NCD991278953_19970301_National Starch & Chemical Corp._FRBCERCLA RA_Groundwater Remediation System OU-3, Conceptual Design & Preliminary Design Report-OCR

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SALISBURY PLANT 1~vl~
'MAR 2 ~ i~91.
GROUNDWATER
REMEDIATION SYSTEM
OPERABLE UNIT 3
CONCEPTUAL DESIGN AND
PRELIMINARY DESIGN REPORT
March 1997
Prepared by
NATIONAL STARCII AND CHEMICAL COMPANY
10 Finderne Avenue
Bridgewater, New Jersey 08807
National Starch and Chemical Company
Salisbury, North Carolina
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TABLE OF CONTENTS
1.0 INTRODUCTION ....................................................... 1
1.1 Purpose and Organization of Conceptual Design Report ................... 1
1.2 Site Location and Description ........................................ 1
1.3 RD/RA Work Plan and On-Site Meeting ................................ 6
1.4 Summary of Site Characteristics ...................................... 7
1.5 Conceptual Design Report Contents ................................... 7
2.0 GROUNDWATER EXTRACTION SYSTEM ............................... 11
2.1 Installation of Extraction Wells ...................................... 11
2.2 Step-Drawdown Pump Tests ........................................ 11
2.3 Packer Testing of Bedrock Wells .................................. 11
2.4 Surveying of Site and Wells ........................................ 15
2.5 Sampling of Groundwater from Saprolite and Bedrock Wells .............. 16
2.6 Pilot Testing of Diffused Air Stripping Treatment System ................. 16
3.0 REMEDIAL DESIGN .................................................. 25
3.1 Design Basis ..................................................... 25
3 .2 Existing Trench Area Pretreatment System Difficulties ................... 2 7
3.3 Proposed Pretreatment System for OU3 and Trench Area Groundwater ...... 27
3.4 Details of the Proposed Groundwater Pretreatment System ................ 28
4.0 PRELIMINARY DESIGN ............................................... 32
4.1 Preliminary Sizes and Preliminary Equipment List ....................... 32
4.2 Preliminary Design Drawings ....................................... 32
4.3 Air Permit Application ............................................. 32
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1.0 · INTRODUCTION
1.1 Purpose and Organization of Conceptual Design Report
This Conceptual Design and Preliminary Design Report is prepared to fulfill requirements
of the United States Environmental Protection Agency's (USEPA's) Unilateral
Administrative Order and the Statement of Work (SOW) for the Remedial
Design/Remedial Action (RD/RA) of Operable Unit No. 3 (OU3) at the National Starch and
Chemical Company's (NSCC's) Cedar Springs Road Plant site in Salisbury, North Carolina.
It is prepared in accordance with the Final RD/RA Work Plan at OU3 approved by the
USEPA on August 20, 1996 and presents the details of the Groundwater Extraction System,
the Groundwater Pretreatment System, and the Preliminary Design of the Groundwater
Pretreatment System.
This Conceptual Design and Preliminary Design Report is comprised of four sections.
Section one of this Conceptual Design and Preliminary Design Report presents and discusses
Site Background Information. Site Background Information includes site location, site history,
and a summary of site soils, sediments and groundwater characteristics. Section two presents
and discusses the details of the Groundwater Extraction System at OU3. Section three presents
and discusses the details of the Pretreatment System including the design basis for the various
unit operations. Section four contains the Preliminary Design Drawings of the Groundwater
Pretreatment System.
1.2 Site Location and Description
The NSCC site, also referred to as the Cedar Springs Road Plant site, is located in Rowan
County, North Carolina, approximately 5 miles south of the City of Salisbury. Salisbury is
approximately 40 miles northeast of Charlotte, North Carolina along Interstate 85. Figure 1-1
illustrates the location of the site.
Land use of the areas immediately adjacent to the site is a mixture of residential and industrial
developments. An industrial park is located on the east and south sides of the site. Grants
Creek forms the western boundary of the site. The Southmark Industrial Park is located along
the southern property line. The Little Acres Mobile Home Subdivision adjoins the extreme
southwestern corner of the site. A housing development, Kings Forest, is adjacent to the north
side of the site. A second development, Stonybrook, lies across Airport Road on the northern
side of the site.
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The NSCC site is approximately 500 acres in size. OU3 at the NSCC site comprises of the
following:
1.
2.
Contaminated groundwater located in Area 2, the parking lot, and the
wastewater treatment lagoons of the Plant; and
Contaminated surface water/sediments in the Northeast Tributary.
The Chemical Production Plant and the wastewater treatment lagoons are located in the
southwestern portion of the property. The portion of the NSCC facility known as Area 2 is
located in the northeast portion of the Plant Operations area. The wastewater treatment
lagoons are located in the south and southwest portion of Plant Operations area. Figure 1-2
illustrates these facilities at the NSCC site.
The Northeast Tributary crosses the NSCC property paralleling Cedar Springs Road and passes
within 50 yards of the front of the Plant Operations Area. This tributary receives runoff from
an industrial complex on the east side of Cedar Springs Road, from Cedar Springs Road itself,
and from the Southmark Industrial Park located to the south. Areas on both sides of the stream
contribute runoff throughout its reach. The watershed boundary is shown in
Figure 1-3. From the Area 2 of the Production Plant, the stream flows for approximately
6,000 feet before joining with Grants Creek located to the north. Grants Creek flows
approximately 12 miles beyond NSCC property where it joins with the Yadkin River
approximately 2 miles downstream from the water supply intake for the City of Salisbury.
The Northeast Tributary receives discharge from the W. A. Brown Plant through a National
Pollutant Discharge Elimination System (NPDES) permit. W .A. Brown is an industrial facility
located on the east side of Cedar Springs Road. The discharge point is a pipe located on the
east bank of the Northeast Tributary, downstream of the NSCC Plant Operations area
(Figure 1-2).
Area 2 of the NSCC facility consists of the reactor room, the tank room, raw material bulk
storage facilities, warehouse tanks, diked storage tanks, and roadway. The wastewater from
Area 2 consists of water from washing/rinsing of reactors and line (piping, pumps, etc.)
flushing. These cleaning operations occur between processing of different products. The
waste stream discharge _includes reactor and feed line wash and rinse, which contains trace
amounts of organic and inorganic compounds in a water solution.
The wastewater from Area 2 is sent to the Plant's Wastewater Pre-Treatment System before
being discharged to the City of Salisbury's Publicly Owned Treatment Works (POTW). The
existing Wastewater Pre-Treatment System is composed of two Lagoons ( Lagoons No. I and
No.2 ) for storing untreated wastewater ( Lagoon No. I is aerated ), a Primary Treatment
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{N;ational Starch and Chemical Company
Salisbury, North Carolina
SCALE:
0 8 16 MILES
Figure 1-1
Site Location Map
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N. C. GRID NORTli (NAO 83)
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NPDES PERMITTED
DISCHARGE POINT\
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SITE PLAN
SALISBURY, NC PLANT
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/ilptlonal Starch and Chemical Company
SALISBURY, NC PLANT
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WATERSHED MAP
MARCH 1997 FIGURE 1-3
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System for solids removal, a Biological Reactor ( Lagoon No.3 ) for stabilizing soluble
organics in the wastewater and an Effluent Lagoon ( Lagoon No.4 ) for storing secondary
effluent prior to discharge into the City of Salisbury sewer system.
The Plant's Wastewater Pre-Treatment System was upgraded to allow Pre-Treatment and
discharge of combined groundwater from OUI and plant effluent. This system, known as the
Combined Pre-Treatment System, is now treating both OUI groundwater (including the Plume
Periphery groundwater and groundwater from the Extraction Wells in the Trench Area) and
plant wastewater.
The Combined Pre-Treatment System is designed to treat two OUI groundwater streams
(Trench Area and Plume Periphery groundwater) in addition to the Plant's wastewater. Trench
area groundwater is now treated in the Trench Area Pretreatment System to remove metals and
organic compounds before being discharged to the existing Lagoon No. l where this flow is
combined with the Plant's wastewater. Lagoon No. I provides equalization and pH adjustment
to the wastewater. Wastewater from Lagoon No. I is pumped to the Primary Treatment System
where solids are removed by chemical precipitation and settling in a Primary Clarifier.
Overflow from the Primary Clarifier flows into Lagoon No.2 for equalization and is
transferred to the Biological Reactor (Lagoon No.3) once a day. Following completion of
treatment, the treated effluent is decanted and pumped to Lagoon No.4 for further storage and
aeration before being discharged to the City's sewer for further treatment at the POTW.
1.3 RD/RA Work Plan and On-Site Meeting
As required by the Unilateral Administrative Order, a Draft RD/RA Work Plan was I prepared and submitted to the USEPA during December 1995 to provide the framework for
conducting the RD/RA of OU3 for remediation of groundwater contamination at this site.
After several revisions of this Draft the Final RD/RA Work Plan was approved by USEPA
during April 1996. During August, 1996 USEPA gave NSCC Notice to Proceed with the
RD/RA Work Plan activities at this site.
A site visit was conducted by the USEPA and the NCDEHNR on October 4, 1996. A
kick-off meeting with the USEPA, the NCDEHNR, the Weil L\·illers and the Packer Testing
Consultant was also held at the site on Friday, October 4, 1996 for initiating the OU3 RD/RA
Work Plan activities. Following this Kick-off meeting field investigations for OU3 were
initiated on October-?, 1996. Field investigations included taking of rock cores; installation
of Extraction Wells; development and packer testing of Extraction Wells; step-drawdown
tests of Extraction Wells; sampling of groundwater, surface water and sediment; field survey;
preparation of summary reports of field investigations and Pilot Testing of Air Stripping.
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1.4 Summary of Site Characteristics
The RI and FS Reports for the OU3 were completed during June, 1993. The overall nature
and extent of comntamination associated with OU3 is based on analytical results of
environmental samples collected from surface and subsurface soils, the groundwater, the
surface water and sediment of the Northeast Tributary, and the physical/chemical and
geological/hydrogeological characteristics of the area. VOCs, SVOCs, one pesticide, and
several inorganic analytes were detected in the soils and groundwater at OU3. Two VOCs and
several metals were detected in the surface water/sediment samples. Table 1-1 lists the
contaminants detected in each environmental medium sampled during the conduct of the RI in
1993 as well as the contaminants detected in each environmental medium sampled during the
field investigations and installation of Extraction Wells for the RD/RA of OU3 in 1996-97.
The frequency and range of concentrations detected are also presented in this table.
1. 5 Conceptual Design Report Contents
This Conceptual Design and Preliminary Design Report for OU3 consists of the following:
1. Results of additional field investigations conducted during the RD/RA of OU3
including (a) Drilling and Installation of Monitoring and Extraction Wells in
the saprolite and bedrock aquifers, (b) Packer Testing of Bedrock Wells to
delineate depths of vertical contamination of bedrock aquifer, (c) Step-
Drawdown Tests of the Extraction Wells installed for OU3, (d) sampling of
groundwater from the Monitoring and Extraction Wells located at OU3, (e)
Pilot Testing of the Diffused Air Stripping Treatment System, (f) sampling of
surface water and sediment in the Northeast Tributary, and (g) laboratory
analysis of.groundwater, surface water and sediment samples:
2. Details of Remedial Design including (a) Design Basis; (b) Sizing of Pipes,
Storage Tanks and Delivery Systems: (c) Conceptual Design of the
~ Groundwater Pretreatment System; and (g) Process Flow Schematics for the
Groundwater Extraction and Pretreatment System; and
3. Preliminary Design Drawings of the Groundwater Extraction and Pretreatment
System.
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Table 1-1
Range and Frequency of Detection of Organic Contaminants and Inorganic Constituents
Phase I and II OU3 RI and Field Investigation of OU3 RD/RA
Comp~und
Volatile Organic Compounds
Acetone
Bromodichloromethane
2-Butanone
Carbon Disulfide
Chloroethane
Chloroform
Dibromochloromethane
1,2-Dichloroethane
1, 1-Dichloroethene
1,2-Dichloroethene
1,2-Dichloropropane
Ethyl benzene
Methylene Chloride
I
Tetrachloroethene
Toluene
1, 1,2-Trichloroethane
Trichloroethene
Total Xylenes
Vinyl Chloride
Groundwater from RI
9-4,200 (15)
4-8 (3)
3-35 (6)
7-8,900 (2)
1-660,000 (30)
1-14 (3)
1-200 (4)
5
9-36 (2)
1-160 (5)
107(4)
1-120(3)
1-5 (10)
2-90 (4)
1-120 (8)
Groundwater from RD/RA
4-2000 J (9)
130-260,000 (I 0)
2-3000 1 (8)
Concentrations for wa,ter samples are reported in micrgrams per liter (ug/1) or in parts per billion
(ppb.) :
Number appearing in parenthesis is the frequency of detection.
The reported values fdr Groundwater RD/RA are only from the ten new extraction wells. I
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Table 1-1 (Continued)
Range and Frequency of Detection of Organic Contaminants and Inorganic Constituents
Phase I and II OU3 RI and Field Investigation of0U3 RD/RA
Compound Groundwater from RI
Semi-Volatile Organic Compounds
Bis(2-chloroethyl) ether
Bis(2-ethylhexyl)phthalate
Di-n-butyl Phthalate
2-Methyl Phenol
N-Nitrosodiphenyllamine
Pesticide
Delta-Hexachlorocyclohexane
13-32 (2)
8
2-17(3)
0.16
Groundwater from RD/RA
3-16 (7)
2 J (l)
2 J (1)
NA
Concentrations for water samples are reported in micrgrams per liter (ug/1) or in parts per billion
(ppb.)
Number appearing in parenthesis is the frequency of detection.
The reported values for Groundwater RD/RA are only from the ten new extraction wells.
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Table 1-1 (Continued)
Range and Frequency of Detection of Organic Contaminants and Inorganic Constituents
Phase I and II OU3 RI and Field Investigation of OU3 RD/RA
Compound
Inorganic Constituents
Antimony
Arsenic
Barium
Beryllium
Chromium
Cobalt
Copper
Cyanide
Lead
Manganese
Nickel
Thallium
Vanadium
Zinc
Groundwater from RI Groundwater from RD/RA
2-30 (3)
2.4
28.2-737 (8)
1-2.5 (2)
12.9-59.6 (6)
47-66.4 (2)
12.4-23.7 (2)
12-16(2)
3.3-3.9 (2)
1.5-12,000,000 (14)
23.4-39.6 (3)
1-3 (2)
10.7-272 (II)
22-6,410,000 (4)
20-55.4 (10)
10.1-46.4 (6)
4.6-17.6 (9)
tbd
59.60-3290 (10)
6.10-16.20 (9)
9.9-746 (10)
Concer.trations for water samples are reported in micrgrams per liter (ug/1) or in parts per billion
(ppb.)
Number appearing in parenthesis is the frequency of detection.
The reported values·for Groundwater RD/RA are only from the ten new extraction wells.
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2.0 GROUNDWATER EXTRACTION SYSTEM
2.1 Installation of Extraction Wells
The Groundwater Extraction System consists of five (5) Saprolite Extraction Wells (NS-45,
NS-47, NS-49, NS-51, and NS-53) and five (5) Bedrock Extraction Wells (NS-46, NS-48, NS-
50, NS-52 and NS~54). Two of the five Saprolite Extraction Wells (NS-45 and NS-47) were
drilled and installed in Area 2 of the Plant and the other three Saprolite Extraction Wells
(NS-49, NS-51 and NS-53) were drilled and installed in the Lagoon Area. Two of the five
Bedrock Extraction Wells (NS-46 and NS-48) were drilled and installed in Area 2 of the Plant
and the other three Bedrock Extraction Wells (NS-50, NS-52 and NS-54) were drilled and
installed in the Lagoon Area. Figure 2-1 illustrates the locations of these Saprolite and
Bedrock Extraction Wells. Table 2-1 summarizes the pertinent well construcion data and other
information for these Extraction Wells. Details of drilling and installation of these Extraction
Wells were provided in the OU3 RD/RA Field Investigations Summary Report.
2.2 Step-Drawdown Pump Tests
Following installation of the ten Extraction Wells. Step-Drawdown Tests were conducted in
each of the Saprolite and Bedrock Extraction Wells to determine (a) Radii of lnflunce of each
well at various pumping rates, (b) Specific Capacities of the Extraction Wells, (c) Maximum
Allowable Pumping Rates (to assure sufficient depth of submergence of the pump at all times
without causing excessive drawdown) from each well, and (d) Design Pumping Rates for each
of the ten Extraction Wells to assure effective control and removal of the Groundwater
Contaminant Plume. Details of the Step-Drawdown Tests and procedures used during the
Field Investigations were provided in the OU3 RD/RA Field Investigations Summary ' Report. Table 2-2 summarizes the results of the Step-Drawdown Tests for the ten Extraction
Wells.
2.3 Packer Testing of Bedrock Wells
The bedrock extraction wells in Area 2 of the Plant and in the Lagoon area were drilled to
depths ranging from 200.4 feet to 201.3 feet below the ground surface. Following drilling of
the five bedrock £~traction Wells, Packer Tests were conducted in the borehole of each
bedrock Extraction' Well.
'
The primary objectives of the Packer Tests were to (a) determine the depth or depths of the
bedrock aquifer from which contaminated groundwater is to be extracted. (b) the vertical
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N. C. GRID NORTH (NAO 83)
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{iif;atlonal Starch and Chem;ca/ Company LOCATIONS OF OU3 EXTRACTION WELLS
SALISBURY, NC PLANT
t.tARCH 1997 FIGURE 2-1
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I Table 2-1
I Cedar Springs Road Plant Site, Salisbury, North Carolina
Operable Unit 3
Extraction Well Construction Data
I Well No. Installation Location Diameter Total Depth Screen Interval Casing Interval
I Zone Inches ft. ft. ft.
I NS-45 Saprolite Area 2 6.00 55.00 -12.7 to -52.7 +3.0 to -12.7
I NS-46 Bedrock Area 2 5.875 200.40 Open Borehole +2.75 to -11.7
No Screen
I NS-47 Saprolite Area 2 6.00 50.00 -11.7 to -41.7 +2.75to-11.7
I NS-48 Bedrock Area 2 5.875 201.30 Open Borehole +2.33 to -49.3
No Screen
I NS-49 Saprolite Lagoon 6.00 115.50 -44.5 to -113.6 +2.58 to -44.5
I NS-50 Bedrock Lagoon 5.875 200.40 Open Borehole +1.0 to-134.0
No Screen
I NS-51 Saprolite Lagoon 6.00 117.60 -43.5 to -112.5 +2.41 to -43.5
I NS-52 Bedrock Lagoon 9.875 200.40 Open Borehole +2.25 to -126.0
No Screen I NS-53 Saprolite . Lagoon 6.00 117.00 -45.0 to -115.0 +2.75 to -45.0
I NS-54 Bedrock Lagoon 9.875 201.00 Open Borehole + 2.33 to -120.0
I No Screen
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Well
No.
NS-45
NS-46
NS-47
NS-48
NS-49
NS-50
NS-51
NS-52
NS-53
NS-54
Table 2-2
Cedar Springs Road Plant Site, Salisbury, North Carolina
Operable Unit 3
Results of Step-Drawdown Tests of Extraction Wells
Zone Max. Pumping
Rate During
Test, gpm
Saprolite 2.0
Bed Rock 8.0
Saprolite 2.0
Bed Rock 11.0
Saprolite 40.0
Bed Rock 40.0
Saprolite 30.0
Bed Rock 30.0
Saprolite 40.0
Bed Rock 30.0
Drawdown Depth to
at Maximum Pump
Pumping, ft. Intake, ft.
44.00 54.45
168.78 188.00
12.36 40 55
95.36 187.00
35.96 107.12
153.17 186.12
97.55 107.22
165 .82 186.12
26.73 107.22
148.85 174.12
Specific
Capacity,
gpm/ft
0.045
0. 162
0.115
1.120
0.261
0.180
1.496
0.201
Allowable
Pumping
Rate, gpm
2.00
6.00
2.00
14.00
60.00
40.00
25.00
25.00
60.00
30.00
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Design
Pumping
Rate, gpm
2.00
6.00
2.00
14.00
15.00
5.00
10.00
5.00
20.00
5.00
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extent of the groundwater contamination in the bedrock aquifer, and (c) the permeability and
transmissivity of the various water producing zones in the bedrock aquifer.
Two inflatable rubber packers were used to isolate the selected test zone in the bedrock aquifer
with a 3-inch submersible pump placed in between the two packers. All equipment used in the
Packer Tests were steam cleaned prior to initiating work at each bedrock well. The rubber
packers were lowered to the desired depths in the bore hole and then inflated with nitrogen gas
supplied from a ground level pressurized tank. Once inflated, the inflated packers isolated the
borehole into three separate zones. Pressures in each zone were monitored during the Packer
Tests using pressure transducers and was recorded on a computer.
Prior to initiating the Packer Tests a slug of water was introduced into the isolated section of
the borehole to determine whether or not that section of the bedrock is fractured and the rate of
exfiltration of the water slug into the bedrock. After the slug of water exfiltrated into the
bedrock, the submersible pump was turned on to pump water from the bedrock section in
between the packers while recording the pressure changes in the three zones. Normally, after
pumping three volumes of water from within the isolated zone a sample of groundwater was
collected for laboratory analysis.
In some sections of the boreholes where the bedrock is less fractured, the exfiltration of the
slug of water took considerable time. In these sections the recharge of water and recovery of
pressure after completion of only one volume of pumping was extremely slow. In these
instances, only one volume of water was extracted from the isolated zone before the
groundwater sample was collected. In sections of the borehole where there was little or no
ex filtration and infiltration, groundwater samples were not collected. However, in all cases
groundwater samples were collected from the lowest section of the borehole to determine
whether or not groundwater contamination reached this level of the bedrock. Samples fJf
extracted groundwater was collected for analysis of VOCs, SVOCs, and TCL metals.
After completion of the Packer Tests of the selected zone of the bore hole representing a
portion of the bedrock aquifer, the rubber packers were deflated and the whole pack was then
lowered to a different zone for another set of tests. This process was continued until the entire
borehole is tested. In some of the zones, because of lack of inflow, Packer Testing could not
be conducted. Results of the Packer Tests were presented and discussed in the OU3 RD/RA
Field Investigations Swnmary Report.
2.4 Surveying of Site and Wells
Following completion of the Extraction Wells. a field survey of all wells located in the Plant
Area and in the Lagoon Area was conducted to develop a detailed site map of the existing
facilities and wells. The survey was carried out to establish accurate horrizontal locations of
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wells and other facilities, and vertical elevations of the well rims and ground surface within the
surveyed area. Elevations of the rims of all Extraction Wells were then used to determine the
relative elevations of the water levels in all wells under different pumping rates in each well.
Field survey of the area next to the existing Trench Area Treatment Building, where the new
OU3 Groundwater Remediation Treatment System will be built, was also conducted to
establish ground contours and elevations for the detailed design. A map of the field survey is
included in the back pocket of this report.
2.5 Sampling of Groundwater from Saprolite and Bedrock Wells
Sampling of groundwater from the ten (10) newly installed saprolite and bedrock wells was
carried out during the conduct of the Packer Tests and after completion of the Step-Drawdown
Tests. As required in the OU3 ROD, sampling of eight (8) existing saprolite wells (NS-13,
NS-14, NS-33, NS-35, NS-37, NS-39, NS-42 and NS-43) and six (6) bedrock Monitoring
Wells (NS-34, NS-36, NS-38, NS-40, NS-41, and NS-44) installed during the Remedial
Investigations for OU3 was also conducted durin)! the sampling of the newly installed
Extraction Wells. The initial sampling of these Extraction Wells and Monitoring Wells during
Packer Testing was carried out to establish the existing contamination baseline.
Figure 2-2 illustrate the locations of all saprolite Extraction and Monitoring Wells. Figure 2-3
Illustrates all bedrock Extraction and Monitoring Wells. Results of the groundwater sampling
and analysis are presented and discussed in detail in the OU3 RD/RA Field Investigations
Summary Report.
2.6 Pilot Testing of Diffused Air Stripping Treatment System
Pilot Testing of the Diffused Air Stripping Treatment System was conducted after install ion of
the Saprolite and Bedrock Extraction Wells. Contaminated groundwater from the Extraction
Wells was first pumped into a 300 gallons Air Stripping Reactor. Figure 2-4 illustrates the
schematic of the Air Stripping Treatment System used for removing the Volatile Organic
Co111pounds from the contaminated groundwater. The Air Stripping Reactor was fitted at the
bottom with a fine bubble diffuser system consisting of four Ceramic Disks. Air was supplied
from the Plant-Air Supply to the bottom of the Ceramic Disks. The supplied air was
discharged as bubbles through the pores of the Ceramic Disks. This created a system of very
fine air bubbles. These fine air bubbles diffused through the contaminated water column in the
Reactor.
Samples of contaminatt;d groundwater were collected for laboratory analysis. After filling the
Reactor with contaminated groundwater. air was supplied to the Reactor at a constant rate for
twelve hours. Water samples were collected from the Reactor for laboratory analysis after
operation of the Reactor for 3 hours, 6 hours, 9 hours aand 12 hours. Altogether, eight (A
C:\PROJECTS1SLSBRY'OU3'0U3CNDES.S\' 16
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through H) separate Air Stripping tests were conducted. The rate of air flow into the Reactor
during these tests was varied from 8 scfm (0.65 scfm/sq. ft.) to 20 scfm (1.63 scfm/sq. ft.) to
determine the most effective aeration rate. Tables 2-3, 2-4, 2-5 and 2-6 present the results of
Air Stripping tests B, C, D, E, F, G, and Hof the Diffused Air Stripping System and its
effectiveness. Results from Test A are not available because the Analytical Laboratory lost the
samples. As seen from the data in these tables, the efficiency of the Air Stripping System
increased with increased air supply to the Reactor. Concentrations of all Volatile Organic
Compounds were below their respective detection limits after 12 hours of aeration. At the air
flow rate of 1.63 scfm/sq. ft.. the effectiveness of the Air Stripping System was better than 99
percent.
The Pilot Testing of the Air Stripping Treatment System was conducted during the Winter
month ( January ) when the water temperture was very low. This reduced the removal
efficincy of the Air Stripping Treatment System as well as increased stripping time in the
Reactor. In the Final Design of the prototype Air Stripping Treatment System a Thermal
Oxidizer will be used to destruct the VOCs and SVOCs contained in the exhaust air from the
Air Stripping Reactors. The Thermal Oxidizer will be operated at 1400 degrees Ferheneit to
destroy the VOCs and SVOCs in the exhaust air fr')m the Reactors. The heat in the exhaust air
from the Thermal Oxidizer will be recovered by using a Heat Exchanger. This recovered heat
will be used to heat the contaminated groundwater in the Reactors. It is estimated that heating
the contaminated groundwater by using recovered heat from the Thermal Oxidizer will
significantly increase the efficiency of the Air Stripping and reduce both the air flow rate and
the aeration time in the Reactor. With use of recovered heat from the Theremal Oxidizer six to
nine hours of aeration should be sufficient to reduce the concentation of VOCs and SVOCs in
the groundwater to below detection level. During start-up of the Groundwater Remediation
Treatment System further tests will be conducted with recovered heat from the Thermal
Oxidizer to confirm this and to determine the most effective air flow rate and duration of
aeration.
C:\PROJECTSISLSBRY·OUJ'OIJJCNOES.SV 17
~i-----------------------------------,7
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N. C. GRID NORTI-i (NAO BJ)
NS-J7
0
\
•
NS--43 0
NS-47
NS-JJ
0
,,--...
X
0
0:::
Q_
Q_
<t:
'-../
w z
_J
>-f-
0::: w
Q_
0
0:::
Q_
0 100 200 JOO 600
F'EET
I LOCATIONS OF SAPROLITE
EXTRACTION AND MONITORING WELLS
[BMfonal Storch and Ch•mfoo/ Company
~'----------------------:----------::::.... ______________________ L ___ s_A_L_1s_s_u_R_Y_:,_N_:_c_PL:::_A ___ N_T~--_JL_~M~AR~c:'.'."...:'~•9~1 __ j_ _ __'.:Fr~cu~R~E~2-:__:2~_J_J
r~-----------------------,---------------------,7
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N. C. GRID NORTli (NAO BJ)
NS-J7
0
\
•
NS-4J
0
NS-47
---\
\
\
-. J
NS-JJ
0
,,--..,
X
0
0::: o_
o_
<t: ..___,
w z
__J
>--\--
0::: w o_
0
0::: o_
0 100 200 JOO 600
FEET
{R;_atlonal Starch and Chom;ca/ Company LOCATIONS OF BEDROCK
EXTRACTION AND MONITORING WELLS
~L-------------------------------.:::_ ______________________ L ___ s_A_L_1s_s_u_R_Y.:_·_N_c_P.::_LA_N __ T ___ _L_~M~A~Rc::"~'~ss~1'--_l-~F~1G~uR!:!E:_22-:::3~-J_J
-- - - - - - - - - --- --- - -11!!!!!1
,--------------------------------~7
SUPPLIED GROUNDWATER
BLOWER
/H;atlonal Starch and Chemical Company
SALISBURY, NC PLANT
EXHAUST AIR
DIFFUSED AERATION
TANK
FINE BUBBLE DIFFUSED
AIR STRIPPING SYSTEM
TREATED GROUNDWATER
PUMP
SCHEMA TIC OF PILOT
AIR STRIPPING TREATMENT SYSTEM
MARCH 1997 FIGURE 2-4 [_~ ___________________ __j_ ___ ___:.__ _ __1_~:::.::.:..::=--=---=-__J_J
-------------------
Table 2-3
Results of Pilot Test Trials Band C
Salisbury Plant Groundwater Remediation System -Operable Unit 3
Trial (flowrate) Trial B (8 scfm)
Sample ID B-1 B-2 B-3
Sample Interval (hr.) 0 3 6
Parameter ( ug/1)
Methylene Chloride 2000 JB 300 JB 30
D
Acetone 10000 u 600 JB 50
1,2-dichloroethane 91000 D 11000 1400
Total Concentration(ug/1) 103000 11900 1480
Percent Removal 88.45 98.56
Notes:
2000 J = Reported value is an estimate
2000 B = The paramter was also detected in the method blank
I 0000 U = The value is less than the detection limit.
C:\l'ROJECTSISI.SBR Y\( )U3\()IJ3CNDES.SV
JB
JB
Trail C (8 scfm)
B-4 C-1 C-2 C-3
9 0 3 6
8 JB 6000 JB 900 JB 300
D D
10 JB 4000 JB 2000 JB 500
D D
220 D 210000 D 43000 10000
238 220000 45900 10800
99.77 79.14 95.09
21
C-4
9
JB 60 JB
JB 280 B
3300
3640
98.35
-------------------
Table 2-4
Results of Pilot Test Trials D and E
Salisbury Plant Groundwater Remediation System -Operable Unit 3
1 n?n1n41n.:o
Trial (flowrate) Trial D (12 scfml
Sample ID D-1 D-2 D-3
Sample Interval (hr.) 0 3 6
Parameter ( ug/1)
Methylene Chloride 2000 JB 40 JB 2
Acetone 2500 u 20 JB 9
1,2-dichloroethane 36000 I 100 78
Total Concentration(ug/1) 40500 1160 89
Percent Removal 97.14 99.78
Notes:
2000 J = Reported value is an estimate
2000 B = The paramtcr was also detected in the method blank
I 0000 U = The value is less than the detection limit.
C:\PROJHTS\SI.SBR YI.( IUJ\OUJCNDES.S V
Trail E /12 scfm)
D-4 E-1 E-2 E-3
9 0 3 6
JB 2 JB 1000 JB 300 J 30
D
JB 6 JB 1000 JB 200 JB 40
D
9 J 90000 ED 8800 790
17 92000 9300 860
99.96 89.89 99.07
22
E-4
9
J 3 J
JB 8 JB
91
102
99.89
---- - - - - - - - ---- - - --
Table 2-5
Results of Pilot Test Trials F and G
Salisbury Plant Groundwater Remediation System -Operable Unit 3
n,n1n,1m.:o
Trial (flowrate) Trial F (I 6 scfm)
Sample ID F-1 F-2 r, . -.,
Sample Interval (hr.) 0 3 6
Parameter ( ug/1)
Methylene Chloride 1400 J lJ
Acetone u 48 DJ 17
B
1,2-dichloroethane 67000 2000 30
Total Concentration(ug/1) 68400 2048 47
Percent Removal 97.01 99.93
Notes:
2000 J = Reported value is an estimate
2000 B = The paramter was also detected in the method blank
I 0000 U = The value is less than the detection limit.
C:\l'ROJHTS\SLSBR Y\< >UJI( HJ3CNDES.SV
Trail G (I 6 scfm)
F-4 G-1 G-2 G-3
9 0 3 6
u 3 J 3100 J u
B 27 B 2800 JB 63 DJ 10
B
2 120000 3400 51
32 125900 3463 61
99.95 97.25 99.95
23
G-4
9
lJ 3 J
JB 10 JB
, J .)
16
99.99
-------------------
Table 2-6
Results of Pilot Test Trials Hand I
Salisbury Plant Groundwater Remediation System -Operable Unit 3
1 n?n1n,1n1,:o
Trial (flowrate) Trial H 120 scfm)
Sample ID H-1 H-2 H-3
Sample Interval (hr.) 0 ' 6 j
Parameter ( ug/1)
Methylene Chloride u u
Acetone 970 JB u 84 DB 12
1,2-dichloroethane 61000 510 D 6
Total Concentration(ug/1) 61000 594 18
Percent Removal 99.03 99.97
Notes:
2000 J = Reported value is an estimate
2000 B = The paramter was also detected in the method blank
I 0000 U = The value is less than the detection limit.
C:\l'RI >JECTS\Sl.Sl!R YIOl JJIOUJCNDES.S V
Trail I /20 scfm)
H-4 1-1 1-2 1-3
9 0 3 6
u u u u
B 13 B 1300 JB 83 B 76
J u 140000 1400 E 76
13 141300 1483 152
99.98 98.95 99.89
24
1-4
9
u u
B 66 B
u
66
99.95
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3.0 REMEDIAL DESIGN
3. 1 Design Basis
As mentioned in Section 2.0 of this Conceptual Design and Preliminary Design Report
Groundwater will be extracted from five saprolite Extraction Wells (NS-45, NS-47, NS-49,
NS-51, and NS-53) and five bedrock Extraction Wells (NS-46, NS-48, NS-50, NS-52 and
NS-54). Four of these Extraction Wells ( NS-45, NS-46, NS-47, and NS-48) are located in
Area 2 of the Plant and the remaining six Extraction Wells ( NS-49, NS-50, NS-51, NS-52,
NS-53, and NS-54) are located in the Lagoon Area of the Plant. The design pumping rates for
each of these Extraction Wells are as follows:
----------------------------------------------------------------------------·---
OU3 Extraction Wells Design Pumping Rate, gpm
---------------------------------------------------------------------
NS-45
NS-46
NS-47
NS-48
NS-49
NS-50
NS-51
NS-52
NS-53
NS-54
2
6
2
14
15
5
10
5
20
5
--------------------------------------------
Total 84
------------------------------------------
A total of about 120,000 gallons of contaminated groundwater will be pumped from these ten
newly installed saprolite and bedrock Extraction Wells for OU3. At this rate of pumping the
groundwater extraction system is expected to have an area vf i1~•Junce covering the
contaminated groundwater plume.
Based on the results of sampling and analysis of groundwater from these Extraction Wells
conducted during the Packer Tests and Step-Drawdown Tests, the quality characterists of the
groundwater have been established for use as the design criteria. These groundwater quality
characteristics and estimated effluent characteristics from the Pretreatment System are
presented in table 3-1.
C:\PROJECTS1SLSBRY10U3'0U3CNDES.SV 25
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Table 3-1
Cedar Springs Road Plant Site, Salisbury, North Carolina
Operable Unit 3
· Influent and Effluent Characteristics for Pretreatment System
Parameters Influent Concentrations, ppb Effluent Concentrations, ppb
I. Volatile Organics
Acetone 2,000 < 10
1,2-Dichloroethane 260,000 < 10
Methylene Chloride 3,000 < 10
Chloroethane* 40 < 10
Chloroform* 9,000 < 10
1, 1-Dichloroethene* 20 < 10
1,2-Dichloroethene* 200 < 10
Ethyl Benzene* 40 < 10
Tetrachloroethene* 120 < 10
Tolune* 120 < 10
Total Xylenes* 100 < 10
Vinyl Chloride* 120 < 10
II. Semi-Volatile Organics
Bis(2-chloroethyl) ether 50 < 10
Di-n-Butyl Phthalate 20 < 10
III. Metals
Chromium* 60 60
Copper 25 25
Lead* 3 3
Nickel* 40 40
.. Zinc 1,000 < 100
Manganese 3.500 < 100
* These VOCs and metals were detected in groundwater samples collected and analysed
during the OU3 RI but were not detected in the groundwater samples collectecd during the
Packer Tests and Step-Drawdown Tests.
C:\PROJECTSISLSBRY'·OU310U3CNDES.SV 26
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3.2 Existing Trench Area Pretreatment System Difficulties
The existing Trtench Area Pretreatment System designed by the IT Corporation has some
defficiencies and causes operating problems for the operators. The Metals Removal System
produces hazardous sludge and solids. Some of these sludge and solids accumulate in the
Packed Tower used for stripping the VOCs. As a result the packing in the Packed Tower gets
clogged and require periodic removal and cleaning. This operation involving removal,
cleaning and recharging of the packing is hazardous to the operators.
3.3 Proposed Pretreatment System for OU3 and Trench Area
Groundwater
To eliminate the undesirable and hazardous operations at the existing Trench Area
Pretreatment System, National Starch and Chemic;\! Company proposes to treat the
contaminated groundwater from the Trench Area together with the contaminated groundwater
from OU3. In this new Pretreatment System all contaminated groundwater will be treated by
using a new Diffused Air Stripping System.
The Trench Area groundwater, which is more contaminated than the groundwater in OU3, will
be treated in a separate Diffused Air Stripping Tank to assure complete removal of all VOCs
and SVOCs present in the Trench Area groundwater. The groundwater from the OU3 will be
treated in three other Diffused Air Stripping Tanks. All of these Diffused Air Stripping Tanks
will be located in a new Pretreatment Building to be located next to the existing Trench Area
Pretreatment Building.
The groundwater in the four Diffused Air Stripping Tanks will be heated using recovered heat
to raise the temperature of the groundwater for more efficient and effective stripping of VOCs
and SVOCs
The exhaust air from each Diffused Air Stripping Tank will be collected and heated to about
1400 degrees Ferenheit in a Thermal Oxidizer to destroy the VOCs and SVOCs. The VOCs
and SVOCs will be converted into harmless gases and compounds. The Thermal Oxidizer will
operate on natural gas and will generate considerable amounts of heat to raise the temperature
of the exhaust air from the Diffused Air Stripping Tanks. NSCC will use a Heat Exchanger to
recover this available heat from the exhaust air. This recovered heat will be used to heat the
groundwater in each Diffused Air Stripping Tank.
After completion of the air stripping treatment the groundwater will be pumped to the existing
Lagoon No. I in the Plant's Combined Pretreatment System. The existing Combined
C:IPROJECTS',SLSBRY'OU310U3CNDES.SV 27
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Pretreatment System consists of a Primary Physical/Chemical Coagulation/Flocculation
Treatment System followed by a Multi-Cycle Sequencing Batch Reactor (MC-SBR) Biological
Treatment System. The Physical/Chemical Treatment Systemwas designed to remove metals
and will remove the metals remaining in the groundwater from OU3 and the Trench Area after
completion of the Diffused Air Stripping Treatment. The Biological Treatment will remove
any remaining dissolved organic contaminants in the groundwater.
3.4 Details of the Proposed Groundwater Pretreatment System
The proposed groundwater Pretreatment System for OU3 consists of the following elements:
a. Storage of extracted groundwater from Extraction Wells NS-45, NS-46, and NS-47 in
a new 2,000 gallons Storage Tank to be located in Area 2 of the Plant;
b. Transfer of contaminated groundwater from the new 2,000 gallons Storage Tank in
Area 2 of Plant to the existing 19,900 gallons Fiber Glass Storage Tank in the Trench
Area Pretreatment System;
c. Pumping of contaminated groundwater from Extraction Wells NS-48, NS-49, NS-50,
NS-51, NS-52, NS-53, and NS-54 to the existing 19,900 gallons Fiber Glass Storage
Tank in the Trench Area Pretreatment System;
d. Pumping of contaminated groundwater from the existing Trench Area Sump in the
Trench Area Pretreatment Building to the existing 11,300 gallons Sludge Storage Tank
in the Trench Area Pretreatment Building;
e. Transfer of contaminated groundwater from the existing 19,900 gallons Fiber Glass
Storage Tank in the Trench Area Pretreatment System to three new 20, 000 gallons
Diffused Air Stripping Tanks for removal of VOCs and SVOCs;
f. Transfer of contaminated groundwater from the existing 11,300 gallons Sludge Storage
Tank to a new 20,000 gallons Diffused Air Stripping Tank for removal of VOCs and
SVOCs;
g. Provide air supply to the Diffused Air Stripping Tanks from Aeration Blowers;
h. Thermal destruction of VOCs and SVOCs contained in the exhaust air from the four
new 20,000 gallons Diffused Air Stripping Tanks by using a Thermal Oxidizer;
1. Recovery of heat from the Thermal Oxidizer by using a Heat Exchanger;
J. Use of recovered heat from the Thermal Oxidizer to heat the contaminated
groundwater in the four 20,000 gallons Diffused Air Stripping Tanks to increase
efficiency of Diffuseed Air Stripping and reduce detention time;
k. Recirculation of contaminated groundwater from the Diffused Air Stripping Tanks
through the Heat Exchanger to raise the temperature of the contaminated groundwater
in the Tanks; and
I. Transfer of groundwater (after completion of stripping) from the Diffused Air
Stripping Tanks to existing Lagoon No. 1 for further treatment in the existing
Combined Pretreatment System at the Salisbury Plant.
C:\PROJECTS\SLSBRYIOU310U3CNDES.SV 28
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Figures 3-IA and 3-1B illustrate the Process Flow Diagram of the Proposed Groundwater
Pretreatmemnt System for the contaminated groundwater from OU3 and the Trench Area.
C:1PROJECTS',SLSBR Y·OU3'0U3C~DES.SV 29
.~. ,-----------------------------~7
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NS-47
2 CPM
NS-46
6 CPM
NS-45
1.8 CPM
AREA 2
SURGE TANK
2,000 CAL.
CONTAINMENT
FROM TRENCH AA[A \lltllS
NS-48
14 GPM
NS-50
5 CPM
EXISTING
Pl.JMPS
NS-51
10 CPM
EXISTING TREND-I WATER SUMP
NS-52
5 CPM
NS-SJ
20 GPM
ABO Ll.2. A1.AM. Se.0., P.l.
NOltTM CMCl.MA P.[_ NO.
OEV. OCSCR!PnON
TRENCH WATER
EQUALIZATION TANK
(EXISTING SLUDGE TANK)
11,JOO GAL
OUJ RAW WATER
EOUALIZATION TANK
(EXISTING HYOR<X.. YSIS TANK)
19,900 GAL
/
/
TRENCH WATER
TRANSFER PUMPS
EXISTING CONTAINMENT
RAW WATER
TRANSFER PUMPS
EXISTING CONTAINMENT
DATE ~r,,
SCAI..£: ~
{jj:,tfonal Starch and Chemical Company
SALISBURY PLANT OPERABLE UNIT 3
GROUNDWATER REMEDIATION SYSTEM
TO AERATION
TANK NO. 4
TO AERATION
TANKS 1, 2. J
PROCESS FLOW DIAGRAM
SHEET 1
MARCH 1997 FIGURE 3-lA
_J
r=---------------------------'----------
1
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FROM TRENCH WATER
EOUAUZATION TANK
FROM OOJ
EOUAUZATlON TANK
l D-\ \----0 \-0 •ow
A.ERA TlON BLOWERS
•OV> MOVlJ
AERATION TANK
NO. 1
"''s---~------.~------//
~ rnSTINC LAGOON NO. 1 .
~ M0V21 D-\ MOV10
TREATtO WATER
TRANsrER PUMPS
-I
l \----0 \----0
•OV2 MQV14
AERATION TANK
NO. 2
l \----0 MOV22
R(OROJLA TION
PU•PS
D-\ l,IQV11
-I
l \----0 \----0
MOVJ M0V15
AERATION TANK
NO. 3
REOROJLA TlON
LINE
l \----0
MOV2J
NA TIJRAL CAS
\----0
OV>2 MOV4 T MOV16
-
AERATION TANK
" "
TO ATMOSPHERE
EXHAUST STACI(
HEAT
EXCHANGER
NO. 4
" "
J
THERMAL 0XI0IZ£R
', \./
I REV. OESCRIPTlON . DA TE Dl!..i:o r<: fai:J. =~ l Nj:rtlonal Slorch and Cht1mical Company
MOV24
" . I-<
I-<
BOOSTER FAN
PROCESS FLOW DIAGRAM
SHEET 2 -~ SALISBURY PLANT OPERABLE UNIT 3
~-------------------------,---------------~'"-"_.!_~_·,_!._"'_.·_. !'_.,_·".;._· _ •. _,.~-~------~--~-"""--"--~~-G_R_o_u_N_D_W_A_T_E_R_R_E_M_E_D_IA_T_1o_N~_s_Y_S_T_E_M_~ ___ M_A_RC_H_l9_9_7 __ ~ ___ F_IG_U_R_E_3_-_1s_~
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4.0 PRELIMINARY DESIGN
4.1 Preliminary Sizes and Preliminary Equipment List
Based on the Design Concept presented in Sections 3.3 and 3.4 of this Conceptual Design and
Preliminary Design Report NSCC has conducted Preliminary Design of the Groundwater
Pretreatment System for OU3 and the Trench Area. Preliminary sizes and dimensions of the
needed equipment for treatment of the contaminated groundwater from OU3 and the Trench
Area have been established. Table 4-1 presents the Preliminary Equipment List and their
sizes. As seen from the data presented in this table, the total dynamic heads (TDHs) of the
pumps have not been determined yet because the layout of the force mains have not been
finalized yet. Following approval of the Conceptual Design and Preliminary Design Report
by the USEPA and the NCDEHNR, National Starch and Chemical Company will finalize these
preliminary sizes and equipment list. All necessary revisions and modifications will be made
to assure fulfilment of all regulatory requirements.
4.2 Preliminary Design Drawings
Preliminary layouts of the proposed Pretreatment System for contaminated groundwater from
OU3 and the Trench Area have been prepared to reflect the Conceptual Design presented and
discussed in Section 3 of this Report. The Preliminary Design Drawings (Figures 4-1, 4-2 and
4-3) are included here as a part of the 30 percent design.
4.3 Air Permit Application
The proposed Diffused Air Stripping System followed by Thermal Oxidation of the exhaust
gases from the Stripping Tanks is expected to destroy all VOCs and SVOCs. The exhaust
from the Thermal Oxidizer will contain some harmless non-hazardous gases such as CO,, 0 2,
Cl, etc. National Starch and Chemical Company will apply for an air discharge permit from
the NCDEHNR following approval of the Conceptual Design and Preliminary Design Report
by the USEPA and the NCDEHNR.
C:1PROJECTSISLSBRYOU310U3CNDES.SV
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l.
2.
3.
Table 4-1
Groundwater Remediation System -Operable Unit 3
Preliminary Equipment List
Extraction Well Pumps
Pump Capacity TQtl!I D):'.namic Head
Well No. gp_m fl
NS-45 2 To be determined
NS-46 6 To be determined
NS-47 2 To be determined
NS-48 14 To be determined
NS-49 15 To be determined
NS-50 5 To be determined
NS-51 10 To be determined
NS-52 5 To be determined
NS-53 20 To be determined
NS-54 5 To be determined
Area 2 Surge Tank (for Wells NS-45. NS-46 and NS-4 7)
Number of Units
Capacity
Dimensions
Material
2,000 gallons
7 ft. Diameter x 7'-6" High
Polyethylene
Area 2 Transfer Pumps A2TP1 & A2TP2 (Area 2 Surge Tank to Raw Water Equalization
Tank)
Number of Units
Type
Capacity
2
Centrifugal
100 GPM -TOH to be determined
C:IPROJECTS\SLSBRYOU3'0U3CNDES.SV
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4.
5.
6.
7.
8.
Table 4-1 (Continued)
Groundwater Remediation System -Operable Unit 3
Preliminary Equipment List
OU3 Raw Water Equalization Tank (existing Hydrolysis Tank T-1005)
Number of Units
Capacity
Dimensions
Material
I
19,900 gallons
I 3'-0" Dia. x 20'-0" High
FRP
Trench Water Equalization Tank (existing Sludge Holding Tank T-1007)
Number of Units
Capacity
Dimensions
Material
11,300 gallons
12'-6" Dia. x 12'-0" High
Epoxy coated carbon steel
Raw Water Transfer Pumps RWTPI and RWTP2 (Raw Water Equalization Basin to
Aeration Tanks I, 2 and 3)
Number of Units
Type
Capacity
2
Centrifugal
350 GPM -TOH to be determined
Trench Water Transfer Pumps TRTPI and TRTP2 (Trench Water Equalization Basin to
Aeration Tank 4)
Number of Units
Type
Capacity
Aeration Tanks I, 2, 3 and 4
Number of Units
Capacity
Dimensions
Material
2
Centrifugal
350 GPM -TOH to be determined
4
20,000 gallons operating
28'-0" long x 12'-0" wide x IO' high
8' water depth
Epoxy primed and painted carbon steel
C:1 PROJECTS\SLSBR Y· OU3'0U3CNDES.SV 34
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9.
I 0.
12.
13.
14.
Table 4-1 (Continued)
Groundwater Remediation System -Operable Unit 3
Preliminary Equipment List
Aeration Blowers ABLI, ABL2, ABL3 and ABL4
Number of Units
Capacity
Accessories
4
500 SCFM at 6 psi
Inlet and Discharge Silencers, Inlet Filter
Aeration System for four Aeration Tanks
Type
Number of discs
Diameter of discs
Fine bubble aeration using ceramic discs
184 per tank (23 x 8)
9"
Treated Water Transfer Pumps TWTPI and TWTP2 (Aeration Tanks to Lagoon No. I)
Number of Units
Type
Capacity
2
Centrifugal
350 GPM -TOH to be determined
Recirculation Pumps RCP 1 and RCP2 (Aeration Tanks to Heat Exchanger)
Number of Units
Type
Capacity
Thermal Oxidizer
Number of Units
Accessories
Heat Exchanger
Number of Units
Accessories
2
Centrifugal
350 GPM -TOH to be determined
Booster Fan, Combustion Air Blower, PLC Control
Corrosion Control Assembly
C:\PROJECTSISLSBR'(l0lJ310U3CNDES.SV 35
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I 6.
17.
I 8.
;,
I 9.
Table 4-1 (Continued)
Groundwater Remediation System -Operable Unit 3
Preliminary Equipment List
6" Motorized Butterfly Valves MOY!, MOV2, MOV3, MOY4 (influent to Aeration
Tanks I, 2, 3 and 4), MOV5, MOV6, MOV7, MOY8 (suction lines from Aeration Tanks
I, 2, 3 and 4 to Treated Water Transfer Pumps/Recirculation Pumps)
Number of Units
Type
Size
Service
8
Butterfly
6"
Water
6" Motorized Butterfly Valves MOV9, MOYI0, MOY! I, MOYl2 (Air supply lines to
Aeration Tanks I, 2, 3 and 4) MOYl3, MOYI4, MOVl5 and MOY! 6 (Air exhaust lines
from Aertion Tanks I, 2, 3 and 4)
Number of Units
Type
Size
Service
8
Butterfly
6"
Air
6" Motorized Butterfly Valves MOY I 7, MOY 18, MOY 19, MOY20 (Recirculation Line
suction from Aeration Tanks I, 2, 3 and 4), MOY2l, MOY22, MOV23 and MOY24
(Recirculation Line discharge to Aeration Tanks I, 2, 3 and 4).
Number of Units
Type
Size
Service
8
Butterfly Valve
6"
Water
Reactor Tank Level Sensors (one in each Aeration Tank)
Number of Units
Type
Output
Material
4
Pressure Transducer type
4-20 mA
17-4 PH stainless steel sensor
304 stainless steel housing
Extraction Well Level Sensors
Number of Units
Type
10
Three electrodes (ground, high level and low level)
C:1PROJECTSISLSBRY•OUJ'"OU3CNOES.SV 36
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20.
21.
22.
23.
24.
Table 4-1 (Continued)
Groundwater Remediation System -Operable Unit 3
Preliminary Equipment List
Number of controller relays 2 (high level and low level) per well
Flow Meter FM 1 (Discharge to Lagoon No. I)
Number of Units
Type
Size
Indicator
Outputs
Range
ElectroMagnetic Flowmeter
6"
Flow in gpm and totalizer in gallons
4-20 mA
0 to 350 gpm
Flow Meters for Extraction Wells
Number of Units
Type
10
Propeller type sensor, analog flow indicator
Pressure Switches (Discharge from each Aeration Blower, suction to Thermal Oxidizer)
Number of Units
Type
Operating Range
Automatic Sampler
Number of Units
Type
Unit Heaters
Number of Units
Type
Size
5
Low Differential Pressure Switches
Single Pole Double Throw
9 to 85" H,O for Blowers, TBD for Thermal Oxidizer
Programmable Refrigerated Composite Sampler
4
Electric
To be determined
25. Exhaust Fans
Number of Units
Size
C :1 PR OJE CTS\SLSBR Y' OlJJIQtJ3CNDES. S V
2
To be determined
37
•~------~---------------------~7
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~
N. C. GRID NORTH (NAO SJ)
_J \
/
/
------~
NS-47
I
I NEW
BUILDING---',-------...
SEE FIGURE 4-3
I
\
\
\
\
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I
,,--...
X
0
0:::
Q_
Q_
<t:
----✓
w z
_J
>-f---
0::: w
Q_
0
0:::
Q_
SEE FIGURE 4-2
' ,,
LEGEND:
• - - - -• ABOVE GROUND PIPING FROM WELLS
NS-45
SCALE:
I-
0 100 200
EXTRACTION WELLS
300 600
FEET
{H;atlonal Starch and Chem;ca/ Company GROUNDWATER REMEDIATION SYSTEM
PRELIMINARY SITE LAYOUT
SALISBURY, NC PLANT MARCH 1997 FIGURE 4-1
_J
rr---------------:--:--------======--:---=--=-------------'--------~7
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\ NS-:
X
AREA 2
SURGE TANK--\--'
-----NS-45
NEW TREATMENT
BUILDING~.----~
SEE FIGURE 4-3
()
N. C. GRID NORTH (NAO 83)
LEGEND:
-.. --ABOVE GROUND PIPING FROM WELLS
NS-45 EXTRACTION WELLS
{R;atlonal Starch and Chemical Company
SCALE:
0 50 100 200 JOO
FEET
GROUNDWATER REMEDIATION SYSTEM
PRELIMINARY SITE LAYOUT
~~---------------~~-------------------------_J ____ sA_L_1s_B_u_RY_._N_c_P_LA_N_T ___ L__'M~A:".'.RC:'.'._H__'..:19'._::97'._ _ _L_'F:.'.':IG'.':_UR~E:....'.4~-~2-_J_J
r.----------------------------------------------i7
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L
11&31
RECIRCULATION
PUMP NO. I
0
' "' N
AERATION
TANK NO. 1
1Fe11
RECIRCULATION
PUMP NO. 2
AERATION
TANK NO. 2
AERATION
TANK NO. J
11931
TREATED WATER
TRANSFER PUMP
NO. 1
AERATION
TANK NO. 4
1R11
TREATED WATER
TRANSFER PUMP
NO. 2 TRENCH WA TtR
EQUALIZATION TANK
1 ..... 11 TRENCH WATER u::._-=:.Jj ~ANSFER PUMP NO. 1
1~11 TRENCH WATER ucc.......;;;~ ~ANSfER PUMP NO. 2
>-----------------------11·-a·-------------------------1
COSTER
FAN
D
HEAT
EXCHANGER
AERA TIQN Bl OWERS
NO. 1 NO. 2 NO. J NO. 4
J.eU Li.2. ALAM. Sc.0., P.E.
-TH CAIIO.JNA P.E. NO.
R{V. DESCRIPTIClf(
RAW WATER
ANSfER PUMP
NO. I
11H1
RAW WATER
EOUAUZATION TANK
r----t---------c----j SCAI..£: l/UI" • 1•-0•
{jf;atfonal Sfarch and Ch•mfoaf Campany
SALISBURY PLANT OPERABLE UNIT 3
GROUNDWATER REMEDIATION SYSTEM
TREATMENT BUILDING
PRELIMINARY EQUIPMENT LAYOUT
MARCH 1997 FIGURE 4-3
_J
i'= "' 0 z
9
"' c.,
Li
z:
BAR GRAPH
::i en
SCALE: 1 • = 40'
~ rll71 Iii HI m!M¥f¥i4W fiii#iiiAA
871 G -~ 7-¥Pifi4§itiiiW 0 20 40 M 120
Ii!! SITE
,
160
TOPOGRAPHIC SURVEY FOR: NATIONAL STARCH &
CHEMICAL COMPANY
I ,
I
NOlE:. ELEVATIONS BASED ON N.G.V.D. OF 1929 t.10N.
"10 JAS 1966 790" -ELEVATION: 789.-452'
LOCKE TOWNSHIP -
DEED BOOK
BOOK OF t.1APS
TAX t.1AP
SCALE: 1 • ·= 40'
ROWAM CO., N.C.
PAGE .PAGE
PARCEL
DAlE: 1-20-97
AIRPORT ROAD
,,,111111,,,, ,,, ,, ,,, -<,\-\ CAflo ,,, •••o~ •••••••• (_IA.',,,. "' ••• ST •• . .,.. ,,,. ~ ~ ··<c,.o' '=~;.-. ..., \ = ,~ 0~ ~ : . . \ ~ :: i L-2667 i i :.:v!r-ct:a:: ~ (1 \-Y-i: .. -1..0/ /f f <:. 1;, ·-.~ SUR-lt·• .::,Q:' •• . ·:!-. ~o .·•········ ... ,<?;; ........
',A l S l~~ ,,
NOlE : THIS t.1AP IS NOT PREPARED FOR RECORDATION~••· H 11,, •••'
SURVEY & MAP BY SHULENBURGER SURVEYING CO.
516 N. MAIN ST., SALISBURY, N.C. PHONE [phone]
• •• j
' ''
,.. ·, j
□ •
0
• "' 181
It
RW
NS-37 • NS-38
Ell NS-01A
Ell EX-06
Ell EX-05 Ell EX-07
Ell EX-08
Ell EX-011
Ell EX-10
Ell NS-03
NOTE: ELEVATIONS BASED ON N.G.V.D. OF 19211 MON.
•10 JAS 1966 790" -ELEVATION: 789.-152'
LEGEND
Existing Stone
New Cone. Man •
Existing Iron
New Iron
Point
Nail
Centerline
Right-of-Way
-------
Ell NS-24
Ell NS-12
Ell NS-45 NS-43
SP-1'-ia,,SP-2
'el......sP-3
(
NS-46
SP-6 NS-36
SP-;~ \ NS-35
NS-47
' NS-44
B.C.-4
NS-40\
NS-39~
NS-54'--e
Ell NS-48
B.C.-1
NS-501 _
........ NS-49
fNS-51
NS-42li E&NS-13
NS-41
.......:_NS-52 Ell NS-53 SP-7
SP-8
Ell NS-14
,':
)\'r / ::u I
□ SP-4
NS-34
' NS-33
AIRPORT ROAD
n' OJ
C < z ~
i!:
25 z
C ~
c..i
z
Point Northing Easting
Point
NS-01A
NS-OJ
NS-12
NS-13
NS-14
NS-24
NS-33
NS-34
NS-35
NS-36
NS-37
NS-38
NS-39
NS-40
NS-41
NS-42
NS-43
NS-44
NS-45
NS-46
NS-47
NS-48
NS-49
NS-50
NS-51
NS-52
NS-53
NS-54
Point
EX-05
EX-06
EX-07
EX-08
EX-09
EX-10
B.C.-1 68777 3. 0806 1544356.4238
B.C.-2 687746.4449 1544300.4484 B.C.-3 687675. 7411 1544164.6780
B.C.-4 687658.2901 1544127.9325
Point Northing Easting
SP-1 688038.5712 1543935.6977
SP-2 688030.1817 1543939.7733 SP-3 688020.8312 1543944.1124
SP-4 687994.0875 15-44665.7373
SP-5 688085.4662 1544172.8738
SP-6 688088.4189 1544191.5383 SP-7 687348.4545 15+.298.8776
SP-8 687343.0814 1544285.5106
(Top of Casing)
Northing
689016.9080
687754.3168
687389.6391
687406.9616
687201 .3077
688457.9525
887269.0518
687282.8024
688123.6266
888136.6160
689191.1974
689179.4258
687404.1162
687408.3171
687376.6586
687385.9925
688212.5863
666200.4359
688229.2728
688086.4757
688082.5678
687871.3146
687465.0684
687467.6553
687393.2356
687348.0701
687307.9678
687364.1173
Northing
688308. 7427
688362.0564
688316.3405
688100. 7920
687932.6444
6877 34.11650
Eostlng Elevation
1541957.9848 787 02'
1543408.5162 77•UB'
154.1581. 7078 777.36'
15+1449. 7632 762.69'
15H453.2417 765.36'
1543548.9324 758.32'
1544769.7920 776.36'
154-4783.0360 776.27'
1544312.9883 746.11'
1544306.8070 745.59'
1543;169.3651 746.11'
1543372.5748 745.61'
1544177.8866 769.91'
1544,87.5495 769.34'
1544361.9094 766.03'
1544..359.9315 766.16'
1544547.1130 759.38'
1544552. 8889 759.30'
154-4107.5843 754.85'
154-1213.3177 768.99'
154-4217.4011 769.62'
1544305.3300 770.22'
1544326.4230 766.98'
154-4321.9131 766.08'
154-4395.4143 764.98'
154-4377. 7372 764.67'
1544135.1892 770.13'
1544" 82.8757 770.28'
(Top of Cosing)
Ea•ting
1542'320.1579
1542 379.1826
154 2999. 2846
1543043. 9496
1542857.9606
1542879.8511
Elevation
781.26'
788.28'
789.23'
789.19'
782.29'
775.92'
BAR GRAPH • • • • • • • • • • 0 100 200
SCALE: 1 • = 200'
400 600
WELL LOCATION SURVEY FOR:
800
JVATIONAL STARCH cl: CHEMICAL CO.
·,
SCALE: 1 • -200'
DATE: 1-21-97
LOCKE TOWNSHIP, ROWAN COUNTY, NORTH CAROLINA
TAX MAP 471
SURVEY AND MAP BY SHULENBURGER SURVEYING COMPANY
MS N. MAIN ST., SALISBURY, N.C. PHONE: [phone]