Document 85XYd3J4X2Erj7EkJDvNo2d6m

Attached is the Willow Island application for a total plant Effluent Permit. The data in the application are the sane which w: presented to you a* a draft at our inforaal March 10th meting in ' Charleston. In addition, we have included in our pernit applicAticn photographs of the important features of our facilities and a sap show ing the overall plant layout. Our total plant effluent application follows the fom suggested in your Kay h, 1959, outline. During intervals when plant operations ap proach present equipment capacity our waste lead will increase, but should not exceed the aaxisua shown in Table Bo. 1 of our application. . It is understood that on the effective date of the new pernit all existing permits for segments of our operation will be revoked.* We will continue our regular waste-load reporting to the State Water Re sources Commission and. In accordance with our discussions, the lead and chromium results will be added. .. , It was a pleasure nesting with you and Mr. Oillenwater in Charleston on March 10th, and I wish to thank you again for the courtesies extended to Dr. Ervin, Mr. Cherry, and myself. We appreciate your interest in our operation and I an sure that from our discussions we both have a better understanding of the problems with which we are mutually concerned. Very truly yours, AMERICAS CIAHAMID COMPUTE A. C. Fennimore T Plant Manager EFFLUENT PERMIT APPLICATION < AMERICAN CYANAMID COMPANY ORGANIC CHEMICALS DIVISION WILLOW ISLAND, WEST VIRGINIA Existing Waste Treatment Facilities . '' ' . r. The principal sewerage system at the American Cyanamid Company's plant in Willow Island, West Virginia, collects process effluents, sanitary sewage and storm water from all hut one manufacturing department in the plant and transports the combined flow to a compositing lagoon for treatment. This treatment unit consists of an earthen basin having a surface area of about 7, 2 acres and a capacity of approximately 27. 5 million gallons. The basin permits the varying constituents in the influent wastes'to coneutralize, co precipitate and settle. As a result, most of the suspended solids are removed and free mineral acidity is eliminated. In addition* a,reduction in organic content is also accomplished. . The wastes in the lagoon pass under a skimming baffle and over a weir equipped for continuous flow measurement. The effluent from this treatment system spills into a mixing chamber and down a cascade, after which it flows about 0. 5 mile and enters the Ohio River approximately at Milepoint 162.0. * Fermentation waste liquors from the manufacture of pharmaceu tical and antibiotic products as well as the sanitary sewage and codling waters from this department receive treatment in a separate installation. These wastes are metered, aerated, settled and biologically treated on high rate trickling filters. Tl,ie effluents from this plant and from the 2 lagoon combine in the mixing chamb er and are chlorinated when necessary to insure stability of the wastes as they flow to the Ohio River. All of the process waste# leave the plant through the single outlet described as Outfall No. 1. Approximately at Milepoiat 161.0 one additional outfall exists which discharges wash waters sad storm water drainage from a fly ash settling basin and which is herein designated as Outfall Me. 2. Walter Quality Constituents Outfall No. i The following water quality constituents are known or estimated to be present in the wastes discharged at Outfall No. 1. Whenever possible, the best estimate of the average amounts and ranges of each constituent is listed ' .v-.f. s VkpifS vil'.';/ i-- ;> Table I * - .< Outfall No. 1 > < ; : Description ; `\ Type of Flow - Process, Sanitary and Storm Water : Si*e - 2-56" Vitrified Tile Pipes Encased in Concrete Elevation Above Sea Level - Pipe Invert: 600 it.; Cascade Bottom: 588 ft . Milepoint - 162. 0 Water Quality Constituent S Quantity of Flow (m. g. d.) ""Alkalinity (lb. /day) * Calcium* (lb. /day) * Chloride (lb. /day) * Chromium* (p.p.m.) ' Hardness (lb./day) Lead* (p.p.m.) Iron (lb. /day) Nitrogen, Ammonia (lb. /day) Nitrogen, Organic (lb./day) ' Oxygen, Biochemical Demand (lb. /day) '/ Oxygen, Chemical Demand (lb. /day) Oxygen, Dissolved (p.p.m.) 'pH Sodium* (lb./day) " Solids, Settleable (ml. /liter) -Solids, Suspended (lb./day) - Solids, Total (lb. /day) ' Sulfate (lb./day) Minimum Average 3.0 10,000 800. 4.2 35,000 ; 2,000 2, 000 4, 300 <1 <2 ; 2, 000 : ,i <1 1 5, 200 <2 | i50 2, 500 iio : 5,000 5,000 15,000 4,000 8,200 10,000 18,000 0 . 2.0 5.0 5, 000 SL0 10,000 0 0. 3 1, 500 3,500 50,000 , 79,600 10,000 31,600 Maximum 5,6 75,000 3, 600 \ 8,000 <3 , 9.000 <3 400 15, 000 !: 5, ooo . 25,000 55,000 * 8.0 ; 15,000 2.0 ` 14,000 120,000 45,000 ^Estimated values based on limited analytical data. General Waste Characteristics ',. *; On January 1, 1960, the Willow Island Plant was equipped to < manufacture six classes of products, five of which contribute process ' wastes to the treatment systems. The following description will serve, to define the chemicals which may be present in the waste streams from each manufacturing department: 1* ) 1. Aniline Department , Aniline is produced in this department. The wastes consist of wash waters and strippings containing inorganic ammonium salts and small amounts of aniline and mononitrobenzene. , 2. Melamine Department ? *; Melamine is produced in this department. The wastes consist of distillation column residues containing methanol, ammonia, caustic and organic nitrogen in the form of triazine ring compounds. 3. Pigments Department Inorganic pigments such as iron blue, chrome green and chrome i yellow are produced in this department. The wastes consist of filtrates and press washings containing sulfuric acid, acetic acid, acetates, nitrates 5 and small amounts of iron, chromium and lead. 4. Synthetic Organic Chemicals Department Organic products such as brighteners, folic acid, choline salts, nitrophenide, ultraviolet absorbers and intermediates for pharmaceuticals and dyes are produced in this department. The wastes consist of spent mother liquors, filtrates, distillation column residues and wash waters. V *( If I t They contain inorganic sodium salfs, inorganic acids, and miscellaneous organic compounds such as acetone, methanol, acetic afcid and organic 1 byproduct residues. I 5. Fermentation Department Fermentation products such as unrefined^chlortetracycline , I (Aureomycin), animal feed supplements and riboflavin are produced in . i' i . ' I this department. The wastes consist of filtrates containing indefinable, byproducts from a fermentation medium composed of carbohydrates, corn i I steep liquor, antifoam oil and miscellaneous trace elements. ; 1 6. Catalyst Department "` \ .Alumina based catalysts are produced in this department. ,No liquid process wastes are discharged from these operations, i Chemical Constituents - Outfall No. 1 Estimates of the major chemical constituents which may enter existing treatment facilities have been listed in Table No. 2. These figures have been determined by estimating and analyzing, wherever V l. possible, the individual effluent streams from each department. The wastes are modified during passage through the treatment plants and S' the exact chemical composition of the combined effluents from these units cannot be measured by existing analytical procedures. The data contained in Table No. 2 can be used for indicative purposes only to show what compounds might be present in the final plant wastes. However, Table No. 1 can be used for control since the I results can be substantiated by standard analytical methods. 0 4 Organic Constituent Acetates (lb./day) Acetone (lb. /day) Aniline (lb. /day) Fermentation Byproducts Methanol (lb./day) Mononitrobenzene (lb. /day) Nitrates (Ib./day) Organic Acids (lb,/day) Triazine Ring Nitrogen (lb./dav F&ulfc li Outfall No, ',1 Minimum 2, 100 , Average 4, 500 *i Maximum .' * ; 7, 000 : 500 1, 500 3,000 <5 <10 <20 Unknown composition - treated biologically t i; 1, 500 . ; ; 4,500 200 : 500 oo 13,000 ? 3,000 ; 5,000 6,000 * 100 ; ; 1,00I0 10,000 : 15, 000 3,000 ; 30,000 5 Waste Constituents - Outfall No. 2 v The following inforrr.af.cn pertains to the discharges from the fly ash settling basin through Outfall No. 2. 1 Table 111 Outfall No, 2 Description Type of Flow - Wash and Storm Water Sjfze - 20" Iron Pipe Elevation Above Sea Level - 590 ft. Milepoint - 161.0 Minimum Average Maximum Quantity of Flow (g. p. d.) Solids, S ettleabl e (ml./liter ^Estimated values based or. limited analytical data. '90,000 Undetermined. `Will Vary with .quantity of stor water run-off. <1 (Range - zero to <4) I