NC0004375_Report_20040606

NPDES DOCUMENT SCANNING COVER SHEET
NPDES Permit:
NC0004375
Clariant Corporation
Document Type:
Permit Issuance
Wasteload Allocation
Authorization to Construct (AtC)
Permit Modification
Complete File - Historical
Engineering Alternatives (EAA)
Correspondence
Owner Name Change
Report
Instream Assessment (67b)
Speculative Limits
Environmental Assessment (EA)
Document Date:
June 6, 2004
Thies document is printed on reuise paper - ignore any
content on the reYerrie snide

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ENVIRONMENTAL °
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UPDATE OF THE EVALUATION
OF BEST AVAILABLE TECHNOLOGY
ECONOMICALLY ACHIEVABLE (BAT) FOR CONTROL
OF NUTRIENT DISCHARGES
CLARIANT CORPORATION
Prepared for:
Clariant Corporation
11701 Mt. Holly Rd.
Charlotte, NC 28214
Prepared by:
AWARE Environmental® Inc.
9305-J Monroe Road
Charlotte, NC 28270-1490
AEI Job No. N130-30
AEI Document No. 13030r001
June 2004

MCI
Section No.
TABLE OF CONTENTS
Description Page No.
um TABLE OF CONTENTS i
LIST OF TABLES i
LIST OF FIGURES ii
LIST OF APPENDICES ii
1.0 INTRODUCTION 1
1.1 GENERAL 1
1.2 EXISTING WASTEWATER SYSTEM 2
1.3 BAT STUDY 3
m4
1.4 CONDUCT OF BAT STUDY 5
2.0 TREATMENT PLANT OPERATIONAL REVIEW 6
2.1 BACKGROUND 6
2.2 TREATMENT PLANT PERFORMANCE 6
3.0 DEVELOPMENT OF BAT EFFLUENT QUALITY 14
3.1 BAT DATA AND DEVELOPMENT OF BAT 14
3.2 ANNUAL EFFLUENT FLOW FOR TN AND TP 14
3.3 TOTAL NITROGEN BAT 14
3.4 TOTAL PHOSPHORUS BAT 18
"" 3.4.1 Phosphorus Treatability 18
3.4.2 Effluent Phosphorus 21
3.4.3 Phosphorus BAT Development 21
3.5 BAT SUMMARY 26
MIR
LIST OF TABLES
MO
Table No. Description Page No.
. 1 Summary of Summer and Winter Operating Data 10
2 Summary of Removal Efficiencies 11
3 Total Phosphorus/Total Nitrogen - Effluent Data 15
4 Summary of Phosphorus Surcharges from Public Owned Treatment
Works (POTW's) 24
OM
OM
i

LIST OF FIGURES
Figure No. Description Page No.
ram
1 Flow/Temperature/Ammonia-N (2003-2004) 8
AIM
AnI
Eft
2 Comparison of Effluent Flow and Treated Flow Through
the Biological System 12
3 Statistical Analysis of Biological Treatment 17
4 Statistical Analysis of Total Nitrogen - Winter 19
5 Statistical Analysis of Total Nitrogen - Summer 20
6 Correlation of Ferric Chloride Addition and Phosphorus Removal 22
7 Statistical Analysis of Effluent Total Phosphorus 23
8 Correlation of Ferric Chloride Addition and Phosphorus Removal
Costs 25
LIST OF APPENDICES
A BAT Test Data
B Jar Test Data

PM
SECTION 1.0
INTRODUCTION
1.1 GENERAL
lel
Clariant operates a chemicals production facility and centralized waste treatment (CWT) plant
,_, near Mount Holly, North Carolina (Clariant-Mt. Holly East Plant). Wastewater from the
facility and from off -site locations are treated in an on -site wastewater treatment plant
., (WWTP) and the treated wastewaters are discharged to the Catawba River under NPDES
Permit No. NC0004375. The current NPDES permit became effective on March 1, 2003.
Pal This permit was issued by the North Carolina Department of Environment and Natural
Resources (NCDENR).
MP
The facility had been a specialty chemical and dye manufacturing site since 1937. In recent
"' years a number of the production units have shut down and the latest NPDES permit authorizes
operation of a centralized waste treatment system.
OBI
The treated wastewaters include:
1. CWT wastewaters from off -site manufacturing operations, hauled to the Clariant
facility;
2. Stormwater from the facility;
3. Process wastewater and domestic wastewater from current on -site manufacturing
operations; and
,a 4. The groundwater from a groundwater pump and treat system and leachate from an
active on -site landfill cell.
r.
In addition to treating hauled -in wastes in the centralized waste treatment operations, Clariant
,..+ has developed the facility as an industrial park for compatible industrial operations. To date,
one (1) new tenant has operations at the facility with treatment of resulting process wastewaters
PP in the on -site WWTP.

1.2 EXISTING WASTEWATER SYSTEM
fir The Clariant Mt. Holly East site has two separate sewer systems, an alkaline and an acid.
Both carry stormwater to the on -site WWTP for treatment in addition to carrying wastewater
'al from site buildings.
PEI
The acid sewer is a gravity system that terminates in a lift station at the WWTP. The lift
station pumps acidic wastewater to a primary treatment process. It can also pump water into
two lined impoundments for storage. The lined sto Ind ents have a capaci
MG. The acid sewer system has a capacity o 500,000 gallons per day.
The primary treatment process includes two neutralization tanks that operate in series. Lime
slurry is pumped into each neutralization tank in a continuous manner for neutralization of
acidic wastewater. The neutralization process can accept up • 750,000 gallons per day of
irl
acidic wastewater
The alkaline sewer is a gravity system that terminates in a lift station at the WWTP. The lift
station pumps alkaline wastewater to a mixing chamber downstream of the two neutralization
tanks where the acid and alkaline sewer streams are mixed together. The lift station can also
pump water into two impoundments. These storage i u s + dments have a capacity of
The alkaline sewer system has a capacity o
The combined and neutralized sewer streams flow into
rimary and secondary solids and
wo primary clarifiers
ca cium sulfate
that operate in
from the neutralization process,
C 0y
ate out and are pumped to two sludge holdin: tanks. Clarified wastewater flows by gravity
from the primary clarifiers to
handle a total wastewater flow o ? ,200,000 gallons
The two clarifiers are designed to
The sludge is pumped from the sludge holding tanks to one of two continuous belt filter presses
for dewatering. Dewatered sludge is accumulated in dump trucks and is hauled to a lined
landfill on the site.
2

�► The 4.5 MG equalization Q� basin has sever 1 mixers and aerators. Wastewater flows from
the EQ basin by gravity to a 2.5 MG activated sludge aeration basin. The activated sludge
" r
aeration basin has jet mixers that maintain a homogeneous mixture of sludge and water. Five
(5) aerators rovi dissolved oxygen for the bacterial population in the mixed liquor. The
separate aeration/mixing controls allow adjustments to optimize nitrification/denitrification.
gal
MCA
Mixed liquor from the aeration basin flows by gravity into two secondary clarifiers. Settled
biological sludge is returned to the aeration basin. Waste activated sludge is pumped to the
primary clarifiers where it mixes with primary sludge and is settled out for dewatering and
landfilling. The secondary clarifiers are designed to handle up to 5,000,000 gallons per day of
r
flow.
Treated effluent exiting the secondary clarifiers flows through an exit canal paralleling the
WWTP. The canal flows to a small final exit pond that has an aerator to provide a positive
dissolved oxygen prior to release into the Catawba River. The exit pond has an effluent lift
station and an exit valve that can shut off flow to the river.
The effluent lift station can divert the entire effluent flow to a 360 MG holding basin for
storage and re -treatment through the WWTP. If any of the permitted effluent parameters are
expected to be exceeded due to WWTP upset or poor treatment process performance, the
WWTP throughput can be pumped into the holding basin. Treated wastewater that is diverted
into the effluent holding basin is eventually released back to the WWTP equalization basin and
re -treated through the activated sludge system prior to discharge.
1.3 BAT STUDY
During 1998 and 1999, the Clariant Corporation conducted an evaluation of best available
technology economically achievable (BAT) for control of the nutrient discharges. The conduct
of the BAT study was based on the requirements in a draft permit issued by NCDENR which
specifically noted:
3

"It has been determined by the Division of Water Quality, through intensive water
quality studies, that discharges upstream of Lake Wylie, including this discharge, need
to control nutrients through the application of best available technology (BAT) that is
economically achievable. The permittee shall provide the Division with a stud which
fully investigates,€eai of meeting a monthly average TP limit of� 0 mg/ and
a summertime
If, it is determined to be beyond reasonable BAT to
reach such concentrations of nutrients, the Division will apply BAT limits based on the
results of this study and the performance of other similar plants. The nutrient study
should be completed by November 1, 1999."
Based on this requirement, AWARE Environmental Inc. (AEI) conducted a study for Clariant
Corporation to evaluate the applicable BAT nutrient criteria. A report on BAT was submitted
to the North Carolina Department of Environment and Natural Resources in This report
was entitled "Evaluation of Best Available Technology Economically Achievable (BAT) for
Control of Nutrient Discharges-Clariant Corporation", October, 1999.
Following the report submittal, the NCDENR included nutrient limits in the recent renewal of
the NPDES permit. Specifically, the nutrient criteria was based on a 12 month rolling average
for total nitro en and total phosphorus._ The specific limits which are based on the results of
the October 1999 BAT study, included a total nitrogenFN) limit of 444.1 1ba y and a total
phosphorus (TP) limit o ' 32.5 lbs/da Compliance is to be based on the results of the first 12
months of effluent testing and will continue on a rolling annual average basis following the
initial 12 months. The monthly average lbs/day was to be based on the arithmetic average of
the concentrations monitored for composite samples collected during the month and the
average daily waste flow for the month.
In addition to a specific limit, based on the changes in the facility, the NCDENR required the
permittee to perform a study which updates the limits for total nitrogen and total phosphorus
which can be met through BAT. The study is to based on twelve (12) months of effluent
monitoring data with the 12 months being utilized in the study as being the first 12 months
4

following the issuance of the new NPDES permit on March 1, 2003. A report on the BAT
�, update study will need to be submitted to NCDWQ for approval by July 1, 2004.
mi+ 1.4 CONDUCT OF BAT STUDY
Based on the requirements in the NPDES permit, Clariant conducted a BAT study to determine
"' the best available treatment technology. The study was designed as an update of the October
1999 study utilizing the data from the 2003-2004 operations. This report presents the results
f., of that study.
5

SECTION 2.0
TREATMENT PLANT OPERATIONAL REVIEW
2.1 BACKGROUND
The 1999 report analyzed, in detail, the wastewater treatment facilities at the Clariant facility.
The results of that analysis indicated that Clariant's treatment facility represented an industrial
BAT facility. The study found that there were elevated levels of nitrogen in the discharge
6.1 because of the nature of the wastewater (the majority of the discharge nitrogen was a refractory
or nitrogen which could not be degraded using conventional nitrification or
denitrification). The addition of hos horus was found to be a key criteria for maintaining
proper biological treatment.
my,
The operation of the facility as a centralized waste treatment (CWT) facility began with the
revision of the NPDES permit in March 2003. Clariant initiated a program, based on
requirements of the NPDES permit, to update the BAT performance. AEI initiated a detailed
MI' review of the treatment plant operations as part of the BAT evaluation.
2.2 TREATMENT PLANT PERFORMANCE
The operation of the treatment plant is complex because of the nature of the NPDES permit
limits. The treatment plant must meet, on a monthly basis, BODs, TSS and ammonia nitrogen
criteria along with criteria for OCPSF and CWT parameters. In addition, the BODs and
ammonia nitrogen discharges are limited based on the river flow during the period of April 1
through October 31. Therefore, the plant must be able to discharge, to the available capacity,
on a year round basis since the storage of excessive quantities of wastewater could result in the
inability to discharge the stored wastewater. AEI conducted a detailed review of the treatment
plant performance in order to update the BAT for TN and TP.
Initially, it was planned to use the routine performance monitoring data for the system as the
basis to establish BAT. However, based on a review of the initial months of data, it appeared
that a more detailed program would be required. Therefore, in August 2003, AEI revised the
6

+an
monitoring program and also established controls to optimize nitrification/denitrification.
These changes included:
1. Laboratory QC confirmation;
2. A minimum of 2 per week influent and effluent total nitrogen and total phosphorus
analysis;
F.' 3. Use of rapid test kits to provide daily aeration basin NH3-N and NO3-N;
4. Operation with a minimum MLSS of 5,000 mg/1;
5. Weekly review of system monitoring data to adjust operation;
6. Modification of aeration basin controls to operate the complete mix basin with a
minimum DO which allows both nitrification and denitrification to occur in a single
basin using its rapid test kit data to adjust system operation; and
7. Jar testing for phosphorus removal.
The results of this program showed that the nitrification process is temperature dependent. NI' 1;\c
tJ
rarl
Following the implementation of the nitrification/denitrification program, the effluent ammonia
nitrogen and nitrate nitrogen averaged less than 2 mg/1 each during the periods of biological ^A"� hi
nitrification. Aeration basin temperature appears to be the primary factor which limits the
biological nitrification. It appears that when aeration basin temperatures are approximately
20°C or higher the system provides complete biological nitrification. However, when the
temperature drops to less than 15°C, the biological nitrification is lost and the BODs removal
is reduced.
044 Figure 1 presents a summary of the discharge flows, aeration basin temperature, and effluent
ammonia nitrogen for the period January 1, 2003 through February 29, 2004. These data
show that once the temperature for nitrification was achieved (approximately 20°C), the
system achieved almost complete nitrification, and when colder temperatures occurred
(approximately 15°C), the system lost the ability to nitrify. The lower discharge flow rates
during the colder months are based on the need to store a portion of the flow (in the 360 MG
basin) for retreatment. This storage capability allows the facility to comply with effluent BODs
and ammonia nitrogen criteria during winter operating conditions.

1 1 1 t
1 1 1 1 I 1 t 1
Figure 1 - Flow / Temperature / Ammonia-N (2003-2004)
6
•
M
(AN46b 4,465 00.,N0\00 5�00\0� 00`�0\03 06\11\\ 0�9`03 00\�0`03 og`o��o3 �0\0�03
�03
\`' 0'``'0`' o�oa�oo0��9`oa
120
- 100
- 80
J
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1
M
1643
20
0
- —Temperature NH3-N
Date

MI
MI
ratt
Art
A summary of the summer and winter operating parameters is presented in Table 1. These
data show that the system is achieving a high level of BOD5 removal both in the summer and
winter.
Under summer operating conditions the effluent BOD5 is normally less than 10 mg/l. Under
winter operating conditions there is an increase in the BOD5 and approximately 50 percent of
the treated wastewater flow is held in the effluent storage basin and recycled back to the
WWTP for re -treatment during warmer operating conditions. The system is operated at an
organic loading (food to mass ratio) of approximately 0.02 to 0.03 lbs BOD5 applied/Lb
MLSS/day both in the summer aninter. This is a very low loading and should allow the
system to achieve maximum levels of BOD5 removal and nitrification. These data indicate that
the system is impacted by cold temperature conditions.
The need to store a portion of the wastewater in the winter means that the flow through the
I.,treatment plant is not equal to the effluent discharge flow. Figure 2 shows that the plant holds
back a portion of the flow during the winter. Therefore, the flow which is discharged is not
,ti the total flow treated through the wastewater treatment plant. This has an impact on the
development of nutrient BAT levels. In looking at annual averages of nitrogen and
lac+ phosphorus, the data needs to be evaluated both in terms of the wastewater which is treated and
the wastewater which is actually discharged during the operating periods.
0.,
In August 2003, the revised program to optimize the performance of the treatment system was
,,. implemented. This included an increase in the MLSS level to be maintained in excess of 5,000
mg/1, maintaining aeration DO level at the 1 to 2 mg/1 level, and using the daily ammonia and
nitrate readings to adjust DO. Ammonia and nitrate test strips were utilized to provide the
daily operating data. Split samples were sent to several laboratories to verify the quality of the
laboratory data.
The full-scale performance data indicated that this program was helpful in optimizing system
nitrification/denitrification performance. Table 2 summarizes the winter and summer effluent
quality following the August 2003 modification of the operating protocol. The test data

919
TABLE 1
SUMMARY OF SUMMER AND WINTER OPERATING DATA
Influent
Flow (MGD)
BOD (mg/1)
NH3-N (mg/1)
0.8
688
10.8
0.6
1416
71.7
4.1 Aeration Basin
F/M (lbs BOD A/lb MLSS-day) 0.02 0.03
MLSS (mg/1) 6125 5998
SVI (mg/gm) 53.4 70.9
D.O. (mg/1) 3.2 2.4
Temperature (°C) 22.6 13
Secondary Clarifier
BOD (mg/1) 11 216
Final Effluent
Flow (MGD) 0.9 0.2
BOD (mg/1) 8 193
(lbs/day) 49 307
NH3-N (mg/1) 1.8 46
10

MIR
021
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ql uTABLE.2
SUMMARY OF REMOVAL EFFICIENCIES
SUMMER (August 1-November 18)
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BOD
688
8
TKN
66
14.8
NIL-N
7.3
1.3
Organic N
58.8
13.4
NOZ/NO3-N
1.6
1.8
TN
64.6
16.6
TP
7.4
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BOD
1416
193
TKN
97.4
116.3
NIL-N
46.8
46.7
Organic N
50.6
69.6
NOZ/NO3-N
2.9
0.5
TN
101.7
104.8
TP
4.3
:.4
Notes:
sfs\ Wad\
�9s W'tlj
A. Total nitrogen includes the sum of TKN (ammonia + organic nitrogen), nitrite, and
nitrate nitrogen. The data for all components of TN were not monitoring at the
same frequency. Outliers were not used in Table 2. Therefore, there may not be a
balance of all parameters.
B. Total phosphorus and total nitrogen - There was more effluent than influent data.
The individual data is shown in Appendix A.
11

i
50.0
45.0
40.0
35.0
30.0
' 25.0
20.0
Figure 2 - Comparison of Effluent Flow and Treated Flow
Through the Biological System
15.0 —
10.0 —
5.0
0.0
oeS
OG�o3Qet �o���,°g� OOGe��et
se,
10 MG Treated 0 MG Discharged i
Month (2003-2004)

indicate that there continues to be a refractory nitrogen component. This appears to be related
to the organic nitrogen and may result from the types of materials that are being hauled in from
textile wastes similar to that which had previously been treated on -site and to the treatment of
contaminated groundwater and stormwater at the Clariant site. Higher levels of nitrogen
occurred in winter because of the colder aeration basin temperatures.
There was no phosphorus addition to the treatment plant during these studies. However, it
appears that there is some phosphorus in the wastewater. The change in phosphorus in the
wastewater appears to be a significant change due to the centralized waste treatment (CWT)
operations.
13

SECTION.3.0
DEVELOPMENT OF BAT EFFLUENT QUALITY
3.1 BAT DATA AND DEVELOPMENT OF BAT
The effluent monitoring data from the Clariant treatment system were utilized to define BAT
for TN and TP. Appendix A presents a summary of all the influent and effluent TN and TP
data which was collected as part of this study.
There was a difference between the flow processed through the wastewater treatment plant and
ot' the effluent discharge flow since a portion of the treated wastewater can be diverted to the
effluent holding basin. Therefore, daily effluent waste loads were calculated using two
different appnache. One used the . ctual effluent discharge • and the other used the actual
flow through the biological s ste A summary of the actual discharge total nitrogen and total
phosphorus and the total nitrogen and total phosphorus which were calculated based on the
flows through the biological system is presented in Table 3.
The procedure for developing BAT was similar to that used in the 1999 report and is based on
U.S. EPA methodology. A statistical analysis of flow, TN and TP concentrations was
developed. The BAT levels for the annual average TN and TP were developed based on these
erer&
3.2 ANNUAL EFFLUENT FLOW FOR TN AND TP
Mc+ The actual 12 months of flows through the biological system were evaluated to define a BAT
flow basis. A summary of the treated flow levels is presented in Figure 3. This indicates that
the 50 percentile flow which would be used to determine the annual waste load is 0.92 MGD.
3.3 TOTAL NITROGEN BAT
The results of the previous BAT report showed that there was no cost effective procedure to
further reduce the total nitrogen beyond the current nitrification/denitrification process.
Therefore, BAT was developed based on an optimized treatment plant utilizing
14

calk.
Rol
Mlak
rott
faM
1
MINA
TABLE .3
TOTAL PHOSPHORUS / TOTAL NITROGEN - EFFLUENT DATA
MARCH 2003 - FEBRUARY 2004
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3-Jun-03
1.28 0.12
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404.53
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0.42 3.6
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25-Aug-03
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27-Aug-03
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120.99
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3-Sep-03
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8-Sep-03
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10-Sep-03
1.26 1.7
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17.86
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15-Sep-03
0.84
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17-Sep-03
1.21
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35.42
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22-Sep-03
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24-Sep-03
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29-Sep-03
0.61 i 5.38
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1-Oct-03
1.11 I 18
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166.63
104.24
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6-Oct-03
0.40
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8-Oct-03
0.69 9.15
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52.34
62.27
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13-Oct-03
0.86 13.7
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98.26
71.51
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70.27
109.13
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20-Oct-03
0.62 14
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72.39
108.59
66.1
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22-Oct-03
0.40 5.6
14.84
18.68
49.51
20.0
53.1
27-Oct-03
0.92
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21.62
46.34
165.89
38.8
138.8
29-Oct-03
1.12 4.4
22.44
41.10
209.61
20.1
102.3
3-Nov-03
0.35 6.56
16.27
19.15
47.49
20.6
51.1
5-Nov-03
0.57 8.24
18.15
39.25
86.42
36.8
81.0
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10-Nov-03
0.53
9.24
17.62
40.84
77.88
46.5
88.7
12-Nov-03
0.67
10.1 22.13
56.44
123.66
59.3
129.9
24-Nov-03
0.29
15.4
18.17
37.25
43.95
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70.5
26-Nov-03
0.17
14.1
150.21
19.99
212.97
60.1
640.7
1-Dec-03
0.35
10.3
150.13
30.07
438.23
41.5
605.2
3-Dec-03
0.44
9.31
130.17
34.16
477.67
1 39.9
558.1
8-Dec-03
0.15
7.71
140.13
9.65
175.30
31.9
580.5
10-Dec-03
0.17
6.23
150.24
8.83
213.01
43.9
1059.7
15-Dec-03
0.05
0.945
8.10
0.39
3.38
3.9
33.7
17-Dec-03
0.22
9.37
69.27
17.19
127.10
41.6
307.7
22-Dec-03
0.17
11.3
86.07
16.02
122.03
49.3
375.5
24-Dec-03
0.14
8.75
140.09
10.22
163.57
32.8
524.5
29-Dec-03
0.23
12.2
190.24
23.40
364.92
46.7
728.1
31-Dec-03
0.21
6.43
99.17
11.26
173.69
24.5
377.2
{ 6-Jan-04
0.14
1.54
14.22
1.82
16.84
6.7
62.3
7-Jan-04
0.15
3.63
26.22
4.63
33.41
11.2
80.9
12-Jan-04
0.22
2.8
93.15
5.05
167.96
11.5
381.1
14-Jan-04
0.21
3.57
86.17
6.17
148.98
9.1
219.5
19-Jan-04
0.21
3.88
110.29
6.66
189.21
11.7
333.3
21-Jan-04
0.18
2.8
92.39
4.11
135.54
10.5
346.0
26-Jan-04
0.18
7.43
93.55
11.08
139.50
23.5
295.5
28-Jan-04
0.16
8.51
92.57
11.41
124.07
36.3
394.4
4-Feb-04
0.27
7.96
89.32
17.92
201.12
50.7
568.8
9-Feb-04
0.27
15.9
86.22
35.80
194.15
68.3
370.3
11-Feb-04
0.26
9.44
240.23
20.47
520.91
40.5
1030.0
18-Feb-04
0.15
11.8
110.30
15.16
141.66
51.8
484.2
23-Feb-04
0.17
12.9
140.36
18.07
196.66
77.2
840.4
25-Feb-04
0.02
13.7
110.38
2.14
17.21
105.9
853.3
Note A - Based on measured flow through the biological system and final effluent
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16

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FIGURE 3
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Drawing: 13030CHART1.DWG.DWG 9305-J MONROE RD. CHARLOTTE, NC 28270

nitrification/denitrification which produced an effluent ammonia-N and nitrate-N of less than 2
NM mg/1 each under summer operations. In developing the total nitrogen BAT, the performance of
the system was divided between summer and winter operations. A summary of the winter total
nitrogen is presented in Figure 4. This shows that the 50 percentile nitrogen concentration in
the inter is 115 mg/l. A summary of the summer total nitrogen is presented in Figure 5.
This shows that the 50 percentile summer total nitrogen concentratio
There is a need to divert a portion of the winter flow to storage. Therefore, the proposed
approach for defining BAT is to separate summer (May through October) and winter
(November through April) conditions. During the summer, the flow to be used for BAT
would be 1.5 x the average flow or 1.38 MGD while for the winter the flow would be 0.5 x
the average flow or .46 MGD. Based on 1.38 MGD and 17 mg/1 TN, this would result in a
TN limit of 196 lbs TN/day in the summer. Based on 0.46 MGD and 115 mg/1 TN in the
winter, this would result i , . N limit of 441 lbs TN/day. he resulting annual avera;
would therefore b
This is a reduction of approximately 30 % in the annual
average total nitrogen limitation as compared to present annual average limit of 444.1 lbs/day.
3.4 TOTAL PHOSPHORUS BAT
The approach for developing the total phosphorus BAT limits was based on a combination of
the total phosphorus in the optimized effluent from the treatment plant and the results of the jar
testing program which was conducted as part of the study for precipitation of the phosphorus.
A precipitation process was used for definition of BAT levels since this treatment plant is not
designed for biological phosphorus removal and biological removal would require a major
change in the treatment plant. Jar tests were performed to determine if precipitation techniques
could be used for additional phosphorus removal.
3.4.1 Phosphorus Treatability
A series of precipitation jar tests were performed on the influent samples and mixed
liquid samples using ferric chloride alum and lime. The results of these tests indicated
Aft that ferric chloride was most effective in removing significant levels of the total
18
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FIGURE 4
STATISTICAL ANALYSIS OF TOTAL NITROGEN - WINTER
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phosphorus. A summary of these data is presented in Appendix B. It appeared that the
ferric chloride precipitation could achieve up to 60 percent phosphorus removal. A
summary of the ferric chloride data is presented in Figure 6. These flu_gnt _phosphorus
�► did not appear to be temperature dependent. Therefore the analysis of effluent total
phosphorus was based on all of the data.
3.4.2 Effluent Phosphorus
A statical summary of the effluent phosphorus is presented in Figure 7. This shows
that the 50 percentile effluent total phosphorus is 7 mg/1. Based on the 50 percentile
ato
flow of 0. • MGD, the effluent total phosphorus from the facility would average
lbs/day on an annual base
3.4.3 Phosphorus BAT Development
It appears that the nature of the total phosphorus for the CWT treatment plant operation
is different than that found in the previous study since phosphorus is no longer added to
the treatment plant. Therefore, a cost analysis was prepared to define the cost to
achieve additional phosphorus removal beyond the 53 Ibs/day effluent total phosphorus.
As a first step in the analysis, the costs for municipal phosphorus removal was updated
from the 1999 study. These updated costs are presented in Table 4 and showed a
typical phosphorus removal cost of $2/1b phosphorus. These costs were then used as a
basis for defining BAT.
The approach for phosphorus removal is based on ferric chloride precipitation. The
cost for ferric chloride is 16.25 cents/lb. The cost analysis is based solely on the
chemical cost and does not include costs related to additional sludge
chemical feed and sludge disposal, therefore this analysis is conservative. Phosphorus
removal would be achieved by adding ferric chloride to the secondary clarifier so that
additional clarification facilities would not be required. A summary of the percent
removals with the ferric chloride addition is presented in Figure 8. Based on the
POTW costs, the
21

1
I
1
3 1 1
PHOSPHORUS REMOVAL (PERCENT)
80
60 ---
40
20
•
50 100 150 200
FERRIC CHLORIDE ADDITION (Mc/L)
CORRELATION OF FERRIC CHLORIDE ADDITION
AND PHOSPHORUS REMOVAL
CLARIANT CORPORATION
MOUNT HOLLY, NORTH CAROLINA
SCALE NOT TO SCALE APPROVED [iv : DRAWN B'r. J.K.S.
DATE MAY 2004
DESIGNED 8Y REVISED
PROJECT NUMBER
N 130- 30
/I Ar • I t» AW1NL; NU.
AE la CI A''ITFIGURE 6
9305-J MOr1R0: kU. l:HA1e�p[1f-. NC :r.: ��

J
1
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FIGURE 7
STATISTICAL ANALYSIS OF EFFLUENT TOTAL PHOSPHORUS
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Drawing: 13030CHART1.DWG.DWG
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TABLE .4
SUMMARY OF PHOSPHORUS SURCHARGES FROM
PUBLIC OWNED TREATMENT WORKS (POTWs)
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V 1 •1• r1• T•• 1:•1:,•:•:`. :y1} �•• ♦ y'Y':•:{':{•.tt 1 '}•L:{•:• •:Ly.•.
,{ .Ly:•.:{L .L �.. •f:4 }. R ..f rY. • . . 1 . y . . }. {1 1{'.
V.tvh:t L r LL} • k{ �� ••.t :1{•:¢ ]: t . ;\,y. t.{•:
t • •{}14J}�• 4
•.V 1� �• �::{L•hL. Y.• L {1. 1 �•'••hf 1{�. •�.Y .tti:Y,{::'
`.�- � �:L �y �.+ �{
{t�,:� •}:••t{tt1 �111•{,:•}':•}�{\'.1V.1':•}~':�:'.5�.{:.�1�1:��1Lyhy':11}:•} \ ii4�4:} }•:�:y:•:1•:' •�
Gastonia, NC
84.70(a)
Norfolk, VA (Hampton Roads Sanitation District)
1 d7.00(b'
Birmingham, AL
200.00(c)
Baltimore, MD
293.44
Pensacola, FL (Escambia County Utilities)
254.30
Average Nutrient Surcharge from Surveyed
POTWs
200.00
(a) Surcharge in excess of 8 mg/L
(b) Surcharge in excess of 250 mg/L
(c) Surcharge in excess of 4 mg/L
1=n
dCA
Pia
MIR
24

1
1
1
1
1
1
1
1.
1
1
PHOSPHORUS REMOVAL (PERCENT)
60
50
40
30
20
10
":„
2
PROPOSED BAT REMOVAL
AVERAGE COST MUNICIPAL
PHOSPHO US REMOVAL
4
6
8
•
10 12
COST PER POUND OF PHOSPHORUS ($/Jb.)
CORRELATION OF FERRIC CHLORIDE ADDITION
AND PHOSPHORUS REMOVAL COST
CLARIANT CORPORATION
MOUNT HOLLY, NORTH CAROLINA
SCALE NOT TO SCALE APPROVED BY : DRAWN BY: J.K.S.
DATE
MAY 2004 DESIGNED BY : REVISED
PROJECT NUMBER
N 130- 30
A WA
!'! I v DRAWING NO.
D. CHARLOTTE. FIGURE 8
9305-J MONRO£ RD. CNARl.O7TE, NC 28270

POTW costs, the BAT level for total phosphorus would require a 24 percent reduction in the
total phosphorus. This results in a BAT total phosphorus limit of 40 lbs/day.
3.5 BAT SUMMARY
In summary, the data for the Clariant facility has been reviewed. It appears that the optimized
operation of the Clariant WWTP receiving centralized waste treatment (CWT) and on -site
wastewaters provides a significant level of reduction in total nitrogen. A total nitrogen criteria
of 318.5 lbs TN/day represents the revised BAT. This compares to the current TN limits of
444.1 lbs/day.
The operation of the treatment plant in terms of total phosphorus (TP) removal indicates a BAT
of 40 lbs TP/day. This is based on the use of effluent chemical precipitation treatment to
reduce effluent phosphorus. This will result in a cost consistent with that which municipal
plants typically experience for phosphorus removal. It is proposed to use a BAT phosphorus
limit of 40 lbs TP/day.
13030r00I
26

APPENDJX A
BAT TEST DATA

Summary of Treatment Plant
Total Nitrogen and Total Phosphorus
Date
4-Mar-03
Influent
TN (mg/1) l TP (mg/1)
Effluent
TN (mg/1)
95.3
2-Apr-03 80.2
?-Mav-03
TP (mg/1)
I1
5.5
19.17
,-Jun-03
,-Jul-03
31.7
1.3
0.12
pazn 6-Aug-03
30.4
3.2
18-Auk 03
19.9
11.93 0_82
20-Aug-03 ; 28
25-Aug-03
44.5
3.0
5.3
40.3
8.5 0.45
27.9
3.6
0.85
17.27
3-Sep-03 10.75
5-Sep-03 ' 9
8-Sep-03
2 7-Aug-03
0.403
4.9
0.97
12.33
10-Sep-03 1800 ( 12.18
15-Sep-03 12.17 6.77
17-Sep-03 150
22-Sep-03
4.8
0.88
1.7
0.72
7.14
31.21 8.7
24-Sep-03 13
18.34
3.51
5.6
29-Sep-03 25.9 0.156
1-Oct-03 21
6-Oct-03 29.65
8-Oct-03 27
0.99
3.36
8.75
5.38
11.26
18
0.488
10.3
10.6
13-Oct-03 45.25
15-Oct-03 36
10.885
9.15
9.97
13.7
20-Oct-03 35.98
22-Oct-03 170
27-Oct-03 28.1
29-Oct-03 ; 21
15.22
9.8
29
21
14
14.84
5.6
5.95
21.62
6.04
3-Nov-03 330.46
5-Nov-03 l 72
22.44
4.4
23.2
16.27
6.56
I8.145
10-Nov-03 89.62 0.21 17.62
12-Nov-03 ? 170
24-Nov-03 •
8.24
9.24
22.13
10.1
22.33
26-Nov-03 250
5.26 ! 18.17
15.4
150.21
1-Dec-03 174.32 4.26 f 150.13
3-Dec-03 220
8-Dec-03
14.1
130.17
10.3
9.31
144.86 ! 0.34
10-Dec-03 97
140.13
7.71
150.24
6.23
Summary of Treatment Plant TP/TN
P1 130\130-30 \VWTP\Summary of TP
Clariant Corp.
June 2004

(continued)
Date Influent
Effluent
,'
TN (mg/I)
J TP (mg/1)
TN (mg/1)
TP (mg/1)
15-Dec-03 0.19 5.08
8.1 ! 0.945
1 7-Dec-03 70 69.27 I 9.37
I22-Dec-03 95.27 1.64 86.07 11.3
2.1-Dec-03 140 140.09 i 8.75
29-Dec-03 46.2 8.31 190.24 12.2
31-Dec-03 0.11 99. 1 7 6.43
6-Jan-04 14.22 ; 1.54
7-Jan-04 10 26.22 3.63
12-Jan-04 104.95 0.8
j 93.15 ( 2.8
14-Jan-04 51
86.17
3.57
19-Jan-04 94.28 i 3.47
110.29
3.88
21-Jan-04 • 52 92.39 I 2.8 I
26-Jan-04 5.1 11.3 93.55 7.43
-Jan 3 28-Jan-04 2 92.57 8.51
4-Feb-04 99
89.315 ' 7.96
9-Feb-04 49.87 5
86.22 15.9
1 1 -Feb-04 89
240.23 9.44
18-Feb-04 250
110.3 11.8
23-Feb-04 144.4 1.34
140.36 ! 12.9
25-Feb-04 310 110.38 13.7
Summary of Treatment Plant TP/TN
P11301130-30 WWTP\Summary of TP 2
Clariant Corp.
June 2004

APPENDIX B
JAR TEST DATA

FSII
FR
PM
Fel
Pef
Fel
PHOSPHORUS REMOVAL JAR TESTING
CLARIANT
AEI JN 130-30A
Jar Tests performed on Mixed Liquor samples
Ferric Chloride (as FeCL3)
Dosage Final pH Filt. Phos Init. Phos Reduction
mg/L su mg/L mg/L
50 7.88 6.31 10.06 37
100 7.28 4.75 10.06 53
200 6.77 4.13 10.06 59
Alum (as AISO4)
Dosage Final pH Filt. Phos Init. Phos Reduction
mg1L su mg/L mg/L
50 7.42 8.03 10.06 20
100 7.19 4.56 10.06 55
200 6.81 8.03 10.06 20
Jar Tests performed on Influent samples
Lime (as CaO)
Dosage Final pH Tot. Phos Init. Phos Reduction
mg/L su mg/L mg/L %
200 8.5 5.61 6.68 16
300 9.65 5.06 6.68 24
450 10.5 3.98 6.68 40