow determination were collected. The
fluorescence measured on background samples was subtracted from the
fluorescence measured on the flow samples.
Special precautions taken to insure against interference in flow
measurements consisted of: 1) cuvettes triple-rinsed with distilled
water between each sample; 2) cuvettes cleaned daily with solvent;
3) cuvettes filled with distilled water and fluorescence measured
twice daily to insure against contamination from operator handling;
4) fluorometer checked for "0" reference between each reading and after
use, using "0" reference blank; 5) all readings were taken on upward
movement of indicator to eliminate any error due to gear "slop;" and
6) rubber gloves were worn when handling raw dye to avoid contamination
during fluorometer operation.
124 of 138
-------
Company-installed meters were used to obtain intake flows and
bioplant influent and effluent flows. USSC personnel calibrate these
flow meters every six months. The last calibration was reported to have
been completed in September 1975.
125 of 138
-------
APPENDIX C
Analytical Procedures and Quality Control
126 of 138
-------
ANALYTICAL PROCEDURES AND QUALITY CONTROL
Samples collected during this survey were analyzed, where appropriate,
according to procedures approved by EPA for the monitoring of industrial
effluents.* The analytical procedures for characterizing trace organic
chemical pollutants are described below. The remaining procedures are
listed in the following table.
Parameter
Cr
TSS
Cyanide
Phenol
Ammonia
Oil/grease
Hexavalent
chromium
Method
Atomic absorption
Gravimetric
Distillation,
colorimetric
Automated
colorimetric
Reference
EPA Methods for Chemical
Analyses of Water and
Wastewater, 1971, p 83
ibid., p 278
ibid., p 41
EPA Methods for Chemical
Analyses of Water and
Wastes, 1974, p 243
Automated phenate ibid., p 168
Freon extractable
material
Colorimetric
Standard Methods, 13th
Ed., p 254
ibid., p 429
Samples for organic chemical pollutant analysis were collected in
clean, solvent-rinsed one-gallon glass containers. These samples were
air-freighted to Denver and extracted with methylene chloride. The
extract was dried with anhydrous sodium sulfate, concentrated, exchanged
* Federal Register} Vol. 4QS No. 111> June 9, 1975
127 of 138
-------
into acetone and analyzed by hydrogen flame ionization gas chromatography.
Those samples that showed adequate response were set aside for character-
ization by combined gas chromatography-mass spectrometry (GC/MS). The
GC/MS analyses were carried out with a Finnigan Model 1015 Quadropole
Mass Spectrometer and a Systems Industries Model 150 computerized data
system. Mass spectra were compared to data files in the NIH Computer
System and also to listing in the Eight Peak Index of Mass Spectra,
Second Edition, 1974, compiled by the Mass Spectrometry Data Center.
All identifications are considered preliminary until authentic standards
of the suspected chemical compounds can be obtained and analyzed under
similar conditions to match the mass spectrum and gas chromatographic
retention time. This procedure does not detect highly volatile organic
chemical pollutants since their presence is masked by the extraction
solvent.
Reliability of the analytical results was documented through an
active Analytical Quality Control Program. As part of this program,
replicate analyses were normally performed with every tenth sample to
ascertain the reproducibility of the results. In addition, where appropriate,
every tenth sample was spiked with a known amount of the constituents to
be measured and reanalyzed to determine the percent recovery. These
results were evaluated in regard to past AQC data on the precision,
accuracy and detection limits of each test. On the basis of these
findings, all analytical results reported for the survey were found to
be acceptable with respect to the precision and accuracy control of this
laboratory.
128 of 138
-------
APPENDIX D
Chain of Custody Procedures
129 of 138
-------
ENVIRONMENTAL PROTECTION AGENCY
Office Of Enforcement
NATIONAL ENFORCEAAENT INVESTIGATIONS CENTER
Building 53, Bo* 25227, Denver Federal Center
Denver, Colorado 80225
July 24, 1974
CHAIN OF CUSTODY PROCEDURES
General:
The evidence gathering portion of a survey should be characterized by the
minimum number of samples required to give a fair representation of the
effluent or water body from which taken. To the extent possible, the quan-
tity of samples and sample locations will be determined prior to the survey.
Chain of Custody procedures must be followed to maintain the documentation
necessary to trace sample possession from the time taken until the evidence
is introduced into court. A sample is in your "custody" if:
1. It is in your actual physical possession, or
2. It is in your view, after being in your physical possession, or
3. It was in your physical possession and then you locked it up in
a manner so that no one could tamper with it.
All survey participants will receive a copy of the survey study plan and will
be knowledgeable of its contents prior to the survey. A pre-survey briefing
will be held to re-appraise all participants of the survey objectives, sample
locations and Chain of Custody procedures. After all Chain of Custody samples
are collected, a de-briefing will be held in the field to determine adherence
to Chain of Custody procedures and whether additional evidence type samples
are required.
Sample Collection:
1. To the maximum extent achievable, as few people as possible should
handle the sample.
2. Stream and effluent samples shall be obtained, using standard field
sampling techniques.
3. Sample tags (Exhibit I) shall be securely attached to the sample
container at the time the complete sample is collected and shall
contain, at a minimum, the following information: station number,
Station location, date taken, time taken, type of sample, sequence
number (first sample of the day - sequence No. 1, second sample -
sequence No. 2, etc.), analyses required and samplers. The tags
must be legibly filled out in ballpoint (waterproof ink).
130 of 138
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Chain of Custody Procedures (Continued)
Sample Collection (Continued)
4. Blank samples shall also be taken with preservatives which will
be analyzed by the laboratory to exclude the possibility of
container or preservative contamination.
5. A pre-printed, bound Field Data Record logbook shall be main-
tained to record field measurements and other pertinent infor-
mation necessary to refresh the sampler's memory in the event
he later takes the stand to testify regarding his action's
during the evidence gathering activity. A separate set of field
notebooks shall be maintained for each survey and stored in a
safe place where they could be protected and accounted for at
all times. Standard formats (Exhibits II and III) have been
established to minimize field entries and include the date, time,
survey, type of samples taken, volume of each sample, type of
analysis, sample numbers, preservatives, sample location and
field measurements such as temperature, conductivity, DO, pH,
flow and any other pertinent information or observations. The
entries shall be signed by the field sampler. The preparation
and conservation of the field logbooks during the survey will
be the responsibility of the survey coordinator. Once the
survey is complete, field logs will be retained by the survey
coordinator, or his designated representative, as a part of the
permanent record.
6.. The field sampler is responsible for the care and custody of the
samples collected until properly dispatched to the receiving lab-
oratory or turned over to an assigned custodian. He must assure
that each container is in his physical possession or in his view
at all times, or locked in such a place and manner that no one can
tamper with it.
7. Colored slides or photographs should be taken which would visually
show the outfall sample location and any water pollution to sub-
stantiate any conclusions of the investigation. Written documenta-
tion on the back of the photo should include the signature of the
photographer, time, date and site location. Photographs of this
nature, which may be used as evidence, shall also be handled
recognizing Chain of Custody procedures to prevent alteration.
Transfer of Custody and Shipment:
1. Samples will be accompanied by a Chain of Custody Record which
includes the name of the survey, samplers signatures, station
number, station location, date, time, type of sample, sequence
number, number of containers and analyses required (Fig. IV).
When turning over the possession of samples, the transferor and
transferee will sign, date and time the sheet. This record sheet
131 of 138
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Chain of Custody Procedures (Continued)
allows transfer of custody of a group of samples in the field,
to the mobile laboratory or when samples are dispatched to the
NFIC - Denver laboratory. When transferring a portion of the
samples identified on the sheet to the field mobile laboratory,
the individual samples must be noted in the column with the
signature of the person relinquishing the samples. The field
laboratory person receiving the samples will acknowledge receipt
by signing in the appropriate column.
2. The field custodian or field sampler, if a custodian has not
been assigned, will have the responsibility of properly pack-
aging and dispatching samples to the proper laboratory for
analysis. The "Dispatch" portion of the Chain of Custody Record
shall be properly filled out, dated, and signed.
3. Samples will be properly packed in shipment containers such as
ice chests, to avoid breakage. The shipping containers will be
padlocked for shipment to the receiving laboratory.
4. All packages will be accompanied by the Chain of Custody Record
showing identification of the contents. The original will accom-
pany the shipment, and a copy will be retained by the survey
coordinator.
5. If sent by mail, register the package with return receipt request-
ed. If sent by common carrier, a Government Bill of Lading should
be obtained. Receipts from post offices and bills of lading will
be retained as part of the permanent Chain of Custody documentation
6. If samples are delivered to the laboratory when appropriate person-
nel are not there to receive them, the samples must be locked in
a designated area within the laboratory in a manner so that no
one can tamper with them. The same person must then return to the
laboratory and unlock the samples and deliver custody to the
appropriate custodian.
laboratory Custody Procedures:
1. The laboratory shall designate a "sample custodian." An alternate
will be designated in his absence. In addition, the laboratory
shall set aside a "sample storage security area." This should be
a clean, dry, isolated room which can be securely locked from the
outside.
2. All samples should be handled by the minimum possible number of
persons.
3. All incoming samples shall be received only by the custodian, who
will indicate receipt by signing the Chain of Custody Record Sheet
132 of 138
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Chain of Custody Procedures (Continued)
accompanying the samples and retaining the sheet as permanent
records. Couriers picking up samples at the airport, post
office, etc. shall sign jointly with the laboratory custodian.
4. Immediately upon receipt, the custodian will place the sample
in the sample room, which will be locked at all times except
when samples are removed or replaced by the custodian. To the
maximum extent possible, only the custodian should be permitted
in the sample room.
5. The custodian shall ensure that heat-sensitive or light-sensitive
samples, or other sample materials having unusual physical
characteristics, or requiring special handling, are properly
stored and maintained.
6. Only the custodian will distribute samples to personnel who are
to perform tests.
7. The analyst will record in his laboratory notebook or analytical
worksheet, identifying information describing the sample, the
procedures performed and the results of the testing. The notes
shall be dated and indicate who performed the tests. The notes
shall be retained as a permanent record in the laboratory and
should note any abnormalities which occurred during the testing
procedure. In the event that the person who performed the tests
is not available as a witness at time of trial, the government
may be able to introduce the notes in evidence under the Federal
Business Records Act.
8. Standard methods of laboratory analyses shall be used as described
in the "Guidelines Establishing Test Procedures for Analysis of
Pollutants," 38 F.R. 28758, October 16, 1973. If laboratory
personnel deviate from standard procedures, they should be prepared
to justify their decision during cross-examination.
9. Laboratory personnel are responsible for the care and custody of
the sample once it is handed over to them and should be prepared
to testify that the sample was in their possession and view or
secured in the laboratory at all times from the moment it was
received from the custodian until the tests were run.
10. Once the sample testing is completed, the unused portion of the
sample together with all identifying tags and laboratory records,
should be returned to the custodian. The returned tagged sample
will be retained in the sample room until it is required for trial.
Strip charts and other documentation af work will also be turned
over to the custodian.
133 of 138
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Chain of Custody Procedures (Continued)
11. Samples, tags and laboratory records of tests may be destroyed
only upon the order of the laboratory director, who will first
confer with the Chief, Enforcement Specialist Office, to make
certain that the information is no longer required or the samples
have deteriorated.
134 of 138
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EXHIBIT I
EPA, NATIONAL ENFORCEMENT INVESTIGATIONS CENTER
Station No.
Data
Tima
Sequence No.
Station Location
fomp
_BOD
_5o!idi
_COD
_»ufrienfJ
_Metali
_Oil and Grease
_DO.
.Bact.
_Otfior
X.
v
Samplers:
Remarks/Preservative:
Front
ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF ENFORCEMENT
NATIONAL ENFORCEMENT INVESTIGATIONS CENTER
BUILDING 53, BOX 25227, DENVER FEDERAL CENTER
DENVER, COLORADO 80225
Back
135 of 138
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EXHIBIT II
FOR SURVEY, PHASE , DATE
TYPE OF SAMPLE ANALYSES REQUIRED
STATION
NUMBER
STATION DESCRIPTION
TOTAL VOLUME
TYPE CONTAINER
PRESERVATIVE
NUTRIENTS |
BOD 1
COD
TOC I
| TOTAL SOLIDS
SUSPENDED SOLIDS
>
*—
z
<
<
o
o
•
X
a
I CONDUCTIVITY- J
•
UJ
cx;
!Z>
h—
<
LU
a
5
LU
1—
TOTAL COLIFORM |
FtCAl COLIFORM |
I TURBIDITY |
1 Oil AND GREASE I
METALS |
BACTI |
PESTICIDES |
c2
Ck'
I-U
X
TRACE ORGANICS 1
O
2
U_
X
Uj
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<
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U
¦
CJ
CTi
—h
REMARKS03
-------
L....BIT
Sampler*:
FIELD DATA RECORD
STATION
NUMBER
DATE
TIME
TEMPERATURE
"C
CONDUCTIVITY
/iinKos/cm
pH
S.U.
DO.
mg/1
Cage Ht.
or Flow
Ft orCFS
-------
EXHIBIT IV
ENVIRONMENTAL PROTECTION AGENCY
Office Of Enforcement
NATIONAL ENFORCEMENT INVESTIGATIONS CENTER
Building 53, Box 25227, Denver Federal Center
Denver, Colorado B0225
CHAIN OF CUSTODY RECORD
SURVEY
SAMPLERS: (Signatufoj
STATION
NUMBER
STATION LOCATION
DATE
TIME
sample iype
SEO
MO
NO OF
CONIAINERS
ANALYSIS
REQUIRED
Wolef
Air
Comp
Grab
Relinquished by: (s,gnoiure)
Received by. is,anaiure)
Date/Time
Relinquished by: isignotuiej
Received by: (S.9*xure/
Date/Time
Relinquished by: fSignafu>w
Received by: (stature]
Date
/Time
Relinquished by: (s,gnoiu«j
Received by Mobile Laboratory for field
analysis: is
------- |