NC0005274_Monitoring Information_20091028

NPDES DOCUHENT SCANNING COVER SHEET
NPDES
Permit:
NC0005274
Document Type:
Permit Issuance
Wasteload Allocation
Authorization to Construct (AtC)
Permit Modification
Speculative Limits
Monitoring Information
Instream Assessment (67B)
Environmental Assessment (EA)
Permit
History
Document Date:
October 28, 2009
This document its printed on reuise paper - ignore arty
contest on tame reszerse side

EVALUATION OF BEST AVAILABLE
TECHNOLOGY ECONOMICALLY
ACHIEVABLE (BAT) FOR CONTROL
OF NUTRIENT DISCHARGES
Prepared for:
Crompton & Knowles Colors Incorporated
PO Box 848, Spencer Mountain Road
Lowell, NC 28098
Prepared by:
AWARE Environmental Inc.®
9305-J Monroe Road
Charlotte, NC 28270-1490
AEI Job No. N272-11
Document No. 27211r001
October 1999

Poll
Section No.
1.0
1.1
1.2
1.3
TABLE OF CONTENTS
Description Page No.
TABLE OF CONTENTS i
LIST OF TABLES iii
LIST OF FIGURES iv
LIST OF APPENDICES iv
EXECUTIVE SUMMARY 1
BACKGROUND 1
EXISTING FACILITY EVALUATION 1
BAT ANALYSIS 2
2.0 INTRODUCTION 4
,.., 2.1 NPDES PERMIT 4
2.2 DEFINITION OF BAT 8
2.3 STATE NUTRIENT LIMITATIONS 9
2.4 BAT STUDY 9
3.0
'a' 3.1
3.2
3.2.1,
3.2.2
3.2.3
3.3
4.0
4.1
4.1.1
4.1.2
4.1.3
4.1.4,
4.2
rim 4.3
5.0
5.1
5.1.1
5.1.2
5.1.4,
Fowl
27211r001
faq
WASTE REDUCTION AND MINIMIZATION 14
AZO DYE PRODUCTION 14
POLLUTION PREVENTION 14
State of North Carolina Pollution Prevention Review 15
CKCI In -Plant Phosphorus Control 15
CKCI Pollution Prevention 19
INDUSTRY WIDE POLLUTION PREVENTION ACTIVITIES20
WASTEWATER TREATMENT OPERATIONS 21
WASTEWATER TREATMENT SYSTEM 21
MSS and F/M 26
Sludge Age 26
D.O. 26
Aeration Basin Temperature and pH 27
PROCESS WASTEWATER CHARACTERISTICS 28
REFRACTORY NITROGEN 29
WWTP OPTIMIZATION AND NUTRIENT USAGE 32
NUTRIENT REQUIREMENTS 32
Sludge Age 33
Treatment Temperature 34
Carbonaceous Waste and Treatment Configuration 34
Wastewater Chemistry 36
FINAL 10/99

moon
11.
OMNI
5.2 NUTRIENT OPTIMIZATION 32
5.2.1 Analytical Monitoring 38
5.2.2 Target Nutrient Addition 40
5.3 PROCESS PERFORMANCE 40
5.4 BASELINE PHOSPHORUS 45
5.5 BASELINE NITROGEN 48
6.0 NUTRIENT REDUCTION TECHNOLOGIES 50
.-7 6.1 CHEMICAL PRECIPITATION 50
6.1.1 Jar Testing Procedures 50
6.1.2 Chemical Screening Jar Test Results 52
6.1.3 Dosage Optimization Jar Test Results 55
6.1.4 Sludge Production 58
6.1.5 Precipitation Conclusions 60
7 6.2 PRETREATMENT WITH OZONE 60
6.2.1 Pretreatment of Samples with Ozone 60
6.2.2 Aerobic Batch Treatment 61
6.2.3 Results and Conclusions 64
1
9 6.3 PAC ADSORPTION TESTING 64
6.4 HYDROGEN PEROXIDE PRETREATMENT 66
6.4.1 Pretreatment of Samples with Hydrogen Peroxide 66
6.4.2 Aerobic Batch Testing 68
6.4.3 Results 68
6.5 EXTENDED AERATION 71
6.5.1 Aerobic Batch Testing 71
6.5.2 Results 71
1 6.6 ANAEROBIC PRETREATMENT 73
6.6.1 Overview of Batch Testing 73
6.6.2 Sample Collection 73
6.6.3 Aerobic Control Reactor 73
6.6.4 Anaerobic Pretreatment Reactor 75
6.6.5 Results and Conclusions 77
6.7 RESIN ADSORPTION 78
6.8 SUMMARY OF RESULTS 78
7.0 COST EFFECTIVE BAT ANALYSIS OF
ALTERNATIVE TERTIARY TECHNOLOGIES 80
7.1 PRECIPITATION USING FERRIC CHLORIDE FOR
PHOSPHORUS REDUCTION 82
7.2 ADSORPTION USING A MACRORETICULAR RESIN FOR
ORGANIC NITROGEN REDUCTION 85
7.3 BAT APPLICABILITY 90
7.4 BAT DEFINITION 90
27211r001 ii FINAL 10/99

MN
MIR
mg
Pull
PER
PPri
PECI
LIST OF TABLES
Table No. Description
2-1
2-2
3-1
4-1
4-2
5-1
5-2
5-3
5-4
5-5
6-1
6-2
6-3
6-4
6-5
6-6
6-7
6-8
6-9
6-10
6-11
6-12
6-13
6-14
6-15
6-16
7-1
7-2
F.+ 7-3
7-4
Summary of Permit Discharge Limits
Effluent Limitations
Summary of Phosphorus Loading and Discharge
Concentrations Following Accidental Flushing of Scrubber
Process Design Summary
Summary of Waste Treatment Operating Conditions
Summary of Mixed Liquor Utilization Rates
Summary of Nutrient Monitoring
Summary of Target Phosphorus Dosages
Summary of Target Nitrogen Dosages
Summary of Long Term Removal Efficiencies
Summary of Treatment Alternatives
Mixed Liquor Chemical Screening Jar Test Results
Final Effluent Chemical Screening Jar Test Results
Mixed Liquor Dosage Optimization Test Results
Final Effluent Dosage Optimization Test Results
Mixed Liquor Sludge Production Results — Repeat Testing
Results of Ozonation Pretreatment
Summary of Aerobic Treatment
Results Following Aerobic Treatment
Results of PAC Jar Testing
Aerobic Reactor Set -Up and Testing Conditions
Results Following Aerobic Treatment
Results Following Extended Aeration
Wastewater Characteristics
Summary of Reactor Conditions
Anaerobic Pretreatment Batch Study Results
Process Design Summary for Tertiary Treatment Using
Precipitation
Tertiary Treatment Technology Cost Estimates
Process Design Summary for Adsorption
Using a Macroreticular Resin
Summary of Nutrient Surcharges from Municipalities
27211 r001 iii FINAL 10/99

LIST OF FIGURES
Figure No. Description
1
2
3
4
5
6
7
9
10
PIR
„ n Appendix A
Appendix B
Appendix C
Appendix D
Appendix E
Appendix F
Pel
Nutrient Contribution from CKCI to Lake Wylie
Process Flow Diagram of CKCI WWTP
CKCI Existing Nutrient Feed Systems: Phosphoric Acid and Urea
Effluent Total Nitrogen (TN) vs. Total Non -Refractory Nitrogen (TNN)
Equilibrium Solubility Diagram for Fe, Al, and Ca
Full -Scale Effluent BOD5 and TSS
Full -Scale Effluent Concentrations
Full -Scale Effluent Organic N, NO2/NO3-N and NH3-N
Tertiary Treatment: Precipitation with Ferric Chloride
Tertiary Treatment: Adsorption with Macroreticular Resin
LIST OF APPENDICES
Contribution of Nutrients from CKCI to Lake Wylie
Summary of Full -Scale Monitoring Data
NCDENR Site Visit Report
Summary of BOD5 and COD Utilization Rates
Statistical Analysis of Nutrient Discharges
Alternative Treatment Design and Cost Estimates
27211r001
iv FINAL 10/99

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SECTION 1.0
EXECUTIVE SUMMARY
1.1 BACKGROUND
Crompton & Knowles Colors Incorporated (CKCI) operates a textile dye manufacturing facility
in Lowell, NC. This is a batch manufacture facility-whieh produces -a wide range of dyes, _
primarily azo, for the textile industry. r The batch manufacturing results in a wide variety of
products and variable wastewater characteristics due to batch operations.
The wastewaters generated by the facility are treated in the plant's BAT treatment facility and
are discharged into the South Fork of the Catawba River under an NPDES permit issued by the
State of North Carolina. The State of North Carolina is proposing to develop nutrient limits
for dischargers into the headwaters of Lake Wylie. The proposed limits are based on a
summer -time monthly average total nitrogen (TN) limit of 6 mg/L and a monthly average total
( TP limit of 1 mg/L, unless a facilitycan determine that it is beyond reasonable
phosphorus ( ) g � Y
BAT to reach such concentrations of nutrients, at which time the division will apply BAT
limits based on the results of a BAT study which was conducted by the discharger. CKCI has
conducted a BAT technology evaluation of its facility.
1.2 EXISTING FACILITY EVALUATION
The waste treatment facilities were evaluated to determine if the CKCI system meets the
requirements of the US EPA best available technology regulations. Based upon the wastewater
treatment plant design, the technologies cited by EPA for BAT in the organic chemical plastics
and synthetic fibers (OCPSF) guidelines, and the consistent compliance with the effluent
guidelines, CKCI has a BATfacility. As part of BAT technology, EPA recognizes the need
for proper nutrients in the operation of a biological treatment system. An evaluation to define
a baseline wasteload and alternative approaches for achieving the desired nutrient levels was
conducted. This included a waste minimization program, optimization of the existing
treatment system, and alternative treatment technology evaluation using laboratory and pilot
scale treatment systems.
27211r001
1 FINAL 10/99

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The results of the waste minimization program indicated that it is possible for CKCI to further
reduced wasteloads. /The only in -plant source of phosphorus is in the production of Blue B
Supra A. Tl s is only a very minor contributor to the wasteload. A phosphorus waste
reduction program has been developed which will reduce this discharge of phosphorus. CKCI
utilized the State of North Carolina Pollution Prevention Group to determine strategies for
reducing wasteloads. In addition, CKCI continues to implement procedures and programs and
works in conjunction with industrial associations to reduce waste generated at the facility.
I\ A sixteen -month study has been conducted to optimize the treatment plant. This study has
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been designed to meet all existing pollution criteria while reducing the nitrogen and .
phosphorus addition to the treatment plant. This time period was required in order to develop ( 2
the optimization program for the treatment plant and to provide optimized operation for a
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period of time to cover some of the wide variation in plant production. The results of this
study indicate that the baseline for the BAT economic analysis for the CKCI facility is a TP
discharge of 7.6 lbs/d and a TN discharge of 144.5 lbs/d. However, because of the r-e �f 1
this wastewater, the organic nitrogen portion of th 'TN si refractory . d will not affect
Sul eutrophication in Lake Wylie. Therefore it is proposed to base BAT on a total nonrefractory
nitrogen(TNN)f(cornib-ined ammonia nitrogen, nitrate nitrogen and nitrite nitrogen) discharge
0.4 �°may -
le' 1 , J
tam
lang
of 44 lbs/d.
1.3 BAT ANALYSIS
1794-1,
1,A9-;(0) s,* ar4
The State plans to implement discharge limits for the industry based on BAT. In order to
define BAT, the treatment plant operations were optimized and a number of treatment
technologies were evaluated. Processes which were considered included biological treatment,
chemical precipitation for phosphorus removal, ozonation, adsorption using macroreticular
resins and activated carbon adsorption. Biological treatment testing included both extended
aeration and anaerobic pretreatment.
Extensive laboratory testing was conducted on these treatment technologies. The results of
these studies showed that the processes effective in providing additional nutrient removal were
27211r001
2 FINAL 10/99

ONIR
chemical precipitation for Bosphorus removal and; adsorption using the macroreticular resins
for organic nitrogen removal. The chemical coagulation process was able to achieve an
effluent TP of 1 mg/1. The resin treatment was able to reduce
mg/1.
Jo( c,
, 7,5"/""/..
TN from 52.5 mg/1 to
In order to compare these technologies with the baseline treatment from the optimized BAT
treatment system, a cost effectiveness evaluation was developed. A process design for the
treatment technology was developed and this was compared to typical costs for removal of both
TN and TP. A survey of wastewater treatment facilities with nutrient removal was conducted
and based on this survey it appears that the cost for phosphorus removal is $1.96 per pound
and the cost for nitrogen removal is $0.55 per pound. The estimated cost for reducin the total
phosphorus from the 2.75 mg/1 baseline level to the 1 1 level is
Mgtcost for reducing the total nitrogen from 52.5 mg/1 to 29.5 mg/1 i
neither of these technologies are cost-effective and based on the results of the study the
,, baseline totai phosphorus oaf1 g 2.75 m / nd total nitrogen of
I p
2.5 m re resent BAT. We
gi
166 per pound,
dthe
i
Therefore,
recommend that as a permit condition the permit be based on mass limits; therefore, the
monthly average discharge limits should be
s per day TP and 144.5 lbs per day TN
,....,?
oftIn evaluating the nitrogen discharge it was determined that a significant portion of the effluent
nitrogen is refractory non -biodegradable organic nitrogen. An alternative approach to setting
,the nitrogen ilimit is to set the limit based on a total non -refractory nitrogen (TNN) which
consists of the sum of the ammonia emitrogen, d nitrate nitrogen. This results
Forl
in a baseline nitrogen dischar,
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be set at 7.6 lbs per day TP an
/4(j);C' cot/6
4 E, I,Q,
&commended that BAT limits
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3 t � Q fi/
27211r001
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SECTION 2. 0
INTRODUCTION
Crompton & Knowles Colors Inc. (CKCI) operates a textile dye manufacturing facility in
Lowell, North Carolina (SIC Code 2865). This is a batch manufacturing facility that produces
a wide range of dyes (primarily azo) for use in the textile industry. All dyes manufactured at
the facility are produced in individual batches in order to prevent cross -contamination between
products.
The discharge of wastewaters from this industry are regulated under the guidelines set by the
U.S. Environmental Protection Agency (U.S. EPA) for the organic chemicals, plastics and
synthetic fibers (OCPSF) category - Subpart H specialty organic chemicals. The OCPSF
effluent guidelines define effluent limitations in 40 CFR 414.
The process wastewater from manufacturing operations are treated on -site at the CKCI
wastewater treatment plant (WWTP). The facility is a state of the art treatment system, which
was upgraded in 1995. The upgrade included all above -ground treatment units with a new
insulated primary clarifier, an insulated equalization basin and a secondary equalization basin,
a neutralization basin, and diffused air activated sludge treatment with fmal chemical polishing.
The addition of nutrients (nitrogen and phosphorus) is an essential part of the activated sludge
treatment system. C ct-
2.1 NPDES PERMIT
The treated wastewater is discharged to the South Fork of the Catawba River under NPDES
permit No. NC0005274, issued by the State of North Carolina (State). The discharge permit
went into effecter July -31, 1995. The NPDES discharge permit for the facility includes
discharge limits for flow, five-daybiochemical oxygen demand OD total suspended solids
g Yg (B s) P
TSS phenols,and of c clic aromatic hydrocarbons (PAHs)and for OCPSF priority
)� P Y Y Y P tY
pollutants. A summary of the non -priority pollutant permit discharge limits is presented in
Table 2-1.
,a„ 27211r001 4 FINAL 10/99

SUMMARY OF PERMIT DISCHARGE LIMITS
i t YSIA lXi�s d A I
xP{*'�a gametes ; >s
lei 1 ff "i�,,,I1A i tt±�d f PI
i ai �,ws. � ':i
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' ' Daly
2R s L 1 1 fY^{ �:' '4 4
4�.r,. r,. 'S.. ..(,.�. ,.yz�
Flow (MGD)
0.400
-
BOD5 (lb/d)
150.0
437.0
TSS (lb/d)
192.0
615.0
Phenols (lb/d)
0.66
1.32
PAH's (µg/L)
-
3.6 (1)
(1) PAH's equivalent to 0.012 lb/d
27211 r001 5 FINAL 10/99

In addition, the permit noted that the state plans to implement nutrient limits unless CKCI can
Pal demonstrate that BAT for their discharge justifies higher limits. Specifically, the permit states
as follows:
"It has been determined by the Division of Environmental Management (now called the
Division of Water Quality), through intensive water quality studies, that dischargers
upstream of Lake Wylie, including this discharge, need to control nutrients through the
application of best available technology which is economically achievable (BAT).
Crompton & Knowles shall provide the Division with a study which fully investigates
the feasibility of meeting a monthly average TP limit of 1.0 mg/L (based on weekly
samples) and a summertime monthly average TN limit of 6 mg/L. 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."
PRI
The North Carolina Department of Environment and Natural Resources (NCDENR) defines
TN to be the sum of the ammonia nitrogen, organic nitrogen, nitrite nitrogen and nitrate
nitrogen.
The U.S. EPA basis for the OCPSF effluent limitations is the Development Document for
Effluent Limitations Guidelines and Standards for the Organic Chemicals, Plastics and
Synthetic Fibers, October 1987 (Development Document). This document specifies minimum
technology requirements and in -plant controls to comply with Best Available Technology
Which Is Economically Achievable (BAT) criteria.
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The OCPSF effluent guidelines provide BAT criteria for a number of constituents in the CKCI
effluent. Effluent limits for the CKCI facility, based on the OCPSF BAT effluent guidelines
for priority pollutants, are presented in Table 2-2. The effluent guidelines are based on the use
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of BAT treatment technology and strictly regulate the pollutant discharge from the CKCI
facility.
0.4
,.w 27211r001 6 FINAL 10/99

TABLE 2-2
EFFLUENT LIMITATIONS
Parameter.:
-
} ._
_
Daily
Maximum
(lb/d)
Monthly
Average
`!/d)
Parameter Q , ` _�
; i ...
:Daily ,
Maximum
Monthly,
Average
(lb/d,..
<..(lblci},
Acenaphthene
0.197
0.073
Naphthalene
0.197
0.073
Acrylonitrile
0.807
0.320
Nitrobenzene
0.227
0.090
Benzene
0.454
0.123
2-Nitrophenol
0.230
0.137
Carbon Tetrachloride
0.127
0.060
4-Nitrophenol
0.414
0.240
Chlorobenzene
0.093
0.050
2,4-Dinitrophenol
0.410
0.237
1,2,4-Trichlorobenzene
0.467
0.227
4,6-Dinitro-o-cresol
0.924
0.260
Hexachlorobe7'ene
0.093
0.050
Phenol
0.087
0.050
1,2-Dichloroethane
0.704
0.227
Bis(2-ethylhexyl)phthalate
0.931
0.344
1,1,1-Trichloroethane
0.180
0.070
Di-n-butyl phthalate
0.190
0.090
Hexachloroethane
0.180
0.070
Diethyl phthalate
0.677
0.270
1,1-Dichloroethane
0.197
0.073
Dimethyl phthalate
0.157
0.063
1,1,2-Trichloroethane
0.180
0.070
Benzo(a)anthracene
0.197
0.073
Chloroethane
0.894
0.347
Benzo(a)pyrene
0.203
0.077
Chloroform
0.153
0.070
3,4-Benzofluoranthene
0.203
0.077
2-Chlorophenol
0.327
0.103
Benzo(k)fluoranthene
0.197
0.073
1,2-Dichlorobenzene
0.544
0.257
Chrysene
0.197
0.073
1,3-Dichlorobenzene
0.147
0.103
Acenaphthylene
0.197
0.073
1,4-Dichlorobenzene
0.093
0.050
Anthracene
0.197
0.073
1,1-Dichloroetlylene
0.083
0.053
Fluorene
0.197
0.073
1,2-trans-Dichloroethylene
0.180
0.070
Phenanthrene
0.197
0.073
2,4-Dichlorophenol
0.374
0.130
Pyrene
0.224
0.083
1,2-Dichloropropane
0.767
0.510
Tetrachloroethylene
0.187
0.073
1,3-Dichloropropylene
0.147
0.097
Toluene
0.267
0.087
2,4-Dimethylphenol
0.120
0.060
Trichloroethylene
0.180
0.070
2,4-Dinitrotoluene
0.951
0.377
Vinyl Chloride
0.894
0.347
2,6-Dinitrotoluene
2.138
0.851
Total Chromium
9.241
3.703
Ethylbenzene
0.360
0.107
Total Copper
11.276
4.837
Fluoranthene
0.227
0.083
Total Cyanide
4.003
1.401
Methylene Chloride
0.297
0.133
Total Lead
2.302
1.068
Methyl Chloride
0.634
0.287
Total Nickel
13.277
5.638
Hexachlorobutadiene
0.163
0.067
Total Zinc
8.707
3.503
27211 r001 7 FINAL 10/99

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2.2 DEFINITION OF BAT
The U.S. EPA describes BAT in the Development Document as follows:
"BAT effluent limitations guidelines, in general, represent the best existing
performance in the category or subcategory. The Act establishes BAT as the principal
national means of controlling the direct discharge of toxic and non -conventional
pollutants to navigable waters.
In establishing BAT, the Agency considers the age of equipment and facilities involved,
processes employed, engineering aspects of the control technologies, process changes,
cost of achieving such effluent reduction, and non -water quality environmental
impacts."
The Development Document and the OCPSF effluent guidelines allow OCPSF facilities to
`a' comply with the effluent criteria using either biological or non -biological treatment
technologies. CKCI has chosen to utilize biological treatment too omply with BAT criteria.
Based on the
technology requirements and CKCI's on -going compliance with effluent limits for
biological en -of-pipe treatment facilities, AWARE Environmental Inc. (AEI) has determined
that CKCI operates an OCPSF BAT treatment facility. CKCI has implemented additional
treatment beyond normal BAT in order to achieve optimum performance. These treatment
nori
technologies include primary and secondary load flow equalization with insulation of the
primary equalization tank, an insulated primary clarifier, chemically assisted secondary
clarification, and nutrient addition. Through conscientious and diligent operation of the
Pa, WWTP, CKCI has consistently been in compliance with the effluent BAT criteria. In addition,
CKCI has maintained an on -going effort to achieve optimum biodegradation and effluent
Frn, quality using
the current BAT treatment facility and continues to implement changes which will
improve the consistency of treatment and the performance of the WWTP.
The statistical procedure used by US EPA to develop monthly average effluent discharge limits
is presented in the Development Document. The procedure is based on the U.S. EPA use of
the 95th percentile of the daily data as the monthly average discharge limit. This same
statistical procedure is confirmed in the US EPA NPDES Permit Writer's Manual, December,
1996 as the basis for monthly average discharge limits.
,�, 27211r001 8 FINAL 10/99

WEN
2 3
34
D.
r
The OCPSF BAT effluent guidelines do not include effluent limits for total phosphorus (TP)
and total nitrogen (TN). However, the Development Document recognizes that the operation
of a BAT biological treatment system normally requires the addition of nutrients for optimum
treatment of OCPSF wastewaters.
?i
2.3 STATE NUTRIENT LIMITATIONS
The NCDENR has determined that dischargers upstream of Lake Wylie need to control
nutrient discharges. CKCI discharges into the South Fork of the Catawba River, which flows
into Lake Wylie. It is our understanding that the objective of the nutrient limits is to reduce
eutrophication in Lake Wylie. The NCDENR is proposing nutrient limits on both municipal
and industrial discharges to decrease eutrophication in Lake Wylie caused by the discharge of
nutrients from the rivers that feed the lake. Nutrient data from the 1995 Catawba River
..1
Basinwide Water Quality Management Plan (Catawba Plan) and CKCI's nutrient discharge
were reviewed in order to evaluate CKCI's contribution of nutrients to Lake Wylie. This data
is presented in Appendix A. The average nutrient contribution from CKCI is summarized in
Figure 1, based on long-term average values. Based on this data, CKCI is a minor contributor
to the nutrients in Lake Wylie and does not contribute to nutrient concentrations in the
Crowders Creek and Catawba Creek arms of Lake Wylie where eutrophication problems have
been identified.
INN
The Catawba Plan indicates that industrial discharges will be developed on a case by case basis
consistent with BAT. The Catawba Plan indicates that the proposed total phosphorus
limitation for domestic discharges of 1 MGD or greater is 1 mg/L. The proposed limit for
domestic discharges of less than 1 MGD is 2 mg/L total phosphorus.
2.4 BAT STUDY
A review of the historical operating data indicates that the CKCI treatment facility has not and
does not currently achieve the target 6 mg/L TN and 1 mg/L TP limits proposed by NCDENR.
Furthermore, this BAT study indicated that these limits would be exceeded during
27211r001 9 FINAL 10/99

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6000
5000
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5 3000
Z
2000
1000
27211s003
Fig1
Figure 1. Nutrient Contribution from CKCI to Lake Wylie
9 Total Load to Lake Wylie
CKCI's Contribution to Lake Wylie
L. Wylie = 6538 Ib/d
_. Wylie = 932 Ib/d
Total Phosphorus
CKCI
= 21.7 Ib/d
Total Nitrogen
10/25/99
10

optimum operation of the treatment system. Therefore, CKCI has chosen to undertake a
Re, detailed BAT evaluation.
Pawl
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Eng
ono
There are a large number of factors that need to be considered in the development of TN and
TP BAT limitations for the CKCI facility. These include:
• Age of equipment and facilities involved
• Processes employed
• Engineering aspects of the control technologies
• Cost of achieving effluent reduction
• Non water quality environmental impacts
• Requirements to operate treatment system in compliance with all established state
and EPA BAT effluent criteria
• Treatment process requirements for nutrient addition
AEI/CKCI have conducted a detailed BAT analysis. The study approach considered those
factors noted above for compliance with the proposed nutrient limits. As part of the overall
evaluation the factors evaluated included:
• Waste Reduction and Minimization Approaches;
• Optimization of the Wastewater Treatment Plant; and
• Evaluation of Alternative Nutrient Reduction Technologies.
The reasons
or including these in the BAT analysis are presented in the following paragraphs.
• Waste Reduction and Minimization Approaches
The
azo
CKCI facility utilizes batch production processes to produce a wide variety of
dyes. The production of azo dyes results in significant concentrations of
refractory (non -biodegradable) organic nitrogen in the effluent. The purpose of the
watte reduction and minimization phase was to consider options for decreasing waste
loafs to the WWTP in order to minimize nitrogen and phosphorus discharges. As
part of this phase of the evaluation the State Division of Pollution Prevention of
NCDENR assisted in the analysis of options for reducing the amount of waste
I., 27211r001 11 FINAL 10/99

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01114
generated at the facility.
• Optimization of the Wastewater Treatment Plant
OCPSF BAT technology recognizes the need for nutrient addition for the operation of a
BAT biological treatment process. The CKCI wastewater does not contain sufficient
dissolved phosphorus for optimum biological treatment. The purpose of the WWTP
optimization phase was to provide the nutrients required for achieving maximum
biodegradation in order to reduce the discharge of pollutants in the effluent. Through
improved biodegradation in the treatment system, nutrients become more easily utilized
in the
system. In order to optimize the treatment process, nutrients must be added to
the wastewater. Throughout the 16-month optimization phase, nutrient addition was
decreased in order to determine the minimum amount of nutrients required while
maintaining optimum treatment performance. Nutrient addition was reduced gradually
over time in order to minimize nutrients in the final effluent without compromising
effluent quality.
• Evaluation of Alternative Nutrient Reduction Technologies
The operation of the optimized WWTP indicated that the facility would not be able to
014 meet the target TN and TP limits proposed by NCDENR. The purpose of the nutrient
reduction treatment phase was to determine if the proposed BAT limits could be achieved
with additional treatment. During the nutrient reduction treatment phase, a number of
technologies were tested to determine whether or not additional treatment would
significantly decrease effluent TN and TP concentrations. Laboratory testing was
performed using wastewater samples from the CKCI WWTP. This evaluation included a
number of conventional treatment technologies and also aggressive non -conventional
treatment technologies.
AEI has assisted CKCI in the development and the conduct of the BAT study. This study has
included evaluation of in -plant controls and waste load reduction, optimization of the full-scale
BAT treatment system, literature reviews, and conduct of treatability tests to reduce effluent
,.., 27211 r001 12 FINAL 10/99

PIM
TN and TP. A summary of full-scale monitoring data collected during the BAT study is
included in Appendix B. This study was initiated in December 1997 and the objective of this
study was to determine if CKCI can comply with NCDENR's proposed target TNandTP
limits, and if not, to define "reasonable" best available technology which is economically
achievable ( AT) for removal of TN and TP from the CKCI discharge. The finding of the
BAT study is presented in this report.
27211r001
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0111
SECTION 3.0
WASTE REDUCTION AND MINIMIZATION
3.1 AZO DYE PRODUCTION
Azo dye manufacturing for use in the textile industry is the primary production operation at the
CKCI facility and is the primary source of nitrogen in the process wastewater. Azo dyes are
exemplified in the application of chemical conversion by diazotization and coupling, and
includes the double nitrogen bond as shown below.
—N=N—
.. The double nitrogen bond will typically be monitored as organic nitrogen. A review of the
literature indicates that this is a refractory non -biodegradable bond., Therefore, the azo dye
Ini
manufacturing process results in an effluent organic nitrogen which is not biodegradable and
which will pass through an OCPSF BAT treatment facility. ,,Since microorganisms in the % �T--
/, activated sludge process cannot degrade the organic nifro-gen, the nitrogen should n 17 14, r
tom= �
J
Iv,-
available to the microorganisms in the receiving waters that cause eutrophication. Therefore,
the refractory organic nitrogen would not contribute to eutrophication in the receiving waters
•
or further downstream.
There is a wide range of azo dyes that can be manufactured using the same basic
manufacturing equipment. Variations in the dye depend on color criteria and specific
applications. Because of the large variety of dyestuffs produced using a batch process, the
dyestuff production can vary significantly on day-to-day basis.
he batch nature of
roduction results in a wide variability in discharge organic nitrogen concentrations. The
discharge of organic nitrogen will vary on a day to day basis depending on the specific dyes
being produced.
3.2 POLLUTION PREVENTION
An important consideration in the control of nutrient discharges is the use of in -plant process
controls. Therefore, CKCI evaluated a number of waste minimization strategies and utilized
the services of the state pollution prevention group.
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3.2.1 State Of North Carolina Pollution Prevention Review
CKCI requested on -site assistance from the Division of Pollution Prevention of the
NCD NR in evaluating all current operations and waste reduction programs. The
objec ive of this program was an overall water minimization. In July 1996,
representatives from the NCDENR conducted a site visit at the CKCI facility in Lowell,
NC. This site visit included an evaluation of current practices and suggestions for
additional waste reduction and recycling techniques that could be implemented at this
facility. This evaluation concentrated on total wasteloads and wasteloads associated
with nutrient control programs. Based on the site visit and reviews of the CKCI facility
the NCDENR made several recommendations for waste reduction strategies and
provided information on other pollution prevention programs and valuable resources.
A copy of the site visit report is included in Appendix C.
The recommendation from the NCDENR to implement the use of wet/dry vacuums for
collecting spilled dye material in the truck and tray dryer area, was implemented by
CKCI. This strategy currently uses wet/dry vacuums for collecting spilled dye material
and to recover residual dye from blending equipment. This practice has helped to
reduce the pollutant load on the wastewater treatment plant.
In addition CKCI has investigated the feasibility of implementing other
recommendations proposed bythe NCDENR. Several of these recommendations were
P P
determined not to be applicable based on the nature of production at the facility. CKCI
continues to investigate alternative strategies in order to minimize waste generated at
the facility and reduce waste loading to the wastewater treatment plant.
3.2.2 CKCI In -Plant Phosphorus Control
A review of the production procedures for nutrient waste minimization noted that
sources of phosphorus in the process wastewater include the following two sources:
1. phosphorus in the City water source, added for corrosion control; and
27211r001 15 FINAL 10/99

2. the use of a packed -tower wet scrubber using phosphoric acid scrubbing
solution to remove amines during the production of one type of dye, Blue B
Supra.
An analysis for ortho-phosphorus was performed on a sample of City tap water and
resulted in 0.45 mg/L ortho-phosphorus. A second sample was analyzed, which indicated
a total phosphorus concentration of 0.77 mg/L. These are low, but are expected to pass
through the system and contribute to the effluent total phosphorus.
During production periods of Blue B Supra, a packed -tower wet scrubber (ID No.
CD9.2) using a phosphoric acid scrubbing solution is used to control the emission of
amines. The scrubber has a 200-gallon tank that holds a dilute phosphoric acid
solution. Approximately 5 gallons of 75 % phosphoric acid are used to make up the
scrubber solution, which is equivalent to 15.8 pounds of phosphorus. At the end of the
production week, the spent scrubber solution is discharged to the treatment system
equalization basins where it mixes with approximately 700,000 gallons of process
wastewater that has collected over the course of the production week. Up to 400,000
gallons of the equalization basin's contents are treated in the waste treatment system
over the weekend while the production facility is shutdown and the remaining balance
of that week's production wastewater is being treated.
The discharge from the scrubber has been identified as the major production source of
influent phosphorus during production periods of Blue B Supra dye. The discharge of
15.8 ounds of phosphorus to 700,000 gallons of process wastewater is equivalent to a
phos horus dosage of 2.7 mg/1 phosphorus (0.023 lb P/1,000 gallons) in the influent
process wastewater. This is slightly less than the recommended phosphorus dosage for
biological nutrient purposes for the CKCI WWTP.
On February 25, 1999, there was an accidental flushing of the scrubber and the
phosphorus -rich scrubbing solution was discharged to the waste treatment system. The
27211r001 16 FINAL 10/99

IMP
scrubber was refilled with fresh scrubber solution following the accidental flushing. On
the following day (February 26), because it was the end of the production week, the
spent scrubber solution was discharged to the waste treatment system. This resulted in
a total discharge of 31.6 lb P discharged to the treatment system over a two-day period.
During this time, phosphoric acid was also being fed to the aeration basin to provide
nutrients for the microorganisms. It was not realized at the time that the discharge
from the scrubber contained sufficient phosphorus to cause elevated concentrations in
the system. A summary of the phosphorus loading and effluent phosphorus
concentrations following the scrubber discharge is presented in Table 3-1. These data
show that the total phosphorus discharged from the scrubber, in conjunction with the
Cl
nutrient feed, caused elevated levels of effluent phosphorus for approximately 21
weeks. Blue B Supra was not being produced during the month of March, therefore the
scrubber was not operated during the following two weeks. The amount of phosphorus
POCI discharged to the system over such a short period of time exceeded the nutrient
requirements of the microorganisms in the biological treatment system. Because of the
continued addition of phosphoric acid to the aeration basin for nutrient purposes,
phosphorus levels remained elevated for several days. Additionally, lower flows
during the week of March 1 and minimal production during the week of March 8
caused phosphorus concentrations to remain elevated. Based on the effluent
phosphorus during this period, it was determined that in -plant controls would be
necessary in order to prevent excess phosphorus loading on the system when the
PIM
scrubber is being used.
In order to control the nutrient load and maintain low effluent phosphorus
concentrations, in -plant controls will be implemented to control the discharge of the
spent scrubber solution and control the nutrient feed accordingly. These in -plant
controls are outlined as follows:
27211r001 17 FINAL 10/99

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TABLE 3-1
SUMMARY OF PHOSPHORUS LOADING AND DISCHARGE CONCENTRATIONS
FOLLOWING ACCIDENTAL FLUSHING OF SCRUBBER
q
ay
Date '
Phosphorus Added
o#fo`r Biological
r icf r q art
`Y r3 • J
N utxzentrAdditaon,
(lb/d
�'Fhos hor us
. ,Discharged =
:` 3k dux iea
k.FX ,3 Aw - t
from,Scrubb"er
(lb/d) _
x tEffiuent
Sortho sph Phoorus
i e a'
1 h
f
(mg/L)
(lb/d).
Thurs.
2/25/99
5.8
15.8
0.497
0.90
Fri.
2/26/99
5.8
15.8
1.73
2.67
Sat.
2/27/99
4.4
0
NM
NM
Sun.
2/28/99
4.4
0
NM
NM
Mon.
3/1/99
4.3
0
1.99
2.71
Tues�!.
3/2/99
4.3
0
2.08
2.79
Wed.
3/3/99
4.3
0
3.5
4.58
Thurs.
3/4/99
4.3
0
3.75
5.07
Fri.
3/5/99
0
0
5.74
4.98
Sat.',
3/6/99
0
0
NM
NM
Sun.
3/7/99
0
0
NM
NM
Mon.
3/8/99
0
0
5.9
4.92
Tues.
3/9/99
0
0
4.24
4.42
Wedgy.
3/10/99
5.8
0
5.2
9.15
Thurs.
3/11/99
5.8
0
4.37
7.69
Fri.
3/12/99
0
0
2.13
3.09
Sat.
3/13/99
4.3
0
NM
NM
Suni
3/14/99
4.3
0
NM
NM
Mon.
3/15/99
4.1
0
NM
NM
Tues.
3/16/99
4.1
0
1.25
1.58
Wed.
3/17/99
4.1
0
1.445
1.84
Thurs.
3/18/99
11.8
0
0.15
0.27
Fri.
3/19/99
6.7
0
0.3
0.61
'°p NM = not monitored
27211r001
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FINAL 10/99

• Spent scrubber solution from the packed -tower wet scrubber will be discharged to a
holding tank prior to being discharged to the waste treatment system. From the
holding tank, the spent scrubber solution will be gradually discharged to the
equalization basins of the waste treatment system. This will prevent excessive
phosphorus loads from being discharged to the treatment system over a short period
of time.
Phosphoric acid will not be fed to the aeration basin for nutrient purposes during
periods when spent scrubber solution is being discharged to the waste treatment
system. The spent scrubber solution will serve as a source of phosphorus for the
microorganisms and will be discharged based on the recommended dosage of
phosphorus for nutrient control.
Phosphorus concentrations in the system will be monitored in order to control
phosphorus loading to the system. Nutrient levels in the system will be closely
monitored and controlled during periods when the scrubber is used, both prior to
and following the discharge of the spent scrubber solution.
These in -plant controls will reduce excessive phosphorus loading on the system in order
to control effluent phosphorus concentrations.
3.2.3 CKCI Pollution Prevention
In addition to the in -plant phosphorus controls, CKCI has incorporated several
important waste reduction and recycling activities as part of normal daily operations.
These activities include the following:
1 \J Multiple use of cleaning water in dyestuff reaction vessels;
)'N2.j Dewatering of wastewater sludge in order to reduce the volume of waste
produced; and
3. Implementation of a solid waste recycling program with over twenty items listed
for recycling or reduction.
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IMO
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CKCI also has in place projects which reduce waste such as the following:
1. Pallet rebuilding
2. Steel drum recycling
3. Cardboard recycling
4. Office paper recycling
5. Press cake box reuse
6. Unsolicited publication reduction
7. Aluminum can recycling
8. Wastewater treatment sludge reduction
9. Sonic deducting to reduce spray dryer washing
10. Control of spent phosphoric acid from scrubber
3.3 INDUSTRY WIDE POLLUTION PREVENTION ACTIVITIES
CKCI is participating on an on -going basis in several formal programs with the goal of
improving waste reduction practices and procedures at the facility. These include:
1. Responsible Care® - CKCI, as a member of the Chemical Manufacturers Association,
participates in the Responsible Care program, which includes a Pollution Prevention Code
of Management Practice.
2. ETAD/EPA - The dyestuff manufacturer's trade organization (ETAD) which CKCI is a
member and the EPA's Office of Pollution Prevention have entered into a joint effort to
monitor and encourage P2 and waste minimization efforts in the dye stuff industry. As an
EPAD member, CKCI has agreed to complete annual assessments of the number of
pollution prevention opportunities that are in place at the facility.
3. CKCI Waste Minimization Program - In coordination with the programs above, a broader
program has been established at this facility. A committee assembles on a quarterly basis
to discuss all valid, ideas and suggestions for the reduction of wastes in all areas, not only
pollution prevention but also recycling and improving treatment technologies.
27211r001
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URI
SECTION 4.0
WASTEWATER TREATMENT OPERATIONS
4.1 WASTEWATER TREATMENT SYSTEM
The process wastewaters from the CKCI facility are treated in an integrated BAT biological
treatment system. A schematic of the wastewater treatment process is presented in Figure 2
and a summary of the process design is presented in Table 4-1. The treatment system includes
a multi -stage equalization process, neutralization, chemical coagulation, primary clarification,
aerobic oxidation, secondary coagulation, secondary clarification, chemical conditioning and
recessed chamber dewatering. In conjunction with OCPSF BAT recommendations, nutrients
to
are added to the biological treatment process. �[Jreaind phosphoric acid are le nutrients
added to the influent in order to provide for healthy biological growth of the mixed liquor
microorganisms. Schematics of the nutrient feed systems are presented in Figure 3. A
cationic polymer is used in the primary clarifier to improve solids removal. Depending on the
chemical composition of the wastewater and the nature of the mixed liquor solids, either alum
or a cationic polymer is added to aid secondary clarifier settling. Frequently, neither alum nor
cationic polymer provides sufficient settling; therefore, bentonite clay is added to the aeration
basin to improve the floc structure and promote settling. Following final clarification, the
treated effluent is discharged to the South Fork of the Catawba River. Wasted primary and
secondary sludges are conditioned by ferric chloride then dewatered using a recessed chamber
filter press and transported off -site for disposal.
PIM
CKCI performs extensive monitoring of the waste treatment system in order to maintain
favorable conditions for optimum performance. Several of the key parameters that are
monitored are presented in Table 4-2. Conditions in the system are monitored on a daily basis
up to three times per day and adjustments are made in order to achieve target conditions. The
target operating conditions in Table 4-2 have been found to provide optimum performance in
the CKCI activated sludge system. The data for the average conditions show that conditions
are being controlled and maintained in the desired operating range. These conditions are
discussed below.
27211r001 21 FINAL 10/99

PROCESS WASTEWATER
AND PROCESS AREA
STORMWATER RUNOFF
October 14, 1999 1:53:54 p.m.
Drawing: V: \N 272\27211 FDI.DWG
LIFT STATION
SULFURIC ACID
OR
SODIUM HYDROXIDE
EQUALIZATION —A
PROCESS WASTEWATER
EQUALIZATION—B
EMERGENCY STORMWATER SURGE
FILTRATE TO
LIFT STATION
1
SLUDGE
FILTER PRESS
0�00000�0 .
.s..0000000000000�' �.
L'�OoO00000O0000000O'-
00 00
SLUDGE TO
LANDFILL
NEUTRALIZATION
UREA
PHOSPHORIC
ACID BENTONITE
POLYMER
PRIMARY
CLARIFIER
-
TTITTIF
WASTED
SLUDGE
AERATION BASIN
RAS
POLYMER
OR ALUM
SECONDARY
CLARIFIER
cn
SLUDGE HOLDING TANK
FINAL EFFLUENT
DISCHARGED TO THE
SOUTH FORK OF THE
CATAWBA RIVER
PROCESS FLOW DIAGRAM OF
CROMPTON & KNOWLES WWTP
SCALE NTS
DATE
OCT. 1999
APPROVED BY :
DESIGNED BY : L. GELLNER
DRAWN BY: MRW
REVISED
PROJECT NUMBER
N272-11
ffA re If"
ii 7INC
DRAWING NO.
FIGURE 2
22

Pal
Pal
law
osdi
TABLE 4-1
PROCESS DESIGN SUMMARY
Equalisation Basins (2)
Diameter
Volume
Depth
Total Detention Time @ 0.40 MGD
Primary Clarifier
Volume
Diameter
Side Water Depth
Surface Area
Surface Loading Rate @ 0.40 MGD
Aerati ? n Basin
Volume
Liquid Depth
Detention Time @ 0.40 MGD
Aeration System
lumber of Blowers
Horsepower, each
Total Horsepower Applied
Air Flow Rate, each
Discharge Pressure
Total Operating Capacity
Secondary Clarifier
Volume
piameter
Side Water Depth
Surface Area
Surface Loading Rate @ 0.40 MGD
Filter Press
Type
Sludge Handling Capacity
Final Processed Solids
Basin A
60 ft
996,670 gal
47 ft
Basin B
60 ft
424,115 gal
20 ft
3.6 days
275,000 gal
60 ft.
lO ft.
2826 ft
142 gpd/ft2
577,000 gal
20ft.
1.4 days
4
60 Hp
240 Hp
800 scfm
7-9 psig
3200 scfm
147,000 gal
147,000 gal
50 ft.
11 ft.
1960 ft2
204 gpd/ft2
Recessed Chamber
100 ft3/load
25% TS
27211r001
23
FINAL 10/99

1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
FLOWMETER
75%
PHOSPHORIC
ACID STORAGE
TOTE
PUMP
(MAGNETIC DRIVE)
NOTE: SYSTEM ACCURACY IS ±0.1 GALLON
75% PHOSPHORIC ACID
1
WATER SUPPLY
MAKE—UP TANK
FOR DAILY FEED OF
DILUTE PHOSPHORIC
ACID
(300 GALLONS)
PUMP (BELLOWS)
1000 ml/min
PHOSPHORIC ACID FEED SYSTEM
AERATION BASIN
50(# BAGS UREA
NOTE: SYSTEM ACCURACY IS ± 1 POUND UREA
(SYSTEM ALSO USED FOR DAILY BENTONITE ADDITION)
SCALE TO WEIGH
UREA
AGITATOR
UREA FEED SYSTEM
PUMP AERATION BASIN
(CENTRIFUGAL)
CKCI EXISTING NUTRIENT FEED SYSTEMS:
PHOSPHORIC ACID AND UREA
SCALE N.T.S.
DATE OCT. 1999
APPROVED BY : DRAWN BY: MRW
DESIGNED BY : L. GELLNER REVISED
Oc:lulht•t 21. 1'I.1!) 1.19:11 I1.m.
(bowing: V: \N212\2 /211 POI wG.f)wc:
PROJECT NUMBER'
N272-11
Me DRAWING NO.
9305—J MONROE RD. CHARLOTTE. NC 28270 FIGURE 3

owl
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TABLE 4-2
SUMMARY OF WASTE TREATMENT OPERATING CONDITIONS
S ( 1°i
A t }
?
A 4
t ;,
Ii d �� 1
t b'✓ i�{
lf
fie���t
, .
. (;?S !x` tt `: t Y•nYN:X `ti!, {I��■■• Me y■�■ ` x f
N Y ✓,t .2 R '' 9} 2 2'1 PA r, ff�, iii t
ae
hoA} oiii A.ES2
;..�{Ie1
II��
....f2
, ��u
e��Rr
tir. •.
} ?o .��- Y ie ✓
"r$
..?.•.
draa 98489).
,-, +f°�Tt I-iR t4 ..is;er^._
MLSS
5,000-6,000 mg/1
5,068 mg/1
F/M (COD)(')
0.10-0.20
0.16
Sludge Age (2)
20-50 days
>36 days (3)
Aeration Basin
D.O.
>2 mg/1
5-6 mg/1 (approx.)
Aeration Bain
Temperature
>20°C
28°C
Aeration Basin
pH
7.0-8.5
7.8
1214 (1) F/M is based on COD and MLSS instead of BOD5 and MLVSS.
(2) Sludge age is based on solids wasted and does not include influent and effluent solids.
(3) It is expected that sludge age averages higher than 36 days because of the higher
rim concentrations of primary clarifier effluent solids.
PPM
RIM
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27211r001
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4.1.1
Food
MLSS and F/M - The mixed liquor suspended solids (MLSS) concentration and
to -Microorganisms Ratio (F/M), expressed here as pounds of COD applied per
day per pound of mixed liquor suspended solids (MLSS), are important indicators of
conditions suitable for oxidation of organic materials. Higher MLSS concentrations are
maintained in order to maintain lower F/M conditions. The lower F/M levels normally
provide an improved environment for oxidation of organics. The target MLSS is used
to maintain the desired F/M. These levels have been shown to provide optimum
perfofmance in the CKCI waste treatment system. Based on this information, MLSS
and 1 /M do not appear to be limiting factors in the treatment of the wastewater.
4.1.2 Sludge Age - Sludge age represents the average time period the biomass remains
in the treatment system before being wasted. Typically, for a complete -mix activated
sludg system, a minimum sludge age of 2-8 days is needed for carbonaceous removal,
and a minimum of 5 days is required for nitrification. Longer sludge ages provide a
longer detention time and usually allow for more complete oxidation of BOD and
nitrogenous material. The CKCI activated sludge system utilizes a long sludge age in
order to achieve more complete oxidation of organics and nitrogenous materials.
Long r sludge ages from 20 to 50 days have been shown to provide sufficient time for
oxida ion of BOD in the CKCI activated sludge system. The data indicates that the
desired sludge age has been maintained and does not appear to be a factor in limiting
treatment of the wastewater.
4.1.3
D.O. -The desired minimum dissolved oxygen (D.O.) concentration for proper
biological oxidation and nitrification in an activated sludge system is 1.5 mg/L.
Adeq ate aeration is extremely important to ensure that D.O. levels are adequate at all
times throughout the aeration basin. The average aeration basin has been maintained at
approximately 5-6 mg/L throughout the study, which is excellent. The aeration system
includes coarse bubble diffusers, which are distributed uniformly over the entire
aeration basin floor. The aeration system provides consistently adequate D.O. levels
POI
27211r001 26 FINAL 10/99

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27211r001 27 FINAL 10/99
throughout the basins and provides a uniform mixing pattern. Based on this, D.O. does
not appear to be a factor limiting the treatment of the waste.
4.1.4 Aeration Basin Temperature and pH — The aeration basin temperature and pH
are important for maintaining proper conditions for biological growth. The CKCI
facilil y maintains the system within the desired conditions. The process wastewater is
usually discharged at a temperature greater than 30°C. Insulated equalization basins,
primary clarifier and aeration basin help to maintain warmer temperatures for the
activ ted sludge process. Proper pH levels are maintained through the use of
neu lization. The nitrification process appears to function best at temperatures in
excess of 20°C and pH levels of 7.2-8.5. The temperature and pH are in the ideal
range for biodegradation and nitrification. These do not appear to be factors limiting
the treatment of the waste.
In order to consistently comply with the effluent criteria, chemical coagulation is required.
Based on long term operations it has been found that alum or a cationic polymer is needed in
the secondary clarifier to aid settling. Depending on changes in production and the nature of
the influent wastewater, alum or polymer has been found to provide good solids — liquid
separation. It has been found that neither polymer nor alum is sufficient for consistently
providing good settling. The addition of bentonite clay to the aeration basin helps to improve
settling performance. The variability in chemical requirements appears to be a direct result of
changes in production. Therefore, the ability to alternate between both chemicals provides the
necessary operational flexibility needed in order to maintain low effluent solids. In general,
polymer addition is preferred because it provides better settling and forms a sludge that is
easier to dewater.
In order to evaluate the biological health of the treatment system, a microscopic evaluation of
the mixed liquor prior to the addition of any chemical coagulants was performed in April 1999.
The examination included a sludge settling test, evaluation of higher life forms, overall
appearance of floc, staining the sample with India ink for identification of filaments and a

quantitative polysaccharide analysis (the anthrone test). The results of the analysis indicated
the following:
• settling was poor with less than 5 % of the volume settling;
• higher life forms were present (stalked ciliates) indicating a healthy sludge;
• no filaments were observed in the sludge;
• India ink staining showed a high amount of viscous material around the flocs
indicating lower than normal bacterial density; and
• the sludge contained 3.3 % bacterial polysaccharide, which also indicates low
bacterial density in the sample.
Overproduction of filaments are usually a result of undesirable conditions in the treatment
process and usually result in poor settling; however, no filaments were observed in the sludge
sample. Therefore the poor settling in the sludge is not associated with overproduction of
filaments. There were some higher life forms present indicating a healthy sludge. Staining of
the sample with India ink showed a high amount of viscous material around the floc particles,
indicating low bacterial density in the floc. This material is not bacterial in nature and appears
to be associated with the nature of the wastewater. The results of the anthrone test showed
3.3 % bacterial polysaccharide on a dry weight basis in the mixed liquor sample, which is or"""
lower than normal (10-20%). The results of the anthrone test further suggest that higher —
MLSS levels are required for this operation and that this results in an operation that requires /
chemical assistance for solids -liquid separation.
4.2 PROCESS WASTEWATER CHARACTERISTICS
CKCI produces a wide variety of azo-based textile dyes. This is a batch production system and
is highly variable on a day-to-day basis due to customer demands for different dyes.
Typically, the facility produces 15-20 different dyes during an average production week.
Production of the dyes utilize a batch -type process in order to prevent cross -contamination
between products, which means that all of the dyes are produced in individual batches.
The operation of a batch dye manufacturing facility results in a highly variable wastewater.
Because of the many different dyes that the facility manufactures (up to 100 different dyes), the
27211r001 28 FINAL 10/99

chemical composition of the wastewater changes daily. Each individual batch of dye produces a
wastewater with different chemical characteristics. Because of the fluctuating wastewater flow
and variable chemical composition, the wastewater treatment process is more difficult than in
other types of production facilities, such as a textile plant or a commodity based OCPSF
chemical manufacturing plant. In these other types of facilities, the same product is produced
- continuously each day and results in a wastewater that does not vary significantly in chemical
composition and flow in comparison to a batch -type production process. The varying chemical
composition of the wastewater and fluctuating influent flow, due to the batch -type production
process at the CKCI facility, makes consistent performance of the wastewater treatment system
difficult.
4.3 REFRACTORY NITROGEN
The wastewater discharge for an azo dye manufacturing facility contains a significant amount
of organic nitrogen. Because of the daily changes in dye production, the chemical composition
of the wastewater is highly variable. Azo dyes contain varying levels of organic nitrogen,
depending on the dye formulation, and this causes variability in the influent wastewater
nitrogen concentration.
The waste treatment system is effective in treating the process wastewater to reduce BOD5 and
TSS with relatively low concentrations of effluent phosphorus, ammonia nitrogen, nitrate and
nitrite nitrogen. However, there is a significant portion of the organic nitrogen in the
wastewater that is not biodegradable and is refractory. The effluent is non -toxic (based on the
results of whole effluent toxicity tests), does not appear to affect water quality, and does not
cause a problem in the environment.
Because of the refractory nature of the effluent organic nitrogen, it will not be available as a
nutrient to the algae in the receiving waters and would not contribute to eutrophication. The
proposed effluent total nitrogen limits are being suggested in order to decrease the eutrophic
conditions in Lake Wylie. However, the majority of the effluent nitrogen from CKCI is non -
biodegradable and should not contribute to eutrophication in the South Fork of the Catawba
27211r001
29 FINAL 10/99

Nal
River or in Lake Wylie. In order to properly evaluate the nitrogen contribution from the CKCI
facility to eutrophication in the receiving waters, only the non -refractory portion of the
nitrogen (ammonia nitrogen, nitrite 'nitrogen and nitrate nitrogen) should be considered. The
portion of effluent nitrogen that would contribute to eutrophication is the total non -refractory
nitrogen (TNN). A chronology of effluent TN and TNN is presented in Figure 4. As shown
in this figure, a significant portion of the TN discharge is refractory and would not contribute
to eutrophication.
27211r001
30 FINAL 10/99

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Effluent Concentration (mg/L)
80
Figure 4. Effluent Total Nitrogen (TN) vs. Total Non -refractory Nitrogen (TNN)
70 -
60 -
50 -
40 -
30 -
20 -
10-
0
5/10/98
27211s002
BAT Fig4
11
\1
u n
u
it
n
11
J
n
e
u
u
— 9— Effluent TN (mg/L), 4-wk moving average
- Effluent TNN (mg/L). 4-wk moving average
n
rl
- r. 11
u
u
L'
u
11
r. s
A
7/5/98
8/30/98
10/25/98
12/20/98
2/14/99
4/11/99
6/6/99
8/1/99
Updated: 10/25/99

psei
gum
I
Awn solids — liquid separation, and to allow good sludge growth, nutrient utilization and minimum
effluent nutrient levels. A lack of nutrients usually results in inconsistent organic removal,
poor settling due to the formation of unhealthy biological floc or overpopulation of filamentous
organisms, and increased discharges of non -limited nutrients. Nutrient addition usually
SECTION 5.0
WWTP OPTIMIZATION AND NUTRIENT USAGE
A major work effort was implemented in order to optimize the nutrient feed to the CKCI
OCPSF BAT treatment system. The objective of this was to continue to comply with
program PY
all effluent requirements while providing only that level of nutrient addition required for good
treatment pl t nt performance.
5.1 NUTRIENT REQUIREMENTS
Nitrogen and phosphorus are essential nutrients necessary for proper system performance in a
biological wastewater treatment application. The OCPSF Development Document notes that
nutrient addition is required for operation of an OCPSF biological BAT treatment system. The
OCPSF Development Document states the following:
"For a biological system to function properly, nutrients such as organic carbon,
nitrogen, and phosphorus must be available in adequate amounts. While domestic
wastewaters usually have an excess of nutrients, industrial wastewaters are sometimes
deficient. If a deficiency is identified, the performance of an industrial wastewater
treatment plant can be improved through nutrient addition."
Proper nutrient addition is needed for optimum oxidation of the organics in wastewater, good
Pri
improves th treatment performance in nutrient -deficient systems because of more complete
oxidation of organics and healthier microorganisms.
Unlike municipal wastewaters, which are naturally high in nitrogen and phosphorus, industrial
wastewater is more likely to be deficient in nutrients. Like many industrial wastewaters,
CKCI's process wastewater is deficient in nutrients. The wastewater influent lacks phosphorus
and lacks nitrogen in a form that is readily available to the microorganisms. The primary
influent nitrogen component is organic nitrogen, which is in the form that cannot be readily
27211r001
32 FINAL 10/99

utilized by microorganisms. The original design of the treatment system called for the addition
of diammonium phosphate as a combined nutrient source; however, later it was recognized that
the system requirements would necessitate separate sources of nitrogen and phosphorus in
,aI, order to achieve the proper balance of nutrients for treatment of the CKCI wastewater.
Therefore, phosphoric acid and urea are added to the wastewater in order to provide the
correct amounts of nitrogen and phosphorus needed for proper biological growth and optimum
treatment performance.
MEI
It is essential to add nutrients in a form that can be easily utilized by the wastewater
microorganisms, such as phosphoric acid and urea. Usually in wastewater treatment
applications, j phosphorus is added in the form of phosphoric acid (ortho-phosphorus) and
nitrogen is added in the form of urea. The generally recommended nutrient needs of activated
sludge are one kg of phosphorus and five kg of nitrogen for every 100 kg of BOD5 oxidized (a •
BOD5:N:P ratio of 100:5:1). This ratio has worked for treatment of most industrial
wastewaters.
A typical bacterial cell has the following chemical composition:
C106H181045N 6P. The exact amount of needed nitrogen and phosphorus is dependent on the
carbonaceous yield factor, which is a variable dependent on substrate type. Assuming a yield
of 0.5 kg of bacteria produced per kg of B0D5 oxidized, the stoichiometric need for nitrogen
and phosphorus would be a BOD5:N:P ratio of 100:4.6:0.65. The generally used ratio of
100:5:1 is usually sufficient to satisfy the stoichiometric need for nutrients. However, some
wastewaters with a high carbonaceous yield factor could have a higher need for nutrients.
There are several factors which effect nutrient needs. These include: sludge age, treatment
temperature,; carbonaceous waste and treatment configuration, and wastewater chemistry.
5.1.1 Sludge Age
The bacterial growth in an activated sludge system is the sum of two major processes,
cell synthesis and cell decay. Cell decay is the natural death rate of bacteria combined
with the cell maintenance requirements and endogenous respiration often expressed as a
fraction of the biomass per day. Cell decay releases nutrients which are internally
27211r001
33 FINAL 10/99

recycled reducing the nutrient requirements. Longer sludge ages can minimize nutrient
requirements. Typically, sludge ages in excess of 20 days have been successful to
reduce nutrient requirements. As noted earlier, the sludge age at the CKCI system
aver ges approximately 36 days, which provides a system with minimum nutrient
requements .
5.1.2 Treatment Temperature
Treatment temperature can significantly effect the nutrient requirements for good
treatment. Cell maintenance needs are higher at higher temperatures which leave
s less
BOD for cell growth and lower nutrient needs per kg of BOD treated. The mesophilic
range for activated sludge operation which is the commonly utilized process in the
OCPSF facilities is 4-39°C. The CKCI system typically operates at temperatures in
excess of 30°C which provides a basis for minimum nutrient requirements.
5.1.3, Carbonaceous Waste and Treatment Configuration
Rapidly simulated soluble carbonaceous substrates require a higher concentration of
soluble nutrients for proper treatment compared to substrates that are more slowly
degraded. This is because wastewater treatment bacteria rapidly take up readily
degradable soluble substrates by facilitated transport while inorganic nutrients such as
nitrogen and phosphorus must enter the cells simply by diffusion. The facilitated
carbon uptake rate can exceed the nutrient diffusion rate causing nutrient deficiency
within the biomass. This imbalance can only be overcome by increasing the nutrient
concentration around the biomass causing an increase in the nutrient diffusion rate into
the biomass.
The CKCI wastewater has a high carbonaceous uptake rate as shown in Table 5-1 and
correspondingly high oxygen uptake rate. BOD5 and COD utilization rates were
calculated for the CKCI treatment system based on data collected during the study.
This data is presented in Appendix D. Based on the results of the anthrone test, as
discussed in Section 4.1, the utilization rates were calculated using an MLVSS that is
27211r001 34 FINAL 10/99

TABLE 5-1
SUMMARY OF MIXED LIQUOR UTILIZATION RATES
Utilizattot ate .
+C
4 - � t 4 Z•* +'
�'�tC t
..� .,.' .i i t:f-..+: r�K^ .�v _...
COD U • 'Atidn a"
i F. t+ °..s't ,�ll�; ('ia P y .� , '
3 ' 4 �y,, f � �"S ?j�` �"`�
� ' a ` F Ak'^.�:x '�Ykl `•5 d � l��.�
} !r C 6 K.( ays ') A A?' ... Y 1
f iEii �, t .n �xi v:s i�'� .;"
®b Ufiliza on,''',afe.
�14 t %- :- ...c
c1 � i " "�v
f r llt fi. `}"�
� c a s 1
r �.>s.� �l-`� .... _
Average
2.8
30
Median
2.4
20
Minimum
0.22
2.7
Maximum
8.6
107
27211r001 35 FINAL 10/99

representative of the actual bacterial density in the mixed liquor sludge.
FAQ
Because of these high uptake rates and the utilization of a complete mix activated sludge
process, which is required for a highly variable batch production facility, the nutrient
requirements can be elevated for this type of operation. In addition, wastewaters that
have a phosphorus diffusion limitation require higher bulk concentrations of soluble
phosphorus for good treatment. Systems with high soluble BOD and high oxygen
'� uptake rates can result in sludges with elevated polysaccharides concentrations which
will then prevent good solid -liquid separation.
5.1.4 Wastewater Chemistry
Phosphorus is usually present as phosphoric acid. Although many forms of residual
phosphorus can be chemically measured, phosphorus residual is usually measured as
two fractions, soluble ortho-phosphorus and total phosphorus. Only the soluble ortho-
phosphorus is available as a nutrient for the biological treatment system and in many
cases the measured ortho-phosphorus is not bioavailable. Phosphorus can be
complexed as sparingly soluble salts of calcium, iron, and aluminum depending on the
wastewater pH. A plot of phosphorus solubility and precipitation with respect to pH
for calcium, iron and aluminum is presented in Figure 5. As shown in this figure,
phosphorus can be complexed by alum, which is used as a secondary coagulant at the
CKCI facility, and ferric chloride, which is utilized as a sludge conditioning chemical at
the CKCI facility. The chemical precipitation of soluble ortho-phosphorus yields a
soluble phosphorus complex that filters and colormetrically measures as soluble
phosphorus but is not readily bioavailable. The literature indicates that effluent ortho-
phosphorus concentrations of at least 2.5 mg/L can be required due to wastewater
chemistry.
27211r001 36 FINAL 10/99

1 1 I 1 1 1 1 1 I I 1 1 1 1 1 1 $ 1 1
Figure 5. Equilibrium Solubility Diagram for Fe, Al, and Ca
Amp
• Ca5(OH)(PO4)3(s)
im Air ow um =11 in
IIM
4
2 CA
L
0
- 3 a
to
o
- 4 -c
a. 0
> E _5
o
0
- 6 . co
0
co
▪ 7 OJ
✓ r -8
4.5 5 5.5 6 6.5 7 7.5 8 8.5 9 9.5 10
pH

NMI
5.2 NUTRIENT OPTIMIZATION
The treatment plant was in compliance with its NPDES effluent criteria at the initiation p of the
BAT study. However, there was a high degree of variability in the treatment plant
performance. Therefore, a nutrient optimization program was implemented at the CKCI
WWTP in May 1998. The objective of this program was to improve biodegradation and
optimize the performance of the treatment system using the current BAT treatment technology.
CKCI initiated a program to optimize nutrient usage in the full-scale WWTP. The primary
objective of the program was to reduce the effluent nutrient concentrations to the lowest levels
possible while providing sufficient nutrients for maintaining optimum treatment performance.
The objective in optimizing the nutrient addition was to develop a baseline nutrient level from
which BAT nutrient limits could be defined. Nutrients were optimized by close monitoring,
process optimization, and implementation of a program to gradually reduce nutrient
concentrations over a 16-month period. During this period, both nutrient concentrations in the
system and effluent quality were closely monitored. Following each reduction in nutrients, the
performance of the system was evaluated to ensure optimum performance was being
maintained.
5.2.1 Analytical Monitoring
The nutrient optimization program included analytical monitoring of nutrients throughout
Mel the waste treatment system. A summary of the full-scale monitoring performed throughout
the study is presented in Table 5-2. Initially, nutrients were monitored up to three times
alla
O
per week,
analytical
As the program progressed and treatment performance became more consistent,
monitoring was reduced to one to two times per week. Throughout the program,
NH3-N and o-PO4 were monitored up to five times per week in the influent, mixed liquor
and final effluent, since these represented nutrient forms most readily available to the
microorganisms.
27211r001 38 FINAL 10/99

sa
NMI
TABLE 5-2
SUMMARY OF NUTRIENT MONITORING
• rametMi`
��� ��y'
i.. <-' f; �
C �'Y
� , P t:ry
ty._.ia
■�, L
i . Y Jr ' . YJ } fC t}••'''
t �..�iY+. : may' ° r.. � ,-�: " .'�
. 'a 1 i yy�• + -t
L ! 4': i3 .� 1 • L i !-. :�
: , . t ; _
_.rY � �'. t., ..S•:
_ ,;k�tA! t.; F L
Y Y Y ouxcea '_
.:.]� 1 ) �.--� :'" a� ,.,.
j 1 ! f .. i " r
t' i�; "9 f 3 } L i d TS
,, l a �� t
.}�++Y1�..---, �.,�., t.,. 3.. ^�'�
} i • .p "•�.�
, tMonitorin 4
iY�,, ,� �.:r�''�yy�..Q ' ,� ;
� 7f- 4" '
i t
requency-.
cr.!-�1 `iFt"�
t•-
S p1e
,r��
§ v'.A• x+, 7
+ 4,
�irtf
t+';3__`".._, ,_, _ .
Ammonia
(NH3-N)
INF, AB, FE
up to 5/week
grab
Nitrite/Nitrate (NO2/NO3-N)
INF, FE
1-3/week
grab
Total Kjeldahl Nitrogen (TKN)
INF, FE
1-3/week
grab
Organic Nitrogen (Org-N)
INF, FE
1-3/week
grab
Total Nitrogen (TN)
INF, FE
1-3/week
grab
ortho-Phosphorus (o-PO4)
1
INF, AB, FE
up to 5/week
grab
Total Phosphorus (TP)
INF, FE
1-3/week
grab
+m (1) Abbreviations are as follows:
am
m,
FRI
INF = influent to aeration basin
AB = aeration basin
FE = final effluent
27211r001 39
FINAL 10/99

5.2.2 Target Nutrient Addition
The treatment plant operating data was evaluated to determine a baseline nutrient addition
rate. The nutrient addition dosages were gradually reduced over a 16-month period while
maintaining optimum treatment performance. The target phosphorus and nitrogen dosages
are summarized in Table 5-3 and Table 5-4. During the initial period of nutrient addition,
prior to my 1998, urea and phosphoric acid were added to the aeration basin in order to
maintain a 1-2 mg/L concentration of o-PO4 and NH3-N in the final effluent. Usually a 1-2
"n' mg/L re idual of o-PO4 and NH3-N indicates that sufficient nutrients are available. From
July 1998 through August 1999, target nutrient dosages were gradually reduced. The
initial effluent data (May - July 1998) indicated a significant reduction in effluent TSS and
BOD5 with the implementation of nutrient addition. As data was collected and it was
shown that sufficient nutrients were being added and the treatment performance of the
system was being maintained, the nutrient dosages were decreased. Target dosages were
decreased gradually in order to maintain effluent quality and not upset the system. In
addition, because of the long sludge ages (approximately 20-40 days), a reduction in
nutrients
would not immediately impact the performance of the WWTP. Therefore, it was
necessarr to allow several weeks of operation at the target nutrient levels to reach
equilibri im and to ensure that performance had not been compromised by the reduction in
nutrient addition.
5.3 PROCESS PERFORMANCE
The process performance of the treatment plant was monitored on an on -going basis throughout
�' the study. This included data for COD, BOD5, TSS, MLSS, F/M, hydraulic loading,
temperature, pH, sludge age and chemical addition. A summary of these data are presented in
Appendix B. As previously noted, prior to the initiation of the nutrient optimization program
there was wide variability in effluent BOD5 and TSS levels on a weekly basis. Through the
system optimization, significant improvements in the treatment plant quality were achieved. A
summary of
reduction in
these data is shown in Figure 6. These data show that there was a significant
effluent BOD5 and TSS levels following the implementation of the nutrient control
program. Following the implementation of nutrient controls the variability in the effluent
27211r001
40 FINAL 10/99

MOEN
TABLE 5-3
SUMMARY OF TARGFWHORUS DOSAGES
(5/98 - 9/99)
Date
Target Phosphorus Dosage (l)
5/22/98 - 7/19/98
1 - 2 mg/L effluent residual
7/20/98 - 7/31/98
0.0648 lb P/1,000 gallons influent
8/1/98 - 2/23/99
0.0288 lb P/1,000 gallons influent
2/24/99 - 5/2/99
0.0264 lb P/1,000 gallons influent
5/3/99 - 9/1/99
0.0240 lb P/1,000 gallons influent
(1) Target phosphorus dosage was based on periods of polymer use
in the secondary clarifier.
TABLE 5-4
SUMMARY OF TARGET NITROGEN DOSAGES
(5/98 - 9/99)
Date
Target Nitrogen Dosage
5/98 - 7/4/98
1 - 2 mg/L effluent residual
7/5/98 - 2/23/99
0.147 lb N/1,000 gallons influent
2/24/99 - 5/2/99
0.124 lb N/1,000 gallons influent
5/3/99 - 9/1/99
0.092 lb N/ 1,000 gallons influent
27211r001 41 FINAL 10/99

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Effluent BODS (mg/L)
100
20 -,
10-
0
11/30/97 1/25/98
27211s002
BAT Fig6
3/22/98 5/17/98
Figure 6. Full -Scale Effluent BOD5 and TSS
Begin nutrient addition May 1998
- - f - -Eff. BOD5. weekly average
e Eff. TSS. weekly average
7/12/98 9/6/98 11 /1 /98 12/27/98 2/21/99
4/18/99
6/13/99
800
— 700
— 600
— 500
m
cr.
— 400 c—ni
CD
3
r
— 300
— 200
— 100
8/8/99
Updated: 10/25/99

levels has decreased significantly and the system has been able to provide overall improved
biodegradation.
Overall, the system provides better biodegradation and is more reliable. The data presented in
Figure 6 demonstrates that the addition of nutrients to the wastewater is critical in optimizing
biodegradation, effluent quality and overall treatment performance. Based on this data, it is
obvious that without the addition of nutrients, the performance of the treatment plant would
suffer and effluent quality would significantly deteriorate.
These data indicate that the system can consistently provide good quality effluent BOD5 but is
prone to variability in terms of effluent TSS. Secondary chemical addition is required in order
to control the effluent TSS levels, and as previously noted the effluent TSS level requires the
addition of alum or polymer. Data on the use of alum and polymer data is contained in the
information presented in Appendix B. Either alum or polymer were added as a coagulant.
These data indicate a very good level of treatment in spite of significant variability in
wasteloads.
A summary of average CKCI WWTP influent and effluent data and removal efficiencies during
the nutrient study is presented in Table 5-5. Over the course of the study (May 1998-August
1999), weekly average influent COD levels (following equalization) have/varied from 820 c
Jio in excess of 6800 lbs/day The treatment system has averaged greater than 75 %
COD removal, 98% BOD5 and 56% TN removal for this same time period. As noted in the
data following the final reduction in nutrient target levels on May 3, 1999, there was an
increase in effluent BOD5 and TSS levels over those levels which had been consistently
achieved over the previous 6 months. Therefore, these data indicate that optimum nutrient
addition levels were reached during this study. It is felt that further reduction in nutrient
addition would result in a deterioration of effluent quality.
27211r001
43 FINAL 10/99

,0 to
TABLE 5-5
SUMMARY OF LONG TERM REMOVAL EFFICIENCIES
Parameter
Influent ")
(mg/1)
Effluent")
(mg/I)
% Removal
BOD5
626
9
98%
COD
2078
504
75%
TP
1.6
1.5(2)
6%
NH3-N
3.7
5.0
--
NO,/NO3-N
0.7
2.1
--
TKN
70
29
59%
Organic N
66
25
62%
TN
70
31
56%
TNN
4.7
6.4
--
(1) BOD5 and COD data presented for the period 5/98-8/99.
TP data present for the period of 10/99-8/99.
Nitrogen data presented for the period of 11/98-8/99.
(2) Effluent concentration does not include phosphorus from accidental flushing on scrubber on
2/25/99.
2721 i roo 1 44 FINAL 10/99

‘0.`0<',ov_,
\.>,e

Fial
5.4 BASELINE PHOSPHORUS
Except as noted for one (1) specific product there is very little phosphorus discharge from the
production facility. Use of the phosphoric acid scrubber in the production facility results in
phosphorus in the process wastewater during production periods of the Blue B Supra azo dye
and a waste minimization program (Section 3.2.2) has been developed to control this
discharge. The primary source of phosphorus in the wastewater is added as a biological
nutrient to enable good biodegradation for the OCPSF wastewater.
Over the course of the study there was a significant reduction in the phosphorus addition and
effluent phosphorus levels. Figure 7 presents the chronological summary of the effluent ortho-
"" phosphorus and effluent total phosphorus along with effluent TSS. The periods of alum
addition are presented on this figure. The target phosphorus dosage was based on the use of
polymer in the secondary clarifier as opposed to alum. During the October 1998 period of
alum addition, o-PO4 concentrations reached low levels. Since alum is commonly used in
Fa,
treatment applications to reduce phosphorus, it was thought that the addition of alum was
causing nutrient deficient conditions in the mixed liquor by precipitating phosphorus.
Therefore, in order to maintain nutrients and avoid a potential treatment upset, target
phosphorus dosages during periods of alum use were increased to provide sufficient nutrients
in the mixed liquor when alum was being used. The phosphorus addition was increased during
periods of alum addition to compensate for less bioavailable phosphorus. However, as the
study progressed, alum addition did not consistently reduce phosphorus to the same levels as
seen during October 1998. It appeared that because of the varying chemical composition of the
wastewater, alum did not consistently reduce phosphorus in the wastewater and that the target
phosphorus dosage could be reduced when alum was being used. During the last phase of the
study, it was determined that the target phosphorus dosages did not need to be increased during
periods of alum use.
27211r001
45 FINAL 10/99

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Effluent ortho-Phosphorus and Total Phophorus (mg P/L)
Figure 7. Full -Scale Effluent Concentrations
t Eff o-P. 4-wk running avg.
20.0
Alum Addition
18.0
16.0 -
14.0 -
12.0 -
10.0 -
8.0 -
6.0 -
4.0 -
2.0 -
o Eff TP, 4-wk running avg. $ Eff TSS, 4-wk running avg.
- 200.0
- 180.0
- 160.0
- 140.0
120.0 S1
m
- 100.0
cn
2
- 80.0 r=
60.0
40.0
20.0
0.0
4/20/98 6/1/98 7/13/98 8/24/98 10/5/98 11/16/98 12/28/98 2/8/99 3/22/99 5/3/99 6/14/99 7/26/99 1 9/6/99
27211s002
BAT Fig7
10/25/99

Under certain circumstances, as noted below, phosphorus was added to the wastewater above
the target dose in order to avoid phosphorus limitation and a deterioration in effluent quality.
Typically, a target phosphorus dosage was maintained. However, changes in the treatment
system requ" ed the addition of phosphorus above the target dosage. These changes included
the following:
• low mixed liquor and effluent phosphorus levels;
• periods of heavy production;
• excessive sludge wasting; or
• higher than expected effluent BOD5 and TSS.
Occasionally, phosphorus was added to the wastewater below the target dose in order to reduce
phosphorus levels in the mixed liquor and avoid high effluent phosphorus concentrations.
As previously noted, because of the high utilization rates and kinetics, the required
concentration (driving force) for phosphorus is higher for the CKCI wastewater than for
domestic or Lasteloads which are not readilysoluble and biodegradable. The presence of the
g
alum compli ates this situation.
The control f phosphorus was found to be difficult during low flow and low production
-- periods. The plant experienced low production activity in March 1999. Under these
conditions there was very little wasteload to the treatment plant. Therefore, there was reduced
phosphorus ilitilization and a subsequent increase in effluent phosphorus concentration. The
data indicate that a minimum phosphorus reduction was reached with the May 3, 1999
reduction. Figure 6 shows an increase in effluent BOD following this reduction.
A statistical analysis of the CKCI WWTP effluent data from October 1998 through August
1999 was performed by AEI since this represented a long term period of stabilized effluent
phosphorus. Statistical plots and data are included in Appendix E. Consistent with EPA
procedures, the 95th percentile phosphorus from the statistical analysis was selected as the
baseline phosphorus. The results of this statistical analysis indicate a total phosphorus
discharge limit o 2.75 mg/l. This is similar to the concentration limits presented in the
27211r001
47 FINAL 10/99

len
rioti
Under certain circumstances, as noted below, phosphorus was added to the wastewater above
the target dose in order to avoid phosphorus limitation and a deterioration in effluent quality.
Typically, the target phosphorus dosage was maintained. However, changes in the treatment
system required the addition of phosphorus above the target dosage. These changes included
the following:
• low mixed liquor and effluent phosphorus levels;
• periods of heavy production;
• excessive sludge wasting; or
• higher than expected effluent BOD5 and TSS.
Occasionally, phosphorus was added to the wastewater below the target dose in order to reduce
phosphorus levels in the mixed liquor and avoid high effluent phosphorus concentrations.
As previously noted, because of the high utilization rates and kinetics, the required
concentration (driving force) for phosphorus is higher for the CKCI wastewater than for
domestic or wasteloads which are not readily soluble and biodegradable. The presence of the
alum complicates this situation.
van
The control of phosphorus was found to be difficult during low flow and low production
+�+ periods. The plant experienced low production activity in March 1999. Under these
conditions there was very little wasteload to the treatment plant. Therefore, there was reduced
phosphorus utilization and a subsequent increase in effluent phosphorus concentration. The
data indicates that a minimum phosphorus reduction was reached with the May 3, 1999
'`` reduction. Figure 6 shows an increase in effluent BOD following this reduction.
A statistical analysis of the CKCI WWTP effluent data from October 1998 through August
1999 was pei formed by AEI since this represented a long term period of stabilized effluent
phosphorus. Statistical plots and data are included in Appendix E. Consistent with EPA
procedures, the 95th percentile phosphorus from the statistical analysis was selected as the
baseline phosphorus. The results of this statistical analysis indicate a total phosphorus
discharge limit o ; 2.75 m /1. This is similar to the concentration limits presented in the
g
27211r001
47 FINAL 10/99

Catawba River Basinwide Management Plan, for domestic plants less than 1 MGD, of 2 mg/L
total phosphorus. At CKCI's present monthly average flow of 0.33 MGD this is equivalent to
a total phosphorus limitation at 7.6 lb/d. (Based on information provided by CKCI, 0.33
MGD represents the current average monthly discharge for the facility.) A mass based
phosphorus limit corresponding to the flow rate for the CKCI facility would be appropriate and
this would be consistent with the application of OCPSF BAT limits. ��•.
5.5 BASELINE NITROGEN
The nitrogen requirements and effluent quality is complicated because of the non -refractory
nitrogen which is present in the wastewater. A chronological summary of effluent organic
nitrogen, nitrite/nitrate nitrogen, and ammonia nitrogen for the treatability study is presented
in Figure 8. This indicated a highly variable effluent nitrogen level during the initial phase of
the optimization program. However, the variability was significantly reduced as the program
developed. As noted in this figure, the effluent ammonia levels for the last ten (10) months of
the study averaged 5.0 mg/L with only five (5) data points in excess of 10 mg/L. The effluent
nitrate level for this same period averaged 1.9 mg/L with only 1 data point in excess of 6 mg/L
and this appeared to result from unusual occurrences. There was significant variability in the
organic nitrogen discharge and it appeared that this was directly related to the dye
manufacturing process.
The effluent organic nitrogen was refractory and could not be further degraded as noted in the
Section 6.0 testing.' Based on our overall review of the data and a statistical analysis of
effluent data, the 95`'' percentile total nitrogen is 52.5 mg/1 and this is the basis for a total
nitrogen limitation. (Statistical plots and data are included in Appendix E.) However, to
better represent the water quality concerns it is recommended that the limits be based on the
total non -refractory nitrogen (TNN). The statistical analysis indicates a limitation of 16 mg/1
TNN. It is recommended that a mass based limit, consistent with application of OCPSF BAT
be applied. At a monthly average flow of 0.33 MGD, this would result in a summertime
baseline limit of 44 lbs/day based on the total of the ammonia, nitrate and nitrite nitrogen.
27211r001 48 FINAL 10/99

Figure 8. Full -Scale Effluent Organic N, NO2/NO3-N, and NH3-N
— e— Org. N, 4-wk running avg
— 0— Eff NH3-N, 4-wk running avg.
-- Eff. NO2/NO3-N, 4-wk running avg
-a, 50 -
E
c
0
is
L
te, 40-
aU
O
rn
0 30
w
0
E 20 -
4/30/98 6/11/98 7/23/98 9/3/98 10/15/98 11/26/98 1/7/99 2/18/99 4/1/99 5/13/99 6/24/99 8/5/99
27211s002
BAT Fig8
10/25/99

Pio
SECTION 6.0
NUTRIENT REDUCTION TECHNOLOGIES
Utilizing the optimized treatment plant performance as a baseline, a number of alternative
nutrient reduction technologies were evaluated for upgrading the treatment facility in an effort
to meet the proposed limits for TN and TP of 6 mg/1 and 1 mg/1, respectively. A detailed
evaluation of the nutrient removal literature was utilized to screen technologies for
consideration. The screening process considered the technology, the application of the
technology for an OCPSF wastewater and the feasibility at the CKCI facility. The alternatives
screened for further consideration are summarized in Table 6-1.
The results of the nutrient reduction technology analysis are summarized in the following
sections.
6.1 CHEMICAL PRECIPITATION
The conventional procedure for phosphorus removal is through chemical precipitation. Testing
was performed to determine if phosphorus could be removed from the wastewater using
ion
various chemical coagulants. Jar testing was performed using both mixed liquor and final
effluent samples from the CKCI WWTP. Initially, the samples were screened using the
different coagulants to determine which chemicals would be effective in reducing phosphorus.
Following chemical screening tests, additional testing was performed to optimize chemical
dosage and evaluate sludge generation.
AR,
PiII
VAR
ISO
6.1.1 Jar Testing Procedures
Jar testing was conducted on grab samples of mixed liquor and final effluent from the
CKCIiI WWTP. Varying doses of coagulants were tested in both the mixed liquor and
final effluent jar tests. In the mixed liquor jar tests, the coagulant was not tested at
various pH levels since a pH of 7 — 8 must be maintained in the full-scale system for
proper biological growth. The pH of the sample was monitored throughout testing in
order to ensure that the addition of coagulant would not cause unfavorable pH conditions
for biological treatment.
27211r001 50 FINAL 10/99

aim
TABLE 6-1
SUMMARY OF TREATMENT ALTERNATIVES
t�ientRemoYe
kFys
`eat
Phosphorus
chemical precipitation
Nitrogen
anaerobic pretreatment
pretreatment with ozone
pretreatment with hydrogen peroxide
adsorption using a resin
adsorption using powdered activated carbon
27211r001 51 FINAL 10/99

In the final effluent jar tests, the pH of the sample was adjusted following the addition
of coagulant to the jar in order to determine the optimumpH for phosphorus removal.
� P P P
After the addition of coagulant, the samples in the jars were rapid mixed, flocculated
and then allowed to settle for approximately 1 hour. There was not good solids -liquid
separation during jar testing, therefore, the supernatant was gravity filtered through a
coarse
filter following settling. Supernatant samples were analyzed for ortho-
phosphorus and total phosphorus.
6.1.2 Chemical Screening Jar Test Results
The c emical screening tests were performed using the following four (4) coagulants:
sodium aluminate, lime, ferric chloride and alum. Prior to conducting the jar testing,
calculations were performed in order to determine the theoretical coagulant dose
required to remove 3-10 mg/L of phosphorus from the mixed liquor and 1-4 mg/L of
phosphorus from the final effluent.
The results of the mixed liquor and final effluent chemical screening jar tests are
presented in Tables 6-2 and 6-3 respectively. In the mixed liquor jar tests, it appears
that ferric chloride was most effective in reducing total phosphorus. Both alum and
sodium aluminate reduced ortho-phosphorus concentrations, but did not significantly
reduce total concentrations. Lime reduced ortho- hos horus concentrations
phosphorus P P
slightly but elevated the pH of the sample to unacceptable levels for operation of a
biological treatment process. Sodium aluminate was not as effective as alum or ferric
chloride in reducing phosphorus.
In the
final effluent chemical screening jar tests, ferric chloride and sodium aluminate
were equally effective in reducing both ortho-phosphorus and total phosphorus
concentrations. Both coagulants produced the lowest total phosphorus at a pH of 6 s.u.
However, varying pH did not significantly affect phosphorus removal. Alum was
27211r001 52 FINAL 10/99

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
TABLE 6-2
MIXED LIQUOR CHEMICAL SCREENING JAR TEST RESULTS
t�
ri
k
.t*f
Dose
.! 7SI.�`Y�`':.N
= , . p�It: `
.ortho Phosphorus. (mg/L)
Total Phosphorus (mg/L)
S�
T"'Y ` ,iT
,:-.: Y s'. - r,
n
Ain''�VJ
j.
.: E�E^;t,,,G
.
i.. blab
, rll...„, :f
..�.
al w
1
, ..:��
Imt al
'.'.1 i:k?, /
, ,� :-
a •
t,
°% Removal
.�.::�
, F�-#
= Initial
.._..
al.
% Removal
1
10
8.0
8.1
2.8
2.3
18%
4.25
4.3
0%
Sodium
2
25
8.0
8.2
2.8
2.1
27%
4.25
3.8
12%
Aluminate
3
50
8.0
8.3
2.8
1.8
36%
4.25
3.6
15%
4
25
8.0
9.1
2.8
2.9
-2%
4.25
4.8
-12%
5
Lime
50
8.0
9.6
2.8
2.6
7%
4.25
4.0
6%
6
100
8.0
10.3
2.8
1.7
39%
4.25
3.4
20%
7
10
8.0
7.9
2.8
2.3
18%
4.25
3.4
20%
8
FeC13
25
8.0
7.7
2.8
(')
(')
4.25
1.0
76%
9
50
8.0
7.6
2.8
(1)
(1)
4.25
1.0
76%
10
10
8.0
7.9
2.8
1.9
33%
4.25
3.0
29%
11
Alum
25
8.0
7.9
2.8
2.3
18%
4.25
3.1
26%
12
50
8.0
7.8
2.8
1.8
35%
4.25
2.5
41%
(1) Analysis of Final sample greater than Initial. Inconsistent with rest of results.
27211r001 53 FINAL 10/99

1 1 1 1 1 1 1 1 1 1 I 1 1 1 1 1 1 1 1
TABLE 6-3
FINAL EFFLUENT CHEMICAL SCREENING JAR TEST RESULTS
t ` ,
' !
t : ,
(. jf.
LflL _--
4�,., zw ik. ,. ,.. ,.,.�,.
:-
Total Phosphorus (nng/L)
( �. '4 { `
��{{,, :aYaT" :,
a? Z(
, t
....: • Ij.� •'tS'a ek-.
�.7j* :::-.
1!
Yi•
,, , , , .
�F�-�i=.:. 4�
a";~
�''��ikfi.l...,i�.�ia�iia.<•+L a. v.Ct,
t�. )"'tS�' # 'w zt.•..: 1::_
. .,l�J i'. - ... ...... ... .. .. ,
,
)
{ 't S.+e n .
•.. f
u a�
r: !"f`4';'lv.� .'
i �>
.
_
}�,� ---,
T �S�Y,%:P1 �)
i�
�' na
'4�'P }3 y1�.!¢��
$x) %ti .'+�F. L
Y Y. if R
�l Removal;
yri
` t!�� • • ��
pi f
•Tn i a t
\
; J' •(� ..
.. .Fi r
nal.
Y, 9. _
F iaF\s'� hYy f ...,
%.Removal
1
12.5
8.1
5.1
2.1
1.9
10%
2.1
1.5
31%
2
12.5
8.1
6.1
2.1
1.5
29%
2.1
1.3
38%
3
Sodium
12.5
8.1
7.1
2.1
1.4
32%
2.1
1.2
45%
4
Aluminate
25
8.1
5.0
2.1
1.2
45 %
2.1
1.1
48 %
5
25
8.1
6.1
2.1
0.9
57%
2.1
0.9
57%
6
25
8.1
7.0
2.1
1.1
50%
2.1
1.0
55%
7
50
8.1
8.7
2.1
1.9
10%
2.1
1.8
17%
8
100
8.1
9.0
2.1
1.6
24%
2.1
1.7
21%
9
250
8.1
9.3
2.1
1.0
52%
2.1
1.1
50%
10
Lime
500
8.1
10.1
2.1
0.8
62%
2.1
0.8
62%
11
750
8.1
11.3
2.1
0.5
76%
2.1
0.6
71%
12
1000
8.1
11.7
2.1
0.3
86%
2.1
0.5
76%
13
12.5
8.1
5.1
2.1
1.3
40%
2.1
1.0
52%
14
12.5
8.1
6.1
2.1
1.1
48%
2.1
1.2
45%
15
Ferric
12.5
8.1
6.9
2.1
1.4
36%
2.1
1.3
40%
16
Chloride
25
8.1
5.1
2.1
0.7
69%
2.1
0.7
69%
17
25
8.1
6.1
2.1
0.5
79%
2.1
0.6
74%
18
25
8.1
7.0
2.1
0.7
67%
2.1
0.7
67%
19
12.5
8.1
5.0
2.1
1.9
12%
2.1
2.1
2%
20
12.5
8.1
6.0
2.1
1.5
31%
2.1
1.7
19%
21
12.5
8.1
7.1
2.1
1.7
19%
2.1
1.7
19%
22
Alum
25
8.1
5.1
2.1
1.6
24%
2.1
1.7
21%
23
25
8.1
6.1
2.1
1.3
38%
2.1
1.2
43%
24
25
8.1
7.0
2.1
1.3
38%
2.1
1.4
36%
27211r001
54
FINAL 10/99

not as effective as sodium aluminate or ferric chloride. Although lime was effective in
pig removing phosphorus, it resulted in elevated pH and fairly high doses were required.
AEI
FlOR
6.1.3 Dosage Optimization Jar Test Results
Based on the results of the chemical screening jar tests, additional jar testing was
performed in order to optimize coagulant dose and evaluate sludge generation due to the
addition of coagulant. Mixed liquor jar tests were performed using both ferric chloride
and alum. Although alum was not as effective as ferric chloride in reducing
phosphorus concentrations in the chemical screening tests, it is frequently used in the
full-scale system at a dose of 400 mg/L to improve settling in the secondary clarifier.
Jar testing wasperformed usingalum at the full-scale doses to evaluate current
phosphorus removal levels associated with alum addition. Final effluent jar testing was
performed using ferric chloride, sodium aluminate and lime. In the mixed liquor and
final effluent jar tests, supernatant samples were collected and analyzed for ortho-
phosphorus, total phosphorus and TSS. In addition, TSS samples were collected during
the flocculation stage, prior to settling, in order to evaluate sludge generation due to the
addition of coagulants.
The results of the dosage optimization jar tests are presented in Tables 6-4 and 6-5
respectively. In the mixed liquor tests, ferric chloride did not produce as much
phosphorus removal as in the chemical screening tests. At 50 mg/L, ferric chloride
removed 0.5 mg/L total phosphorus (39% removal). In the chemical screening tests, 50
mg/L of ferric chloride removed approximately 3.1 mg/L total phosphorus (76%
removal).
I•,
Alum, which is used in the full-scale system to provide settling in the secondary
clarifier, was tested at doses comparable to those used in the full-scale system. These
results indicate that alum is effective at a dosage of 200-400 mg/L in providing
aft significant phosphorus removal. However, in the full-scale system, effluent data shows
IMO
27211r001 55 FINAL 10/99

1 1 1 I 1 1 1 1 1 1 I 1 1 1 1 1 1 1 1
TABLE 6-4
MIXED -LIQUOR-DOSAGE OPTIMIZATION TEST RESULTS-
�Coa last
l� .. �
..:; ,.. ... ,
a � x: �.
., e,. � i» � f...: '. {:,,
�i.. (�.
• : ,. , ...a .•
�L•� '�};
'
, -Jar #,�.
, .,
..,
, u: ,.,.
sl �
>.. �> .. ,. x
. 3 x, z ,.
y, , ,,;) r ,
':A�
1.
s Dose..,,
. ..: .
r ,. w �..
„ .,... 4 ) .� :..�
µµ,'s��r'�{�.... ya N.�,.
, �
,
v
..fit � b p:
�> �H
.
�P
x• ..:z >,.. ,..
..v.�. ..._
ti.
u. !,
:��» �;.
,.
,.
;., .n4^-. .. sr'..:.,...:.
......✓ ..
'�r
Si 4.
��� rtho.,.as �hor�ts 1L
Q �.
� _; Pw.n ,, �!�mi g>
,_��770. � y.r.."....sr+ �{ r � � ly.
E ..��.sxi-Fx47..,:..'9�r,ot'.` .. ).., Sa . .,,
�_�^��'S�`x,' X
To Plio� 'horns m /L
� P ( )
g
:>f. .. � f�r�,..«. h, .l ,-
�.TSS ° m lL
{ )
... g
e �..
�€a
<..d •> .p .r .....
_� .
,i t., gyp.:,
r`..
.e a:"iu:
. � �
,(
:t. .....
W r:_ . f
� f .
,„
��
'a1
".3..ii4`l
. �`�...,p,N
,x , .
r{> yggt sty 1, r.
S'7 ! .
) o p
,,•W$y3.191141,.
t 3. .�`3,
., ....
�r�*wy lA..f;.
dal
.+:r:�br:-st x''�s'.`
,..:� a
X^ .4:t
al
f.3,'cK"'!)+ - .. 17.: a:2.?n
.
� -@.
%Remo
.. •t ,,.. t , ... ,' •,•
.�Se. 4
- In�tt�t
y
, t .. -.. 1...,, .
in
3 _ ^_
Ferric
Chloride
1
10
7.7
7.5
0.77
0.71
8%
1.84
1.5
16%
4100
3460
2
25
7.7
7.4
0.77
0.65
16%
1.84
1.6
13%
4100
3280
3
50
7.7
7.2
0.77
0.61
21%
1.84
1.1
39%
4100
2740
4
100
7.7
7.0
0.77
0.31
60%
1.84
1.3
29%
4100
1800
Alum
5
100
7.7
7.3
0.77
0.41
47%
1.84
1.0
46%
4100
1900
6
200
7.7
7.0
0.77
0.25
68%
1.84
0.6
67%
4100
1620
7
400
7.7
6.6
0.77
0.15
81%
1.84
0.4
78%
4100
2380
27211r001 56 FINAL 10/99

1 l 1 I 1 l 1 1 1 1 1 1 1 1 1 1 1 1 1
TABLE 6-5
FINAL EFFLUENT DOSAGE OPTIMIZATION TEST RESULTS
Jar #
«:
-
-Coa ante
f p=,}��3:1.7.='. L
E 3i'5 •. `� "' ; '""
Dose
# S'r�% reef
,f i
: k
_t... ....`e�Z
t taL
H � .
r. �'. :I:C'.t«
ieth
. 7....-t T�7'�' t
; .e e- --•.,
P os io
... ;xf r
m' L •�_
Qi.-.-..� '�.!w� a.k'.. .
r . Y�.f • .r.--r .-�.
s>
.a.Total�>Piios
�Ga�.L'^ .s _c ��
,:.'
horus
•i ..
't .Y.�- -
m" !L
,. •.^r. ...
r . ,r. e:+.:.. •
' TSS -
.. ..t
: e
m /L
.
�.1 .�
t
.--!a..:. .:..J•
.'. a::..v .��' �'-. �`�
,L
• � t�
.:tlt'.:".aY+.r. �...E .:a�:-r
-,3 • { '. '
k 'ii�4FLF.�
., 7_•v
�TitT
aM�
h�R.� a.
•r:�, t
T3`C ny
sw.
Ir7+9%Ger�J�'.�.�
'�.• it t
4
�a�S' -�
:t�
R_,11 .:• .,t-
, L ±'�uaal
Y: tA4[: :.j.. •xt
.'+s h.. Fi
.t `7,•.� Y`Y.�"'
%.y.,.Re!mm ov►fa1
�f��
s'.iiTw-SIf14{��%=ii+lr'T �4.w`II: ..r
S.• 4:'''.-:
?�;'
In6
t
l:':a: @th .ire n..
; : +i al
�. � � '�.
1 .
x .�._.
�% Removal
'.:. �i�._ .0 t.: ,�.'.Y.. :..}.Y
•.• •
:Imtia1
-.
•
, Final'
..
•. ..,d ��.' r.
1
100
7.3
5.1
0.16
<0.01
94%
0.53
0.27
49%
165
220
2
Ferric
100
7.3
6.0
0.16
0.06
63%
0.53
0.47
11%
165
190
3
Chloride
100
7.3
6.9
0.16
0.13
20%
0.53
0.15
72%
165
250
4
100
7.3
8.0
0.16
<0.01
94%
0.53
0.26
51%
165
330
5
25
7.3
5.0
0.16
0.15
6%
0.53
0.25
53%
165
65
6
Sodium
25
7.3
5.8
0.16
0.02
88%
0.53
0.19
64%
165
130
7
Aluminate
25
7.3
7.0
0.16
0.09
44%
0.53
0.36
32%
165
120
8
25
7.3
7.9
0.16
0.08
50%
0.53
0.34
36%
165
135
9
Lime
250
7.3
9.1
0.16
0.11
31%
0.53
0.43
19%
165
155
10
500
7.3
9.9
0.16
0.20
-25%
0.53
0.35
34%
165
192 I
27211r001
57 FINAL 10/99

gmII
MINP
that phosphorus removal varies significantly when alum is used. In addition, the
continued use of alum and the recycle of the sludge to the aeration basin appears to
reduce the available soluble ortho-phosphorus the microorganism utilize as a nutrient.
Therefore, this would result in an increase phosphorus addition rate and would negate
the effectiveness of phosphorus removal.
The initial phosphorus concentration in the final effluent sample was low in comparison
to the
sample used in the chemical screening tests. This was not unexpected since
historical data shows fluctuations in effluent phosphorus concentrations. The results
from this set of jar tests show that ferric chloride, sodium aluminate and lime were not
as effective in reducing phosphorus concentrations as in the chemical screening tests.
Ferric chloride was most effective in removing phosphorus at a pH of 7 while sodium
aluminate was most effective at a pH of 6.
6.1.4 Sludge Production
TSS samples were collected from each of the jars during the flocculation stage of the jar
tests in order to evaluate sludge production. The TSS results are included in Tables 6-4
and 6115. The mixed liquor results indicate that as coagulant dosage increases, TSS does
not in&ease, indicating excess sludge is not generated. It appears from these results,
that the addition of coagulant may release some of the bound water from the sludge.
Repeat testing for TSS generation in the mixed liquor was conducted and these results
are presented in Table 6-6. The data confirms the initial results.
In the
final effluent tests, TSS increased with the addition of ferric chloride, but did not
significantly increase with the addition of sodium aluminate. Lime increases the
amount of sludge in the sample at the higher dosage. The use of ferric chloride would
increase the amount of sludge generated by 15-100%
2721 ir001 58 FINAL 10/99

TABLE 6-6
MIXED LIQUOR SLUDGE PRODUCTION RESULTS - REPEAT TESTING
Coagulant
Coagulant Dose
(mg/L)
Initial TSS
(mg/)
Final TSS
(mg/L)
10
5351
4549
Ferric Chloride
50
5351
4893
100
5351
4833
Alum
200
5351
4726
400
5351
4682
27211r001 59 FINAL 10/99

Inil
PIM
depending on the pH of the sample. Sludge generation was highest using ferric
chloride at a pH of 8.
6.1.5 Precipitation Conclusions
The results from phosphorus removal jar tests in conjunction with the phosphorus
removal performance of the full-scale system indicate that chemical addition to the
mixed liquor cannot provide consistent effluent phosphorus. The inconsistent
phosphorus removal results appear to be associated with daily changes in the chemical
composition of the wastewater.
The use of ferric chloride for tertiary treatment at a 50-100 mg/L dosage can reduce the
phosphorus to the 1 mg/L level. Therefore, this process was deemed a viable treatment
alternative. An evaluation of the technical and cost effectiveness of this alternative is
presented in Section 6.1 of this report.
6.2 PRETREATMENT WITH OZONE
Testing was conducted to determine if pretreatment with ozone would help to break down the
nitrogen in the waste into a more readily biodegradable form in order to reduce the discharge
of total nitrogen from the WWTP. In order to evaluate the results of the pretreatment in the
full-scale system, the wastewater samples were polished using aerobic biological treatment.
6.2.1 Pretreatment of Samples with Ozone
Samples of influent, primary clarifier effluent, and secondary clarifier effluent were
collected from the CKCI WWTP. Prior to aerobic treatment, a portion of each sample
was sent to Praxair, Inc. for ozonation pretreatment. The portion of sample not
pretreated by ozonation was kept refrigerated until initiation of the aerobic treatment
phase.
The inifluent wastewater was treated at a ozone dosage of 1600 mg/L, the primary
clarifier effluent at 750 mg/L and the secondary effluent at 100 mg/L. Prior to
27211r001
60 FINAL 10/99

41111
NEM
11111111
Fag
0111111
ozonation, acid was added to each of the samples to reduce the pH to 3.0 s.u.
Following ozonation, the samples were filtered through a 1 um filter. Each of the
samples was analyzed for TKN, ammonia (NH3-N) nitrite/nitrate (NO2/NO3-N), COD
and total phosphorus (TP) prior to and following ozonation. The results of these
analyses are presented in Table 6-7.
In each set of samples it appears that pretreatment by ozonation reduced the COD of the
influent and primary clarifier effluent samples by 25-30 % . It also appears that
ozonation converted a portion of the organic nitrogen in each of the samples to
ammonia. Ozonation did not have as much of an impact on the secondary clarifier
effluent in comparison to the other samples, with regard to organic nitrogen.
6.2.2
Aerobic Batch Treatment
Folio ing pretreatment with ozonation, aerobic batch testing was initiated. Testing
was performed using both the ozonated and unozonated samples. A total of six (6)
aerobic batch units were operated. Units 1, 3 and 5 contained the unozonated samples
and served as controls. Units 2, 4 and 6 contained the ozonated samples and served as
the test units. A summary of the batch testing is presented in Table 6-8.
Return activated sludge (RAS) from the CKCI WWTP was used to seed the units. The
units were seeded with 10% RAS. Because of the limited amount of ozonated sample
provided, the final volume in each unit was 2.8 L. Phosphoric acid was added to each
unit in order to maintain proper biological growth conditions.
27211r001 61 FINAL 10/99

Pig
TABLE 6-7
RESULTS OF OZONATION PRETREATMENT
if f a e
ma, _
Pa`ram
t _ ztf
' ` � a `/i Y pn;..L t
. - .. ....
t,ttsrzt,rYN
tery `_
,. ' :t Gz
F <
•.i ..
� - , µ, Influen ,�}
� �(O`zo�ne=1580 rig/L
dte�y y ., �'� L Iit 4
� t
{ Cl :.N ir3w1 " t a •- i-
° sPrim H £ClariIaer o'r xf
a°Irar }s°5,.!dar
" � ' Effluent Y� _ "
_ 4: r-,-- [Sr -
D ff ,e, a.
(ozone 738 mg )
SecondarypuClarifier
; .T ram,
Effluent A'
-. N ..a , 1r%:`
(Ozone=1O5 mgl L)
.: "]Rl �.
saa
� • in y7tsP
r sIalt�
.Y .'r:...1_.ai'i.�«.:.:�d..'•
i�-�tr I di`ys,: p
Ozonated
.. �.. ... �.. .Ys.
r F �L � t
4f Imt al k
r ..._ ... -
e f.iSiDgc £ i �
Ozoanated
r .....- _,?v.•. .- ...
.'•x`• sri'�
h•aut a
... _•.. .5%Y."v:i; ,.+:t.. -
;Ozonated
-~ .+k _. ,... .. ... .r.-
NH3-N (mg/L)
2.7 (4.5)
9.4
4.7 (3.0)
10.1
1.1 (0.5)
2.9
NO3/NO2-N (mg/L)
0.8 (0.5)
7.9
0.1 (0.1)
3.9
0.3 (0.1)
1.2
TKN (mg/L}
51 (73)
25.5
42 (46)
26.5
14 (18)
11.5
Organic N (mg/L)
48 (69)
16
37 (43)
16
13 (18)
9
TN (mg/L)
52 (74)
33
42 (46)
30
14 (18)
13
COD (mg/L)
2920 (2920)
1672
2510 (2285)
1680
374 (390)
350
TP (mg/L)
3.3 (2.5)
2.5
2.5 (1.5)
5.7
3.0 (1.7)
4.3
11.4 Note: Values in parentheses represent analyses performed by laboratory.
27211r001 62 FINAL 10/99

ram
mot
011111
RIM
P1
PURI
Fgat
.o
Inn
TABLE 6-8
SUMMARY OF AEROBIC TREATMENT
. .� .et,t etp'
.. Y .iA ,V%^<iTj ': . S.. int t if' ' .. L :7 L 'b v'S t�
1
1. Control
Influent
2
- Test
Ozonated Influent
3
Control
Primary Clarifier Effluent
4
- Test
Ozonated Primary Clarifier Effluent
5
- Control
Secondary Clarifier Effluent
6
- Test
Ozonated Secondary Clarifier Effluent
„ag, 27211r001
63
FINAL 10/99

prigi
POI
0
NMI
The units were aerated for a period of seven (7) days. Aeration was provided using an
aquarium air pumpand diffuser stone. Temperature was maintained at 20 - 25 °C pH
q P �
was maintained at 6 - 9 s.u., and dissolved oxygen was maintained at a minimum of 2
mg/L. Samples were collected from each of the units prior to and following 7 days of
aeration. These samples were analyzed for TKN, NH3-N, NO2/NO3-N, COD and TP.
The results from these analyses are presented in Table 6-9.
6.2.3
Results and Conclusions
Following aerobic treatment, the total nitrogen concentration in the test units was
similar to that in the controls, which suggests that ozonation does not convert nitrogen
into a more biodegradable form.
Overall it appears that pretreatment by ozonation does not have a significant impact in
converting organic nitrogen to a more biodegradable form. In addition, ozonation does
not significantly improve removal of COD from the wastewater. Based on this study,
use of ozonation as a treatment step would require the wastewater to be acidified to a
pH ofj 3.0 s.u. Following the ozonation step, the wastewater would then need to be
neutralized using a chemical such as lime, which would increase the amount of sludge
generated. The use of ozonation would provide a significant increase both chemical
and sludge disposal costs without any significant improvement in wastewater treatment.
6.3 PAC ADSORPTION TESTING
Adsorption jar testing using powdered activated carbon (PAC) was performed to evaluate the
removal of TKN from the final effluent through adsorption. Testing was performed on a
sample of final effluent from the CKCI WWTP. Two (2) different types of PAC were used in
the testing, a bituminus-based (Calgon WPL) and a lignite -based
27211r001 64 FINAL 10/99

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
TABLE 6-9
RESULTS FOLLOWING AEROBIC TREATMENT
Parameter
a) .
,t.fi..Yv?:.>".'..s}'es_,.:. ...._.�..E,...�•...:,: :;.d..
. .'r�.,k,+.s.�{it.
.. i v>, ,,T 'v
Y w..p.At. ..,..":
., .C{,`c l+i.;.s.
{ r1.
1..,.t.e..�,�..1..,..y.
.. ConS..Y. .... t.ir>ol
.,-%b,.iivFv{
it 31,...w...-..,
Un2 Te
2;gtiAi:
3 - Co„f.ntrol
a
,,
Unt4-.ik.T.<
Unit
o.n o�
ni6,stitia
t
�.,U.�....;.._.-.Sn..
1:„-,.--,;,-a,:::::,
a•�
Ai.
•
'hR�K
�-
a.sat:R{?
M •.qa
:...�..i-]114t
.�.,.
vaii2)
A
t)
_
Unit
•
��E $c
r
S'tv,
.twin. !
"♦ e
Ii ,l...l..+0-J.�
�,.
?p ♦:id<
aal
x l•i.)
tniai
,LFi.na,'
i )
',: :.:.i..,X,:::
A.
t.M`'_�.......-;:.R-.S,.4..�.rx.
it'.��i.„r.r'.!';.�,•
,
_
,
.��" 7"�
t{c;,,,,Y^3,
w,fi.
s.
1_,.,.. i�
o.."'9�.
Ai•e�tns.
`�aeu
:v
;:..:
NH3-N (mg/L)
4.9
< 1
10.8
4.9
5.7
2.6
9.6
10.0
3.5
2.2
6.0
8.0
NO3/NO2-N (mg/L)
0.10
0.05
4.4
1.65
0.11
0.09
3.2
0.01
0.11
0.35
0.9
0.07
TKN (mg/L)
37.2
32.8
27.6
23.6
(3)
22.7
30.8
23.2
17.2
14.5
16.8
16.1
Organic N (mg/L)
32.3
31.8
16.8
18.7
(3)
20.1
21.2
13.3
13.7
12.3
10.8
8.1
TN (mg/L)
37.3
32.9
32.0
25.2
(3)
22.8
34.0
23.2
17.3
14.9
17.7
16.2
COD (mg/L)
2215
1031
1670
729
2140
656
1630
528
366
392
366
303
(1) Samples collected from the units prior to aeration.
(1) Samples collected from the units following 7 days of aeration.
(2) TKN results was less than NH3-H result and not consistent with other results.
27211r001 65 FINAL 10/99

fan
PAC (Hydro Darco C). Jar testing was performed at a PAC dose of 1,000 mg/L under various
pH conditions. The results of the jar testing are presented in Table 6-10.
Based on the results of this testing, it appears that lower pH improves the performance of the
activated carbon adsorption process. The data indicates that some of the TKN (organic
nitrogen) can be reduced in the final effluent through the use of PAC; however, a fairly high
dosage is required. At a PAC dose of 1,000 mg/L, approximately 35 % to 45 % of TKN is
removed from the final effluent. The results of these tests indicate that using PAC to treat the
final effluent would not result in a significant decrease in final effluent nitrogen concentration
and that extremely high dosages of PAC would be required.
6.4 HYDROGEN PEROXIDE PRETREATMENT
Batch testing was conducted to evaluate the use of hydrogen peroxide (H2O2) to help break
down the nitrogen in the waste into a more readily biodegradable form in order to reduce the
discharge of total nitrogen from the WWTP. Primary clarifier effluent was pretreated with
rim
100 mg/L of H2O2. In order to evaluate the results of the pretreatment systems in the full-scale
system, the wastewater samples were polished using aerobic biological treatment.
6.4.1 Pretreatment of Samples with Hydrogen Peroxide
Samples of primary clarifier effluent (PCE) and return activated sludge (RAS) were
collected from the CKCI WWTP. Prior to initiating aerobic treatment, samples of PCE
were pretreated with 100 mg/L H2O2 at a pH of 5, 7 and 9. The PCE samples were
mixed for 2 hours following the addition of H2O2 and then aerobic treatment was
initiated.
27211r001
66 FINAL 10/99

TABLE 6-10
RESULTS OF PAC JAR TESTING
Carbon Type (1)
PAC Dose
(mg/L)
pH
TKN (mg/L)
NH3-N (mg/L)
NO2/NO3-N (rng/L)
Initial
Final
% Removal
Initial
Final
Initial
Final
Control
Calgon WPL
Hydro Darco C
0
1,000
1,000
5.0
14.1
14.1
14.1
14.4
7.5
9.7
-2%
47%
31%
4.1
4.1
4.1
4.5
3.6
3.8
1.9
1.9
1.9
2.2
3.5
3.1
Control
Calgon WPL
Hydro Darco C
0
1,000
1,000
7.0
14.1
14.1
14.1
13.8
8.8
(2)
2%
38%
(2)
4.1
4.1
4.1
4.0
3.3
3.4
1.9
1.9
1.9
2.0
4.4
3.0
Control
Calgon WPL
Hydro Darco C
0
1,000
1,000
9.0
14.1
14.1
14.1
14.1
9.5
9.1
0%
33%
35%
4.1
4.1
4.1
3.8
3.9
3.0
1.9
1.9
1.9
1.6
3.8
2.9
(1) Control = no carbon, Calgon WPL = bitumus based PAC, Hydro Darco C = lignite based PAC
(2) TKN Result > 14 mg/L not consistent. Insufficient sample available for repeat analysis.
27211r001
67
FINAL 10/99

AND
6.4.2 Aerobic Batch Testing
A total of four (4) batch aerobic activated sludge reactors were operated. Each reactor
contained 10.8 L of PCE and 1.2 L of RAS. Reactor 1 contained PCE that had not
been pretreated with H202 and served as the control. Reactors 2, 3 and 4 contained the
H202 pretreated samples and served as the test reactors. A summary of the batch
testing conditions is presented in Table 6-11. Phosphoric acid was added to each unit
to maintain proper nutrients for biological growth conditions.
The reactors were aerated and mixed for a period of seven (7) days. Aeration was
provided using an aquarium air pump and diffuser stone. Mixing was provided using a
variable speed mixer. Temperature was maintained at 20 - 25°C, pH was maintained at
6 — 9 s.u., and dissolved oxygen was maintained at a minimum of 2 mg/L. The
reactors were shutdown after 7 days of aeration. Samples were collected from each of
the reactors at start-up and following 7 days of aeration. These samples were analyzed
for TKN, NH3-N, NO2/NO3-N, COD and TP. The results from these analyses are
presented in Table 6-12.
6.4.3
Results
The results of the study indicated that the hydrogen peroxide treatment did not provide
any significant improvement in the total nitrogen removal. The peroxide pretreatment
step provided less than 15 % total nitrogen removal and up to a 15 % COD increase.
However, following the aerobic treatment polishing step, the improvement in total
nitrogen removal was less than 10% and there was no difference in the overall COD
removal.
Based on this study, the use of 100 mg/L H202 as a pretreatment step would not result
in any significant improvement in total nitrogen removal through the wastewater
treatment system.
27211r001 68

TABLE 6-11
AEROBIC REACTOR SET-UP AND TESTING CONDITIONS
Reactor
No.
Reactor
Contents (1)
Condition Tested
1
1.2 L RAS +10.8 PCE
Control
2
1.2 L RAS + 10.8 PCE
PCE pretreated with 100 mg/L H2O2, pH = 5
3
1.2 L RAS + 10.8 PCE
PCE pretreated with 100 mg/L H2O2, pH = 7
4
1.2 L RAS + 10.8 PCE
PCE pretreated with 100 mg/L H2O2, pH = 9
(1) RAS = Return Activated Sludge
PCE = Primary Clarifier Effluent
27211r001 69 FINAL 10/99

TABLE 6-12
RESULTS FOLLOWING AEROBIC TREATMENT
Reactor
No.
TKN (rng/L)
NH3-N (mg/L)
NO2/NO3-N (mg/L)
TN (mg/L)
Day 0(1)
Day 7(1)
Day 0
Day 7
Day 0
Day 7
Day 0
Day 7
1
28
22
2.2
3.5
0.28
0.16
28
22
2
24
23
3.1
4.9
0.23
0.23
24
23
3
25
20
2.7
2.7
0.04
0.27
25
20
4
27
20
2.7
3.3
0.20
0.05
27
20
Reactor
No.
Organic N (mg/L)
COD (mg/L)
TP (mg/L) (2)
Day 0
Day 7
Day 0
Day 7
Day 0
Day 7
1
26
19
1070
380
9.3
10.6
2
21
18
1180
416
8.3
10.0
3
22
17
1205
397
9.3
10.5
4
24
17
1245
377
9.5
9.8
(1) Day 0 = Reactor start-up; Day 7 = Reactor shut -down.
(2) 9 mg/L of P added to each reactor.
27211r001
70
FINAL 10/99

6.5 EXTENDED AERATION
Batch testing was conducted to evaluate the effects of extended aeration for reducing the
discharge of total nitrogen from the CKCI WWTP. This testing was conducted in parallel with
the hydrogen peroxide pretreatment batch testing, presented in the previous section of this
report.
6.5.1 Aerobic Batch Testing
Samples of secondary clarifier effluent (SCE) and return activated sludge (RAS) were
collected from the CKCI WWTP. Since the extended aeration test was conducted at the
same time as the hydrogen peroxide pretreatment test, the control reactor (Reactor 1)
from the hydrogen peroxide pretreatment test was also used as the control reactor
during the extended aeration test. The control reactor contained 10.8 L of PCE and the
test reactor contained 10.8 L of SCE. Both reactors were seeded with 1.2 L of RAS.
Each reactor had a final volume of 12.0 L.
The reactors were aerated and mixed for a period of seven (7) days. Aeration was
provided using an aquarium air pump and diffuser stone. Mixing was provided using a
variable speed mixer. Temperature in the reactors was maintained at 20 . - 25 ° C, pH
was maintained at 6 — 9 s.u., and dissolved oxygen was maintained at a minimum of 2
mg/L. The reactors were shutdown after 7 days of aeration. Samples were collected
from each of the reactors at start-up and following 7 days of aeration. These samples
were analyzed for TKN, NH3-N, NO2/NO3-N, COD and TP. The results from samples
collected from the control reactor are presented in Table 6-12 (Reactor 1). The results
from samples collected from the test reactor are presented in Table 6-13.
P
6.5.2 Results
Following 7 days of aerobic treatment, the total nitrogen concentration in the test
reactor remained unchanged from the initial start-up conditions. These results indicated
that extended aeration is not effective in reducing the total nitrogen in the waste.
27211r001 71 FINAL 10/99

TABLE 6-13
RESULTS FOLLOWING EXTENDED AERATION
Parameter
Day 0
Day 7
TKN (mg/L)
12
12
NH3-N (mg/L)
1.0
<1.0
NO2/NO3-N (mg/L)
1.1
.55
TN (mg/L)
13
13
Organic N (mg/L)
11
11
COD (mg/L)
312
315
TP (mg/L)
1.5
2.4
27211r001 72 FINAL 10/99

.w
Fig
6.6 ANAEROBIC PRETREATMENT
Batch treatability testing was performed to evaluate the use of anaerobic biological
pretreatment to help break down the nitrogen in the waste into a more readily biodegradable
form in order to reduce the discharge of total nitrogen from the WWTP. In order to evaluate
the effectiveness of anaerobic pretreatment in the full-scale system, the samples were polished
using aerobic biological treatment following anaerobic pretreatment.
6.6.1
Overview of Batch Testing
Two reactors were operated during testing, an anaerobic test reactor and an aerobic
control reactor. Both reactors were operated in parallel for seven days. After seven days
of treatment, the aerobic control reactor was shutdown. In the anaerobic reactor, the
supernatant was transferred to an aerobic reactor and treated for an additional seven days.
Following seven days of aerobic biological treatment, the reactor was shutdown.
6.6.2 Sample Collection
Samples of return activated sludge (RAS) and primary clarifier effluent (PCE) were
collected from the CKCI WWTP. The RAS and PCE were used in both the aerobic
control and anaerobic test reactors. Samples of anaerobic sludge were collected from
the City of Winston-Salem Archie Elledge WWTP (Winston-Salem, NC) and from the
Fleischmann Inc. WWTP (Gastonia, NC). The anaerobic sludge samples were used to
seed the anaerobic reactor. All samples were analyzed for supernatant TKN, NH3-N,
NO2/NO3-N, COD and TP. The wastewater characteristics are presented in Table 6-
14. Based on the characteristics of the waste samples, the anticipated concentrations in
each reactor were calculated. These values are also included in Table 6-14.
6.6.3 Aerobic Control Reactor
The aerobic control reactor was started -up with 10.8 L of PCE and 1.2 L of RAS from the
CKCI WWTP as shown in Table 6-15. The total volume in the reactor was 12.0 L.
Phosphoric acid was added to the reactor in order to provide sufficient phosphorus for the
microorganisms. Samples were collected from the reactor at start-up and analysis was
27211r001
73 FINAL 10/99

i � 1
TABLE 6-14
WASTEWATER CHARACTERISTICS
Wastewater Sample
TKN
(mg/L)
NH3 N
(mg/L)
NO2/NO3 N
(mg/L)
COD
(mg/L)
TP
(mg/L)
RAS Supernatant
24
11.5
0.15
270
0.44
Fleischmann's Anaerobic Sludge (Supernatant)
348
224
1.76
3936
26
Archie Elledge Anaerobic Sludge (Supernatant)
440
428
0.32
478
168
CKCI PCE (Supernatant)
26
2.4
0.15
1828
0.25
Aerobic Control Supernatant (Day 0 anticipated)(`)
26
3.3
0.15
1672
0.27
Anaerobic Reactor Supernatant(Day 0 anticipated)(`)
75
46
0.27
1774
13.1
(1) Calculated based on supernatant concentrations and volume of sample added to lack reactor.
TABLE 6-15
SUMMARY OF REACTOR CONDITIONS
Reactor
Reactor Contents
Operating Conditions
Aerobic
•
10.8 L PCE
•
pH = 6 - 9
Control
•
1.2 L RAS
•
Temp = ambient (>20°C)
Reactor
•
DO = >2 mg/L
Anaerobic
•
16.0 L PCE
•
Temp = 95°F ± 3°F
Pretreatment
•
1.33 L RAS
•
DO = 0 mg/L (anaerobic)
Reactor
•
1.33 L Archie Elledge WWTP Anaerobic Sludge
•
1.33 L Fleischmann WWTP Anaerobic Sludge
Aerobic
•
10.8 L Supernatant from Anaerobic Pretreatment Reactor
•
pH = 6 - 9
Polishing
(following 7 days of anaerobic pretreatment)
•
Temp = ambient (>20°C)
Reactor
•
1.2 L RAS
•
DO = > 2 mg/L
27211r001
74
FINAL 10/99

performed on the supernatant. The results of these analyses (Day 0) are presented in
Table 6-16.
The contents of the reactor were mixed for seven days and aeration was provided using an
aquarium air pump and diffuser stone. The operating conditions in the reactor are
presented in Table 6-15. Dissolved oxygen (DO) was monitored daily and maintained
above 2 mg/L. Temperature was maintained above 20°C (ambient temperature) and the
pH was adjusted daily to maintain a pH between 6.0 and 9.0 s.u. A floating foam cover
was used in the reactor to prevent evaporation during testing.
After seven days of aeration and mixing, the reactor was shutdown. The solids were
allowed to settle and the supernatant was collected for analysis. The results of these
analyses (Day 7) are presented in Table 6-16.
6.6.4 Anaerobic Pretreatment Reactor
The anaerobic reactor was started -up with 16.0 L of PCE, 1.33 L of RAS, 1.33 L of
Archie Elledge WWTP anaerobic sludge and 1.33 L of the Fleischmann WWTP
anaerobic sludge as shown in Table 6-15. The final reactor volume was 20.0 L. The
reactor was mixed and samples were collected for analysis of the supernatant. The results
of these analyses (Day 0) are presented in Table 6-16. Following sample collection, the
reactor was sealed to maintain anaerobic conditions. The reactor was operated for seven
days. Mixing was provided using an air powered mixer and the temperature was
maintained at 95°F using a heating/cooling water recirculator.
After seven days of anaerobic treatment, the anaerobic reactor was shutdown. The solids
in the' reactor were allowed to settle and the supernatant was collected for polishingin an
P
aerobic reactor. The supernatant was also analyzed and the results (Day 7) are presented
in Table 6-16.
27211r001 75 FINAL 10/99

1 i y
TABLE 6-16
ANAEROBIC PRETREATMENT BATCH STUDY RESULTS
Reactor
TKN (mg/L)
NH3-N (mg/L)
NO2/NO3 N (mg/L)
Total P (mg/L)
Day 0
Day 7
Day 0
Day 7
Day 0
Day 7
Day 0
Day 7
Aerobic Control Reactor
27
28
2.8
6.1
0.05
0.27
7
10
Anaerobic Pretreatment Reactor
Aerobic Polishing Reactor (I)
110
140
160
31
73
64
88
<1
0.10
0.32
0.20
33
15
25
21
14
Reactor
Organic-N (mg/L)
Total N (mg/L)
COD (mg/L)
Alk (mg/L)
Day 0
Day 7
Day 0
Day 7
Day 0
Day 7
Day 0
Day 7
Aerobic Control Reactor
24
22
27
28
1446
422
-
-
Anaerobic Pretreatment Reactor
Aerobic Polishing Reactor (1)
37
76
72
30
110
140
160
64
1802
1714
2184
609
1175
-
2150
-
(1) Aerobic Polishing Reactor = 10 8 L of supernatant from the anaerobic pretreatment reactor + 1.2 fresh CKCI RAS.
27211r001 76 FINAL 10/99

The aerobic polishing reactor was started -up with 10.8 L of anaerobic supernatant
and 1.2 L of fresh CKCI RAS. The final volume in the reactor was 12.0 L.
Phosphoric acid was added in order to provide the sufficient phosphorus for the
microorganisms. ernatantisms. Samples were collected from the reactor and the supernatant
g p
was analyzed. The results of these analyses (Day 0) are presented in Table 6-16.
The aerobic polishing reactor was operated identical to the aerobic control reactor
as shown in Table 6-15 and was operated foraperiod of seven days.
pY
After seven days of aeration and mixing, the reactor was shutdown. The solids
were allowed to settle and the supernatant was collected for analysis. The results
of these analyses (Day 7) are presented in Table 6-16.
6.6.5 Results and Conclusions
Thee results from the testing are summarized in Table 6-16. The organic nitrogen
Day7 results for both the aerobic reactor and the aerobic polishing reactor are
p g
similar, indicating that anaerobic pretreatment did not help to break down the
CKCI waste into a more biodegradable form. The aerobic polishing reactor
contains higher levels of nitrite/nitrate on Day 7; however, this is mainly
attributed to the nitrification of the ammonia contained in the anaerobic sludges.
The high levels of nitrite/nitrate do not seem to be related to a break down of the
CKCI waste. The COD results indicate that this did not improve COD removal.
The alkalinity results indicate that proper conditions were maintained throughout
anaerobic treatment.
Based on the results of this testing, it does not appear that anaerobic pretreatment
will help to break down the organic nitrogen in the CKCI waste into a more
readily degradable radable form.
27211r001 77 FINAL 10/99

6.7 RESIN ADSORPTION
Laboratory testing was performed using a macroreticular resin to evaluate the removal
of TKN from the CKCI final effluent through adsorption. Testing was performed using
a 1.7-inch diameter glass column filled with 16 inches of Amberlite XAD7HP
macroreticular resin (Rohm and Haas). Final effluent was loaded onto the resin column
at a rate of 0.011 gpm/ft3. This loading rate, which is below the recommended full-
scale rate
of 0.25-2.0 gpm/ft3, was used in order to allow complete contact between the
wastewater and the resin.
The TKN in the final effluent was reduced from 15.0 to 5.5 mg/L (63 %) after being
passed through the resin column. Influent and effluent NH3-N concentrations were less
than 1 mg/1, therefore the fraction of nitrogen removed was organic nitrogen. Based on
the results of this testing, it appears that a portion of the TKN (organic nitrogen) can be
reduced in the final effluent through the use of the resin.
This testing indicates that using resin to treat the final effluent would result in a
decrease of total nitrogen. In order to treat a maximum full-scale flow of 0.40 MGD, a
minimum resin bed volume of 140 ft3 would be required at a resin cost of $565/ft3. The
resin would need to be regenerated using a water-soluble solvent such as methanol,
.., isopropanol or acetone and would require a solvent recovery still.
MEI
6.8 SUMMARY OF RESULTS
Extensive treatability testing was conducted on the CKCI wastewater. The results of
the tests showed that tertiary precipitation using ferric chloride could reduce the
effluent phosphorus concentration.
The results of the process evaluation and treatability testing indicate that biological
treatment using nitrification and denitrification would not be applicable for the CKCI
facility. Tertiary treatment of up to 7 days did not provide any additional treatment. In
27211r001
78 FINAL 10/99

NMI
SO4
4.41
ONO
�0-
U
addition, there was significant variability in the nitrogen fraction due to ammonia
nitrogen and nitrate and nitrite nitrogen. There are only periodic episodes of elevated
ammonia nitrogen and nitrate nitrogen concentrations. The effluent ammonia nitrogen
and nitrate and nitrite nitrogen is typically less than 3 mg/1 and in many cases less than
1 mg/I. In order for a biological nitrification-denitrification process to operate
effectively, a consistent feed of these forms of nitrogen is needed. The variability in
wasteload at the CKCI facility limits biological treatment. A more consistent food
source is required because of the inherent variability in this treatment system.
Therefore, nitrification-denitrification would not be effective and biological treatment
does not appear to be an option.
The addition of high dosages of PAC at low pH is effective in reducing organic
nitrogen. However, because such high daily dosages of PAC addition would be
required, treatment of the waste with PAC would not be a cost effective treatment
alternative. The only feasible process which showed ability to reduce nitrogen levels
was the use of macroreticular resins. The use of macroreticular resin for nitrogen
removal and the use of ferric chloride for phosphorus removal was evaluated for cost-
-
effectiveness in Section 7.0 of this report.
WNW
27211r001
79 FINAL 10/99

011011
SECTION 7.0
COST EFFECTIVE BAT ANALYSIS OF
ALTERNATIVE TERTIARY TECHNOLOGIES
Through the detailed review and optimization program the baseline total phosphorus
and nitrogen wasteload from the existing BAT OCPSF treatment system has been
developed. The objective of this section is to review the technically feasible systems
for providing additional treatment.
The total nitrogen (TN) in the discharge includes ammonia nitrogen, organic nitrogen,
nitrate nitrogen, and nitrite nitrogen. There is very little nitrite nitrogen in the
wastewaters so that the parameters of concern are ammonia nitrogen, organic nitrogen
and nitrate nitrogen.
There are several problems in being able to define BAT technologies for achieving
removals beyond the baseline levels defined in Section 5.0. A conventional approach
`�' for providing removal of ammonia nitrogen and nitrate nitrogen would be through
biological nitrification and denitrification. However, because of the variability in
wasteloads, biological nitrification/denitrification does not appear to be effective for the
CKCI wastewaters. For biological nitrification or denitrification to occur, there needs
to be a constant loading of these constituents to the treatment plant. This provides a
consistent base for growth of the organisms which remove these constituents, primarily
1.1
nitrosomonas, nitrobacter, pseudomonas, achromobacter, bacillus and micrococcus.
However, there are only periodic episodes of elevated ammonia nitrogen and nitrate
nitrogen concentrations in the wastewater. The effluent ammonia nitrogen and nitrate
nitrogen are typically less than 3 mg/L, and in many cases less than 1 mg/L.
Therefore, there is not an adequate food source because of the inherent variability of
the treatment facility and a biological nitrification/denitrification process would not be
effective.
27211r001
80 FINAL 10/99

Alternative physical -chemical treatment technologies would need to be implemented to
provide ammonia and nitrate removal when these are present. The technologies include
land application, breakpoint chlorination, steam stripping, and ion exchange. A
preliminary review of these technologies indicates inherent problems that would negate
their use in this application. For example steam stripping and ion exchange are very
�• expensive, breakpoint chlorination could result in significant toxic by-products and
there is limited land available for land application. Therefore, the technologies that
were found in Section 6.0 to reduce the nitrogen, address the organic nitrogen fraction.
Based on the results of the treatability testing presented in Section 6.0, additional
nutrient removal can be achieved through precipitation using ferric chloride for
phosphorus reduction and adsorption using macroreticular resins for organic nitrogen
reduction. The objective of these technologies are to provide treatment to levels which
can meet or approach the proposed nutrient limits of 6 mg/I total nitrogen and 1 mg/1
total phosphorus. The process designs are presented in this section along with a
discussion of their specific merits and preliminary cost estimates. A cost effectiveness
analysis has been conducted to determine if these are consistent with BAT technology
criteria.
Process designs were developed for each of the nutrient removal technologies
mentioned above and were developed based on typical waste loads in the full-scale
system. The process designs are presented in this section along with a discussion of
their specific merits and preliminary cost estimates. The basis of the designs and cost
estimates are included in Appendix F. A cost effectiveness analysis has been conducted
to determine if implementation of these technologies is consistent with BAT technology
criteria. This section focuses on a presentation of the actual design parameters and the
estimated cost to implement and operate each of these treatment technologies.
27211r001
81 FINAL 10/99

INN
OM
7.1 PRECIPITATION USING FERRIC CHLORIDE FOR PHOSPHORUS
REDUCTION
As discussed previously, precipitation using ferric chloride has been shown in
laboratory testing to reduce phosphorus concentrations in the CKCI final effluent to less
than 1 mg/1. Based on the results of the laboratory testing, a tertiary precipitation
treatment system was designed. Table 7-1 presents the design information and Figure 9
presents a process flow diagram of the system. The system was designed as a tertiary
treatment system and should be implemented following secondary clarification.
The system would include a rapid mix tank, flocculation tank, tertiary clarification and
neutralization. The rapid mix tank will provide flash mixing for chemical addition.
Liquid ferric chloride will be flow -paced to the rapid mix tank using a chemical
metering pump and a magnetic flow meter. The results of the jar testing indicated
extremely poor settling; therefore polymer will be added in the rapid mix tank to aid
settling in the tertiary clarifier. Slow mixing is provided in the flocculation tank to
allow proper floc formation to occur. The tertiary clarifier is designed to handle the
poor solids settling with an overflow rate of 200 gpd/ft2. A portion of the settled solids
from the tertiary clarifier will be pumped back to the flocculation tank to serve as a
seed in order to enhance precipitation. The remaining settled tertiary solids would be
handled by the existing sludge handling equipment. Based on the estimated solids
generation, the existing sludge press has sufficient capacity to handle the additional
solids load.
The addition of ferric chloride causes a slight reduction in pH; therefore, following
tertiary clarification the wastewater will need to be neutralized in order to prevent a
violation due to low effluent pH below the permitted discharge limit of 6.0. The
neutralization system has been sized usingsodium hydroxide. The neutralization tank
�., Y Y
will be equipped with a pH probe connected to a controller. The pH controller will be
used to meter NaOH to the neutralization tank. Following neutralization, the treated
wastewater will be discharged to the South Fork of the Catawba River.
27211r001
82 FINAL 10/99

TABLE 7-1
PROCESS DESIGN SUMMARY FOR TERTIARY TREATMENT USING
PRECIPITATION
i
Pad , eter -' r K
..,_.� S i� 5 ��. s^ , r..-- t•�.�.. .... ., ,..i t rh �1 A r '{
Design Value
is iS's ^i
Flow
Design
Long Term Average
0.40 MGD
0.33 MGD
Phosphorus
Secondary Clarifier Effluent »
Estimated Removal
Final Effluent
2.75 mg/L
1.75 mg/L
1.0 mg/L
Ferric Chloride Dose
75 mg/L
Polymer Dose
75 mg/L
Caustic Dose
55 mg/L
Rapid
Mix Tank
Volume
Detention Time @ 0.40 MGD
200 gal
45 sec.
Flocculation Tank
Volume
Detention Time @ 0.40 MGD
4,350 gal
15 min.
Tertiary Clarifier
Diameter
Surface Area
Side Water Depth
Overflow Rate
50 ft.
1,964 ft2
14 ft.
200 gpd/ft2
Neutralization Tank
Volume
Detention Time @ 0.40 MGD
1,500 gal
5 min
Estimated
Sludge Generation
Settled Sludge (est. 1 % solids)
Dewatered Sludge (est. 25 % solids)
4000 gal/d
21 ft3
ased on baseline effluent total phosphorus.
27211r001
83 FINAL 10/99

1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
I
1
1
POLYMER
STORAGE
FERRIC
CHLORIDE
STORAGE
SECONDARY
CLARIFIER
EFFLUENT
POLYMER FEED
SYSTEM
r--
LEGEND
FLOW METER
October 14. 1999 1: 36: 23 p.m.
Drawing: V: \N272\27211102.DWG
FERRIC
CHLORIDE
METERING PUMP
RAPID MIX
TANK
pH
CON TROLLER
FLOCCULATION
TANK
4.01
NaOH
STORAGE
NaOH
METERING
PUMP
EMMEN
NEUTRALIZATION
TANK
i TERTIARY
CLARIFIER
�-- TO SLUDGE DEWATERING
DISCHARGE TO
SOUTH FORK OF
CATAWBA RIVER
TERTIARY TREATMENT: PRECIPITATION WITH
FERRIC CHLORIDE
SCALE N.T.S. APPROVED BY : DRAWN BY: MRW
DATE SEPT. 1999 DESIGNED BY : L. GELLNER REVISED
PROJECT
N272 1 1 9305-J MONROEDRAWING RO. CHARLOTTE. NC 28270 FIGURE 9

ao
composition of the wastewater it will be difficult to consistently meet a total phosphorus
discharge limit of 1 mg/L.
A summary of the estimated cost for this system is summarized in Table 7-2.
WO
Based on laboratory testing, this treatment technology appears to be effective in
reducing phosphorus concentrations; however, because of the changes in the chemical
Construction and installation of the new facilities will cost approximately $691,100,
with an annual operating cost of $184,100. The annualized cost for this treatment
technology is $291,800 per year, assuming a capital recovery factor for 10 years at 9%
interest. Based on a phosphorus removal of 1.75 mg/L and an average flow of 0.33
MGD, the cost of treatment is $166/lb P.
7.2 ADSORPTION USING A MACRORETICULAR RESIN FOR ORGANIC
NITROGEN REDUCTION
Organic nitrogen is the primary source of nitrogen in the CKCI effluent. As discussed
0'1 previousl , adsorption using a specialized macroreticular resin has been shown in
laboratory testing to be effective in reducing the organic nitrogen in the wastewater by
63 % . The adsorption system is not a conventional treatment technology because of the
regeneration procedure used. The macroreticular resin must be regenerated using a
MEI
water-soluble solvent such as methanol, isopropyl alcohol or acetone. Treatment of the
solvent -based regenerant is more complex than typical adsorption/ion which typically
use an aqueous -based regenerant. In order to treat the regenerant in the resin system,
distillation must be used. Based on the results of the laboratory testing and the
characteristics of the wastewater, a tertiary adsorption treatment system was designed.
The system would include three 12-foot diameter columns, each loaded with 556 ft3 of
macroreticular resin (1668 ft3 total). Secondary clarifier effluent would be treated
through the columns and then discharged to the South Fork of the Catawba River. This
is expected to reduce the organic nitrogen concentration by approximately 63 % based
on the results of laboratory treatability testing. The resin columns would be
regenerated using a water-soluble solvent such as methanol.
27211r001
85 FINAL 10/99

TABLE 7-2
TERTIARY TREATMENT TECHNOLOGY COST ESTIMATES
Treatment Technology
Description
Estimated Costs
Precipitation with
Ferric Chloride
Adsorption Using a
Macroreticular Resin
Major Processes cost
$411,400
$2,267,000
Electrical
$41,100
$131,000
Engineering
$41,100
$131,000
Contingency
$123,400
$394,000
Contractor OH&P
$74,100
$236,000
Total Project Cost
$691,100
$3,159,000
Annual Operating Cost
$184,100
$641,400
Equivalent Annual Cost (1)
$291,800
$1,133,600
(1) Based on a Capital Recovery Factor for 10 years @ 9% interest.
27211r001 86 FINAL 10/99

1•
Regeneration would require approximately 12,500 gallons of methanol to be pumped
through each adsorption column in order to regenerate the resin. Each column would
be regenerated every 3 days. The spent regenerant would be treated by distillation in
order to recover the methanol for reuse. Still bottoms from the distillation process
would be hauled off -site for disposal. Table 7-3 presents the design information and
Figure 10 presents a process flow diagram of the system.
There is very little information on the full-scale application of macroreticular resins. In
analyzing the economics of the system, vendors have indicated that it may be very
�► difficult to treat the regenerant using steam stripping and disposal of the regenerant may
be necessary. If this occurred this would significantly increase the cost of operating the
system. Furthermore, it is has not been determined how frequently the resin would
need to be regenerated. A higher frequency of regeneration would result in higher
operating costs and potentially higher capital costs. If this process were to be
implemented in the full-scale system, additional treatability and pilot testing would need
to be performed in order to evaluate performance under various conditions and perform
a more detailed economic analysis.
Based on the results of treatability testing, this system is estimated to reduce the organic
nitrogen by 63 % . However, because the design hydraulic loading rate of this system is
almost twice as high as the rate used in the treatability testing, nitrogen removal
pin
efficiency may be lower than 63 % . Based on the statistical analysis of the full-scale
data for TN, 63 % removal of organic nitrogen is equivalent to 23 mg/1 TN removed.
The resin adsorption system requires 1668 cubic feet of macroreticular resin in three (3)
adsorption columns in order to treat the waste. A summary of the estimated cost for
this system is presented in Table 7-2. Purchase and installation of the system will cost
wal approximately $3,159,000, with an estimated annual operating cost of $641,400. The
annualized cost for this treatment technology is $1,133,600 per year, assuming a capital
recovery factor for 10 years at 9% interest. Additionally, it is estimated that the resin
MCI
27211r001
87 FINAL 10/99

TABLE 7-3
PROCESS DESIGN SUMMARY FOR ADSORPTION
USING A MACRORETICULAR RESIN
:: Paia peter 4 , :
, Desi ga»' , lue,
>6. •, Rita ,A
Design Flow
g 0
0.40 MGD
Nitrogen Removal
Secondary Clarifier Effluent TNT')
Organic Nitrogen Removal(2)
Total Nitrogen Removal
Final Effluent TN
52.5 mg/L
23 mg/L
23 mg/L
29.5 mg/L
Resin Columns
Number of Columns
Diameter
Volume of Resin, per Column
Total Volume of Resin
Bed Depth
3
12 ft.
556 ft3
1668 ft3
5 ft.
Hydraulic Loading
Hydraulic Loading Rate
Treatment Cycle
0.25 gpm/ft3
94 BV (3)
Regeneration
Regeneration Rate
Regenerant
Regeneration Cycle
Regenerant Volume, per Column
0.25 gpm/ft3
methanol
3 BV
12,500 gal
Regenerant Recovery System
Process
Processing Rate
Volume Regenerant Processed
Methanol Recovered
Still Bottoms Generated
Distillation
700 gph
12,500 gpd
11,250 gpd
1,250 gpd
(1) Based on baseline effluent total nitrogen
(2) 63 % organic nitrogen removal based on treatability testing
(3) BV = Bed Volume
27211r001 88 FINAL 10/99

B
1
1
1
1
1
1
1
1
SECONDARY
CLARIFIER
EFFLUENT
• „
•
t
1
SPENT McOH
(REGENERANT)
STORAGE TANK
SOLVENT
RECOVERY SYSTEM
ADSORPTION
COLUMNS
October 26, 1999 1:42:48 p.m.
Drawing: V: \N272\27211PO1.DWG
1
TREATED SECONDARY
CLARIFIER EFFLUENT
DISCHARGED TO SOUTH FORK
OF CATAWBA RIVER
RECOVERED McOH
(REGENERANT)
STORAGE TANK
RECOVERED
M e0H
STILL BOTTOMS
HOLDING TANK
n
F•t11)t>),1);t)lt)t)t11)<7�
. ,",`_; 111)1111t)1.(11 ()1'1)_,
_U_ U.U_ L_U_ U_U_U_U_V ..
( ) (_.)( )
STILL BOTTOMS
HAULED OFF FOR
DISPOSAL
TERTIARY TREATMENT: ADSORPTION WITH
MACRORETICULAR RESIN
SCALE APPROVED BY : DRAWN BY:MRW
DATE OCT. 1999 DESIGNED BY : L. GELLNER REVISED
PROJECT NUMBER DFIRAWING N0.
N272-11 A144117�,N�GURE 10

OMR
will need to be replaced every 10 years, which will result in significant future costs.
Based on a nitrogen removal of 23 mg/1 at 0.33 MGD, the cost of treatment is $85/lb N
based on operation from April 1 through November 1.
7.3 BAT
APPLICABILITY
In order for a treatment technology to be applicable for BAT it must be cost-effective.
A conventional approach for evaluating cost-effectiveness is a comparison with the cost
associated with treatment through a conventional treatment facility. In order to develop
this economic basis a survey was conducted of nutrient removal costs and surcharges
from some of the major municipalities in the eastern southeastern United States which
have nutrient surcharges. A summary of the nutrient costs is presented in Table 7-4.
The results of this survey indicates that the average cost for nitrogen removal is $0.55
per pound of nitrogen and the cost for phosphorous removal is $1.96 per pound of
phosphorus. To define if the treatment technologies defined in this evaluation are cost
effective, the cost should be equal to or lower than the cost for a typical conventional
system. The results of this comparison, as shown in Table 7-4, indicate that the cost
for reducing the CKCI phosphorus is $166 per pound and for the nitrogen is $85 per
pound. These costs are based on a reduction of nutrients from the baseline monthly
average levels. The cost per pound of nutrient removed is substantially higher if
nutrient reduction is calculated using the long term averages. The cost for additional
treatment is significantly higher than that found for the conventional system.
Therefore, there are no cost-effective treatment technologies to achieve nutrient levels
beyond the levels achieved through optimization of the existing system and these levels
were deemed to be equivalent to BAT.
ROI
7.4 BAT DEFINITION
The results of the BAT analysis indicates that the optimized treatment plant
performance -baseline phosphorus and nitrogen represent BAT. The individual BAT
27211r001
90 FINAL 10/99

TABLE 7-4
SUMMARY OR NUTRIENT SURCHARGES FROM MUNICIPALITIES
Major Municipality
Nutrient Surcharge
Nitrogen
($/1001b N)
Phosphorus
($/100 Ib P)
Norfolk, VA (Hampton Roads Sanitation Dist.)
$20.36
$129
Raleigh, NC
$72
NA
Savannah, GA
$45
NA
Birmingham, AL
NA
$200
Baltimore, MD
$50
$200
Pensacola, FL (Escambia County Utilities)
$90
$254
Average Nutrient Surcharge from Major
$55.47/ 100 Ib
$195.75/ 100 lb
Municipalities
(S0.55/lb)
($1.96/1b)
Cost for CKCI to Reduce Nutrients Using
$85/ Ib
$166/ lb
Additional Treatment
= not applicable
27211r001 91 FINAL 10/99

limits are:
Total Phosphorus (TP)
Total Nitrogen (TN)
Total Non -Refractory Nitrogen (TNN)
p-/,:i/,i3 . i 3 L "`Ye_
324- d - ,
� T
A
0-4. c e'frei."--X
i ''
7.6 lbs/day
144.5 lbs/day
44 lbs/day
27211r001
92
FINAL 10/99

Appendix A
Contribution of Nutrients from CKCI to Lake Wylie

Nma
Major NPDES Discharger locations with facility name and avg. 93-94 daily nutrient loads for total nitrogen
(TN) and phosphorus (TP).
Long Creek
Gastonia 8.0 MGD
TP - 408 lbs/d (6.1 mg/I)
TN - 1069 lbs/d (16.0 mg/I)
Gastonia 9.0 MGD
TP - 282 lbs/d (3.8 mg/I)
TN - 955 lbs/d (12.7 mg/I)
JPS 4.0 MGD
TP - 90 Ibs/d (2.7 mg/I)
TN - 293 Ibs/d (8.8 mg/I)
Catawba Creek
Crowders Creek
Bessemer City 1.5 MGD
TP - 30 lbs/d (2.4 mg/I)
TN - 328 Ibs/d (26 mg/I)
Nutrient loadings fibs/day-
7.
TP 3.01, TN: 991'
I Pred Avg Chi a 74 ug/I '__
TP-801 Ibs/d
TN-7346 Ibs/d
60%
Catawba
River
Mt. Holly
4. 4.0 MGD
W TP - 110 Ibs/d
(3.3 mg/I)
TN - 304 Ibs/d
(9.1 mg/I)
Belmont
5.0 MGD
TP - 345 Ibs/d
(8.3 mg/I)
TN - 624 Ibs/d
(15 mg/I)
LAKE WYLIE
12%
Nutrient loadin_crs (Ilas/d�v) �
TP 150, TN_ 895' 1
Pred. `Avg. rC l a 43 ug/I 12 %
Gastonia 6.0 MGD
TP - 100 Ibs/d (2.0 mg/1)
TN - 423 Ibs/d (8.4 mg/I)
Legend/Explanation of terms
r
Nutrient Loadings:
TP - 1 195 Ibs/d
TN - 9726 lbs/d
Predicted average
ChI-a: 18.2 ug/I
To Lake Wylie Dam
0
— Nutrient sensitive lake areas where the state standard of 40 ug/I for chlorophyll -a is predicted to occur
I at some time during the growing season. Standard violations were observed twice in a 1989-90 study.
Areas where predicted average Chl-a concentrations exceed the state standard of 40 ug/I and where chronic
algal bloom conditions have been observed.
Note: Daily nutrient loadings in the 4 lake arms are based on 89-90 measured background levels plus
actual average 93-94 loadings from dischargers. Nutrient loading in the main lake is based on percentages
of the lake arm loadings that are thought to reach the lake based on a field -calibrated in -lake nutrient
transport model.
Figure 3.4 Schematic Diagram of Lake Wylie Showing Nutrient Loadings and Predicted
Chlorophyll -a Concentrations in the 4 Major Arms and the Mainstem of the Lake
4
i
w
■
■
w
■
■
P t Ca -F0./W (0— V-i Ue-✓ Tfit, rA V31.cLe. ir aQ.t• 4- -P LCvvk [ C1 S
■

1 1 1 1 1 1 1 1 i 1 1 1 1 1
EVALUATION OF NUTRIENT CONTRIBUTION FROM CROMPTON & KNOWLES COLORS INC. TO LAKE WYLIE
Data for Nutrient concentrations taken from the
Catawba River Basinwide Water Quality Management Plan (1995)
Source
TP (Ib/d)
TN (Ibld)
% Transported to Lake
Wylie (1)
Estimated Mass TP
Transported to Lake
Wylie (Ib/d)(')
Estimated Mass TN
Transported to Lake
Wylie (Ib/d)(2)
Catawba River
801
7346
60%
481
4408
South Fork
993
4760
40%
397
1904
Catawba Creek
301
991
12%
36
119
Crowders Creek
150
895
12%
18
107
Total
2245
13992
932
6538
(1) Percent transported obtained from Catawba Plan, 1995.
(2) These values were calculated from the % transported values.
C&K Discharge
Flow
(MGD) (1)
TP Discharge from
CKCI
TN Discharge from
CKCI
CKCI Transported to
Lake Wylie (2)
% Nutrients in S. Fork
from CKCI
% Nutrients in Lake
Wylie from CKCI
(mg/L)
(Ib/d)
(mg/L)
(Ib/d)
TP (Ib/d)
TN (Ib/d)
TP
TN
TP
TN
Case 1
0.203
3.0
5.1
50
85
2.0
33.9
0.51 %
1.78%
0.22%
0.52%
Case 2
0.203
2.0
3.4
10
17
1.4
6.8
0.34%
0.36%
0.15%
0.10%
Case 3 (ay. disch) (3)
0.203
1.9
3.2
32
54
1.3
21.7
0.32%
1.14%
0.14%
0.33%
Case 4 (proposed)
0.203
1.0
1.7
6.0
10
0.7
4.1
0.17%
0.21%
0.07%
0.06%
(1) Long Term Average: 4/1/99 - 9/30/99
(2) Assumed 40% transport in Catawba River based on information in Catawba Plan, 1995.
(3) Long Term Average: TP = during nutrient redution plan (11/98 - 8/99), TN = average over past 12 months (8/98-8/99).
27211s003
Lake Wylie 1
10/26/99

Appendix B
Summary of Full -Scale Monitoring Data

NUTRIENT DATA SUMMARY, WEEKLY AVERAGES
CROMPTON and KNOWLES COLORS Inc.
IMO
OEM
Week
Date
Inf. COD
(tb/d)
Inf. COD
(mg/L)
Eff. COD
(Ib/d)
Eff. COD
(mg/L)
Inf. BOD
(tb/d)
Inf. BOD
(mg/L)
Eff. BOD
(ib/d)
Eff. BOD
(mg/l)
Eff. TSS
(Ib/d)
Eff. TSS
(mg/1)
No.3
5/11/98
6854
2885
1813
700
-
-
141
52
520
205
. No.4
5/18/98
3965
2115
1113
425
-
-
237
91
512
194
No.5
5/25/98
4229
2360
1446
613
-
-
41
18
514
225
No.6
5/30198
4996
2636
1340
585
-
-
41
19
119
55
No.7
6/6/98
4844
2430
1213
531
-
-
50
24
73
34
No.8
6/13/98
4569
2116
1471
577
-
-
61
24
199
78
No.9
6/20/98
2851
1712
871
393
-
-
28
14
130
62
No.10
6/27/98
820
1734
-
-
-
-
5
_
10
27
13
No.11
7/4/98
3686
1938
1224
564
-
-
39
22
182
. 336
No.12
7/11/98
3291
1446
829
345
-
-
31
13
155
148
No.13
7/18/98
4675
2118
1344
547
-
-
109
45
150
64
No.14
7/25/98
5056
2714
1485
813
-
-
27
15
170
100
No.15
8/1/98
6421
3432
735
373
-
-
30
16
105
54 ••
No.16
8/8/98
3865
2321
521
318
-
-
31
19
47
28
No.17
8/15/98
3582
1585
1264
510
-
-
31
13
53
23
No.18
8/22/98
3791
1662
992
448
-
-
27
12
100
45
No.19
8/29/98
4586
1962
1271
556
-
-
34
15
43
19
No.20
9/5198
2829
1980
900
535
-
-
12
8
29
10
No.21
9/12/98
4467
2342
1236
584
-
-
9
4
41
20
No.22
9/19/98
4402
2177
1187
691
-
-
12
7
137
79
No.23
9/26/98
4288
1945
1372
622
-
-
27
15
134
94
No.24
10/3/98
6205
2800
1655
968
-
-
31
16
105
49
No.25
10/10/98
4206
1804
-
-
-
-
24
11
39
18
No.26
10/17/98
3826
2210
-
-
-
-
6
4
28
18
No.27
10/24/98
3796
1972
-
-
-
-
7
4
32
18
No.28
10/31/98
3407
1333
-
-
-
-
17
7
82
36
No.29
11/7/98
4124
1812
-
-
-
-
9
4
24
_
11
No.30
11/14/98
2452
1687
425
473
-
-
12
6
66
30
No.31
11/23/98
2101
2097
394
455
-
-
4
6
8
10
No.32
11/30/98
3200
2019
698
468
-
-
9
6
26
18
No.33
12/7/98
3089
1897
774
520
-
-
22
15
195
156
No.34
12/14/98
1512
1813
539
700
-
-
25
29
9
9
No.35
12/21/98
1689
1727
366
425
-
-
9
16
8
10
No.36
12/28/98
2363
1986
696
613
-
-
4
7
8
10
No.37
1/4/99
5244
2337
885
411
-
-
10
4
54
25
No.38
1/11/99
5292
2606
1171
598
1085
531
14
7
28
15
No.39
1/18/99
6073
2561
1616
720
1982
770
14
6
38
17
No.40
1/25/99
4691
2001
1197
538
1559
670
19
8
88
40
No.41
2/1/99
4486
1713
491
176
1620
573
17
6
54
21
No.42
2/8/99
5660
3187
969
545
2143
1049
12
7
• 62
34
No.43
2/15/99
5343
3378
758
517
-
-
14
9
49
32
No.44
2/22/99
4586
2506
809
473
-
-
19
10
33
18
No.45
3/1/99
3315
2363
488
395
-
-
4
4
62
53
No.46
3/8/99
1107
782
519
405
-
-
4
3
59
48
No.47
3/15/99
3360
1892
478
297
-
-
8
6
11
7
No.48
3/22/99
1806
2599
161
279
-
-
3
6
6
10
No.49
3/29/99
1411
1885
140
226
-
-
2
3
6
9
No.50
4/5/99
1762
1424
183
174
-
-
2
2
20
21
No.51
4/12/99
4433
2607
486
334
-
-
16
11
36
23.
No.52
4/19/99
2576
1925
830
497
-
-
16
10
87
56
No.53
4/26/99
3408
1629
1011
526
-
-
20
11
96
57
No.54
5/3/99
3558
1639
1052
546
324
137
6
3
38
20
No.55
5/10/99
2939
1672
1222
750
-
-
5
3
45
27
No.56
5/17/99
3161
2352
850
685
809
634
4
3
44
36
No.57
5/24/99
3418
2549
1008
757
697
619
4
3
100
76
No.58
5/31/99
4860
2199
1739
793
1030
434
11
5
117
52
No.59
617/99
2634
1374
1461
806
-
-
3
2
37
22
No.60
6/14/99
3909
1836
711
368
1810
832
7
3
187
90
No.61
6/21/99
3169
1792
488
250
1015
780
20
15
215
173
No.62
6/28/99
4262
1885
767
388
1055
806
24
12
93
50
No.63
7/5/99
1824
1616
165
147
92
99
8
7
146
151
No.64
7/j12/99
4975
2363
666
364
1774
684
23
15
120
67
No.65
7419/99
3567
2011
915
522
-
-
20
13
148
100
No.66
7/26/99
4621
1798
-
-
1206
283
18
7
106
41
No.67
8/2/99
5081
1960
1242
412
-
-
38
13
87
30
No.68
8/9/99
3010
1940
-
-
-
-
13
6
152
64
Notes:
Plant upset Week 60. 2-inch rainfall on 6/18/99. Settling problems in secondary.
alum not effective at 400 - 600 ppm. Added 250 ppm Bentonite on 6/23/99.
Week 63 = no production. EQ basin emptied for recoating.
272115001
wk avg
Updated: 10/25/99
Page 1 of 5

NUTRIENT DATA SUMMARY, WEEKLY AVERAGES
CROMPTON and KNOWLES COLORS Inc.
Week
Date
MLSS1
(mg/I)I
COD
F/M
Hydraulic
Load
(MGD)
Effluent
Row
(MGD)
Temp
(D)
Temp
(N)
pH
Nutrient Addition
85% P
Acid (Ib/d)
P
(mg/I)
75% P
Acid (Ib/d)
P
(mg/1)
P (Ib/MG)
Urea
(Ib/d)
N
(mg/l)
N (Ib/MG)
No.3
5/11/98
36561
0.39
0.302
0.333
30
30
7.5
52
5.0
-
-
42
314
51.7
431
No.4
5/18/98
3765I
0.22
0.204
0.295
32
31
7.7
70
7.8
-
-
65
400
76.9
641
No.5
5/25/98
38771
0.23
0.220
0.270
30
30
8.0
84
10.1
-
-
84
400
83.5
696
No.6
5/30/98
4048
0.26
0.215
0.264
31
31
7.7
84
10.3
-
-
86
229
48.3
402
No.7
6/6/98
4018
0.25
0.242
0.269
31
31
7.5
80
9.8
-
-
81
243
50.6
422
No.8
6/13/98
4175'
0.23
0.245
0.308
30
30
7.7
56
6.0
-
-
50
386
71.7
598
No.9
6/20/98
4309
0.14
0.202
0.226
31
30
7.6
-
-
84
11.1
93
343
90.7
756
No.10
6/27/98
4777
0.04
0.057
0.064
32
-
7.7
-
-
34
21.3
178
129
158.7
1324
No.11
7/4/98
4386
0.17
0.222
0.182
31
31
7.8
-
-
62
12.6
105
236
88.5
738
No.12
7/11/98
40831
0.17
0.277
0.283
31
30
7.8
-
-
71
7.5
63
200 •
41.8
349
No.13
7/18/98
42591
0.23
0.276
0.307
32
31
7.7
-
-
74
7.2
60
186
35.0
292
No.14
7/25/98
55381
0.19
0.227
0.223
32
31
7.9
-
-
63
8.1
67
171
43.8
365
No.15
8/1/98
6132
0.22
0.226
0.226
33
32
7.8
-
-
66
8.4
70
100
25.8
215
No.16
8/8/98
67701
0.12
0.196
0.196
33
32
7.8
-
-
57
8.5
70
64
18.5
154
No.17
8/15/98
62391
0.12
0.287
0.287
31
30
7.7
-
-
85
8.6
72
82
15.5
129
No.18
8/22/98
6849 .
0.12
0.278
0.270
32
31
7.6
-
-
49
5.2
43
36
7.8
65
No.19
8/29/98
67591
0.14
0.283
0.267
33
32
7.7
-
-
33
3.5
29
0
0.0
0
No.20
9/5/98
73541
0.08
0.201
0.184
31
31
7.6
-
-
21
3.6
30
0
0.0
0
No.21
9/12/98
7814
0.12
0.238
0.228
31
31
7.7
-
-
21
2.4
20
0
0.0
0
No.22
9/19/98
8191
0.11
0.238
0.209
32
30
7.8
-
-
26
3.6
30
54
14.6
122
No.23
9/26/98
7833
0.11
0.254
0.237
30
30
7.9
-
-
58
8.3
70
89
24.0
200
No.24
10/3/98
66331
0.19
0.270
0.266
30
30
7.9
-
-
59
6.3
52
68
14.6
122
No.25
10/10/98
6101
0.14
0.271
0.262
29
29
7.9
-
-
68
7.5
62
75
16.2
135
No.26
10/17/98
5691I
0.14
0.203
0.202
27
27
7.8
-
-
64
10.3
86
68
21.0
175
No.27
10/24/98
5750
0.14
0.245
0.213
28
27
8.0
-
-
27
3.7
31
50
13.3
111
No.28
10/31/98
5444
0.13
0.310
0.293
26
26
7.7
-
-
74
7.9
66
29
5.8
49
No.29
11/7/98
5768
0.15
0.242
0.214
25
26
7.5
-
-
37
8.7
72
46
10.6
88
No.30
11/14/98
6106
0.08
0.185
0.168
25
25
7.9
-
-
28
10.2
85
50
29.4
245
No.31
11/23/98
4617
0.09
0.126
0.108
23
23
7.8
-
-
16
4.6
39
29
16.3
136
No.32
11/30/98
4467
0.15
0.193
0.180
24
24
7.9
-
-
32
5.0
42
62
19.3
161
No.33
12/7/98
41971
0.15
0.171
0.174
25
26
8.0
-
-
47
7.6
63
63
21.4
179
No.34
12/14/98
36001
0.09
0.120
0.111
20
-
8.0
-
-
74
22.1
184
64
36.9
307
No.35
12/21/98
33931
0.10
0.120
0.103
19
19
8.1
-
-
37
10.2
85
42
23.1
193
No.36
12/28/98
3572
0.14
0.139
0.134
18
18
8.0
-
-
44
9.7
81
100
44.5
371
No.37
1/4/99
39161
0.28
0.268
0.261
20
21
7.7
-
-
118
12.4
104
134
27.7
231
No.38
1/11/99
4782
0.23
0.236
0.226
23
23
8.0
-
-
28
3.7
31
76
19.2
160
No.39
1/18/99
5515I
0.23
0.281
0.268
24
24
8.0
-
-
44
4.8
40
86
18.0
150
No.40
1/25/99
6008
0.16
0.278
0.264
26
26
8.2
-
-
41
4.5
37
85
18.1
151
No.41
2/1/99
6258
0.15
0.296
0.293
24
24
7.7
-
-
39
3.8
31
61
13.0
108
No.42
2/8/99
6657
0.18
0.211
0.196
26
25
7.7
-
-
26
4.1
34
69
20.9
174
No.43
2/15/99
6630I
0.17
0.184
0.176
24
25
8.1
-
-
23
3.8
32
37
11.4
95
No.44
2/22/99
64141
0.15
0.214
0.198
23
24
8.0
-
-
24
3.5
29
58
16.5
137
No.45
3/1/99
57411
0.12
0.154
0.136
24
24
7.9
-
-
10
1.8
15
46
19.7
165
No.46
3/8/99
47621
0.05
0.177
0.162
20
20
7.9
-
-
12
1.9
16
49
17.8
148
No.47
3/15/99
47751
0.15
0.197
0.184
20
20
7.7
-
-
26
4.1
34
55
17.5
146
No.48
3/22/99
43061
0.09
0.076
0.068
-
23
8.0
-
-
23
9.5
79
57
47.2
393
No.49
3/29/99
3659I
0.08
0.076
0.076
-
23
8.0
-
-
10
4.0
34
13
11.6
96
No.50
4/5/99
35931
0.10
0.145
0.131
26
25
8.0
-
•
12
2.9
24
18
6.8
57
No.51
4/12/99
4104
0.22
0.205
0.187
26
26
8.0
-
-
21
3.2
27
51
15.4
128
No.52
4/19/99
4438
0.12
0.178
0.201
-
-
-
-
-
69
10.9
91
53
15.1
126
No.53
4/26/99
4209
0.17
0.258
0.219
25
24
7.8
-
-
86
13.5
113
54
12.1
101
No.54
5/3/99
4142
0.18
0.226
0.192
25
26
7.7
-
-
81
13.0
108
72
22.6
188
No.55
5/10/99
3833
0.16
0.215
0.200
27
27
8.0
-
-
54
9.3
77
59
18.9
158
No.56
5/17/99
4081
0.16
0.164
0.148
29
28
8.0
-
-
16
3.1
26
34
12.8
107
No.57
5/24/99
41521
0.17
0.164
0.162
30
29
7.9
-
-
25
4.7
40
33
11.3
94
No.58
5/31/99
4138I
0.24
0.265
0.263
31
29
7.6
-
-
75
8.2
68
50
10.6
88
No.59
6/7/99
39781
0.14
0.234
0.216
30
29
7.5
-
-
62
8.8
73
42
11.5
96
No.60
6/14/99
39631
0.21
0.259
0.236
30
29
7.7
-
-
75
9.4
78
50
12.2
101
No.61
6/21/99
39601
0.17
0.234
0.234
30
29
7.8
-
-
69
9.6
80
47
13.0
109
No.62
6/28/99
4745'I
0.19
0.249
0.219
30
31
7.6
-
-
80
11.1
92
54
14.5
121
No.63
7/5/99
4669'
0.08
0.128
0.129
33
31
8.1
_
-
-
39
9.2
77
25
11.1
92
No.64
7/12/99
4658 ,
0.22
0.206
0.194
31
30
7.7
-
-
65
12.3
103
43
16.3
136
No.65
7/19/99
5478 ,
0.14
0.208
0.201
32
31
7.2
-
-
57
8.7
73
38
11.4
95
No.66
7/26/99
5165
0.19
0.298
0.269
33
31
7.7
-
-
52
5.7
47
61
13.6
114
No.67
8/2/99
52971
0.20
0.311
0.291
33
32
7.8
-
-
31
3.3
27
62
12.8
107
No.68
8/9/99
62881
0.10
0.230
0.244
33
32
7.8
-
-
25
2.9
24
50
11.5
96
27211 s001
wk avg
Updated 1025/99
Page 2 of 5

NUTRIENT DATA SUMMARY, WEEKLY AVERAGES
CROMPTON and KNOWLES COLORS Inc.
Week
Date
Total N (mg/1)
TKN (mg/I)
NO2/NO3 (mg/I)
NH3-N (mg/I)
TNN
mg/L)
Inf.
Inf + Nut
Eff.
Inf.
Inf + Nut
Eff.
Inf.
Eff.
Inf.
Aer.
Basin
Eff.
Inf.
Eff.
No.3
5/11/98
68
119
82
67
118
80
0.9
1.8
8.5
-
11
9.4
12.9
No.4
5/18/98
69
146
65
68
145
61
0.5
3.9
5.6
-
12
6.1
15.7
No.5
5/25/98
71
155
81
71
154
45
0.4
37
5.2
-
5.1
5.6
41.6
No.6
5/30/98.
87
136
70
86
135
34
1.0
36
8.0
-
3.2
9.0
39.2
No.7
6/6/98 ;
65
115
43
62
113
27
2.6
16
7.7
-
3.5
10.2
19.1
No.8
6/13/981
64
136
57
63
135
39
1.1
18
5.1
-
16
6.2
34.3
No.9
6/20/98I
55
146
59
55
145
21
0.5
38
4.8
-
5.5
5.3
43.8
No.10
6/27/98I
60
219
24
60
219
15
0.1
9
7.4
-
1.8
7.5
10.7
No.11
7/4/98 I
54
142
89
53
142
21
0.7
69
5.9
-
3.5
6.5
72.0
No.12
7/11/98I
55
97
49
54
96
35
0.5
14
3.6
-
10.3
4.1
24.7
No.13
7/18/98I
80
115
49
80
115
29
0.3
20
1.8
-
5.3
2.1
25.0
No.14
7/25/981
67
111
59
67
111
30
0.2
29
4.1
-
3.2
4.2
32.2
No.15
8/1/98 I
73
99
41
73
99
25
0.1
16
4.7
-
3.4
4.8
19.3
No.16
8/8/98 I
85
104
38
85
103
24
0.1
14
5.0
-
4.4
5.1
18.1
No.17
8/15/98
85
100
27
85
100
14
0.3
13
5.9
-
2.7
6.2
15.2
No.18
8/22/98I
87
94
40
86
93
18
1.1
22
4.5
-
2.9
5.6
24.9
No.19
8/29/98
93
93
22
93
93
17
0.3
5
3.8
-
5.1
4.1
9.6
No.20
9/5/98 I
55
55
31
55
55
11
0.1
20
10.0
-
2.8
10.1
22.8
No.21
9/12/98
96
96
49
96
96
21
0.1
28
16.0
-
3.3
16.1
31.3
No.22
9/19/98 !
70
85
39
70
85
30
0.2
9
5.9
-
1.9
6.1
10.8
No.23
9/26/98 1
-
-
-
-
-
-
-
-
-
-
-
-
-
No.24
10/3/98
82
97
40
81
96
40
1.1
0.2
-
-
-
-
-
No.25
10/10/98
44
60
37
44
60
37
0.1
0.1
36.0
-
12.0
36.1
12.1
No.26
10/17/98
12
33
37
12
33
37
0.1
0.2
5.3
-
16.0
5.4
16.2
No.27
10/24/98
86
99
39
86
99
39
0.1
0.1
8.1
-
11.0
8.2
11.1
No.28
10/31/98I
80
86
40
80
86
32
0.5
7.8
15.0
-
19.0
15.5
26.8
No.29
11/7/98I
79
89
18
78
89
17
0.6
0.9
5.5
-
2.5
6.1
3.4
No.30
11/14/98
-
-
-
-
-
-
-
-
-
-
-
-
-
No.31
11/23/98I
-
-
-
-
-
-
-
-
6.7
-
8.9
-
No.32
11/30/98
80
99
73
78
97
73
1.9
0.1
6.2
-
2.4
8.1
2.5
No.33
12/7/98
75
96
50
74
95
50
0.9
0.1
4.5
-
3.9
5.4
4.0
No.34
12/14/98
-
-
-
-
-
-
-
-
-
-
-
-
-
No.35
12/21/98I
-
-
-
-
-
-
-
-
-
-
-
-
-
No.36
12/28/98
-
-
-
-
-
-
-
-
-
-
-
-
-
No.37
1/4/99 I
-
-
-
-
-
-
-
-
5.2
-
15.4
-
-
No.38
1/11/99I
57
76
19
57
76
19
0.1
0.1
2.8
0.7
1.0
2.9
1.1
No.39
1/18/99I
77
95
25
76
94
25
0.9
0.1
2.8
-
5.9
3.7
6.0
No.40
1/25/99
81
99
29
81
99
29
0.2
0.1
1.6
1.5
2.6
1.8
2.7
No.41
2/1/99 I
60
73
38
58
71
37
1.7
0.6
1.8
12.9
13.9
3.5
14.5
No.42
2/8/99 I
84
105
21
84
105
21
0.1
0.1
1.5
0.1
0.3
1.6
0.4
No.43
2/15/99 '
67
78
21
67
78
21
0.1
0.1
3.6
0.2
0.4
3.7
0.5
No.44
2/22/99
73
90
18
73
89
18
0.5
0.1
3.0
0.1
0.3
3.5
0.4
No.45
3/1/99
66
86
23
66
86
23
0.3
0.1
2.8
0.7
1.2
3.1
1.3
No.46
3/8/99
45
63
50
44
62
50
1.3
0.2
7.8
26.5
27.8
9.1
28.0
No.47
3/15/99
83
101
28
83
101
28
0.4
0.1
5.9
5.2
7.5
6.3
7.7
No.48
3/22/99
-
-
-
-
-
-
-
-
0.7
0.3
0.1
-
-
No.49
3/29/99 1
-
-
-
-
-
-
-
-
2.1
11.8
11.5
-
-
No.50
4/5/99
88
95
18
87
94
18
0.8
0.2
4.0
8.5
8.2
4.8
8.3
No.51
4/12/99
81
97
22
81
96
22
0.3
' 0.1
5.2
9.6
9.6
5.5
9.7
No.52
4/19/99
77
92
46
76
91
46
1.1
0.2
7.2
-
7.4
8.3
7.6
No.53
4/26/99
-
-
-
-
-
-
-
-
1.0
2.0
11.0
-
-
No.54
5/3/99
74
97
14
73
96
14
1.2
0.2
3.3
2.4
1.8
4.5
1.9
No.55
5/10/99
53
72
23
53
72
17
0.1
6.0
1.9
1.3
2.6
2.0
8.6
No.56
5/17/99
85
98
16
84
97
16
1.3
0.1
4.5
1.3
1.1
5.8
1.2
No.57
5/24/99
54
65
19
52
63
19
1.5
0.1
3.1
0.4
0.6
4.6
0.6
No.58
5/31/99 !
110
121
31
110
121
25
0.1
5.9
4.6
0.6
1.4
4.7
7.3
No.59
6R/99
55
67
46
55
66
12
0.1
34.0
4.0
0.4
0.9
4.1
34.9
No.60
6/14/99
60
73
69
60
72
66
0.5
2.5
3.1
0.7
0.8
3.6
3.3
No.61
6/21/99
29
42
19
29
42
19
0.1
0.1
2.3
3.2
3.6
2.4
3.7
No.62
6/28/99
71
85
37
70
85
37
0.7
0.1
4.7
3.4
4.0
5.3
4.2
No.63
7/5/99
-
-
-
-
-
-
-
-
0.7
0.8
0.1
-
-
No.64
7/12/99
70
86
30
69
85
30
0.5
0.2
4.9
0.3
1.1
5.5
1.3
No.65
7/19/99
74
86
31
73
84
31
1.1
0.4
7.3
-
2.7
8.4
3.1
No.66
7/26/99
53
66
16
52
66
16
0.8
0.1
1.7
0.2
1.5
2.5
1.6
No.67
8/2/99 1
85
97
25
84
97
25
0.6
0.1
3.6
3.6
4.2
4.2
4.3
No.68
8/9/99 I
-
-
-
-
-
-
-
-
2.2
7.6
9.8
-
-
27211s001
wk avg
Updated: 10/25/99
Page 3 of 5

NUTRIENT DATA SUMMARY, WEEKLY AVERAGES
CROMPTON and KNOWLES COLORS Inc.
Week
Date
Organic N (mg/I)
Total P (mg/I)
o-PO4 (mg/I)
COD:TKN:P
Inf.
Inf + Nut
Eff.
Inf.
Int + Nut
Eff.
Inf.
Aer.
Basin
Inf + Nut
Eff.
Nutrient
Loading
No.3
5/11/98
58
110
69
2.1
7.2
2.9
0.05
-
5.1
0.05
100:4:0.2
No.4
5/18/98
63
140
49
2.0
9.8
4.2
0.7
-
8.5
1.3
100:7:0.4
No.5
5/25/98
66
149
39
2.2
12.3
4.7
0.8
-
10.9
4.2
100:7:0.5
No.6
5/30/98
78
127
31
1.8
12.1
4.5
0.8
-
11.1
4.0
100:5:0.4
No.7
616/98
54
105
24
3.3
13.0
6.6
2.3
-
12.1
5.5
100:5:0.5
No.8
6/13/98
58
130
23
3.1
9.1
4.9
1.6
-
7.6
4.2
100:6:0.4
No.9
6/20/98
50
141
15
2.6
13.7
5.5
1.3
-
12.4
4.5
100:8:0.7
No.10
6/27/98
53
211
13
2.2
23.5
4.6
0.5
-
21.8
4.7
100:13:1.3
No.11
7/4/98
47
136
17
1.3
13.9
5.8
0.5
-
13.1
5.8
100:7:0.7
No.12
7/11/98
51
93
24
2.0
9.5
7.7
0.5
-
8.0
6.7
100:7:0.6
No.13
7/18/98
78
113
24
1.9
9.1
5.2
0.6
-
7.8
5.1
100:5:0.4
No.14
7/25/98
63
107
27
2.0
10.1
6.3
0.8
-
8.8
6.0
100:4:0.3
No.15
8/1/98
68
94
21
2.1
10.5
4.8
0.8
-
9.2
4.1
100:3:0.3
No.16
8/8/98
80
98
20
1.9
10.4
5.7
0.6
-
9.1
5.8
100:4:0.4
No.17
8/15/98
79
94
11
2.1
10.6
5.7
-
-
6.2
-
No.18
8/22/98
81
89
15
10.0
15.2
12.5
8.5
-
13.6
9.5
100:6:0.8
No.19
8/29/98
89
89
12
9.2
12.7
9.5
8.1
-
11.6
8.0
100:5:0.6
No.20
9/5/98
45
45
8
6.7
10.3
6.2
7.7
-
11.3
7.4
100:3:0.6
No.21
9/12/98
80
80
18
9.6
12.0
9.7
8.7
-
11.1
9.6
100:4:0.5
No.22
9/19/98
64
79
28
3.2
6.8
8.0
2.0
-
5.6
7.1
100:4:0.3
No.23
9/26/98
-
-
-
-
-
-
-
-
-
-
-
No.24
10/3/98
-
-
-
1.6
7.9
0.7
0.7
-
7.0
0.2
100:3:0.3
No.25
10/10/98
8
24
25
1.3
8.8
0.2
0.2
-
7.6
0.2
100:3:0.4
No.26
10/17/98
7
28
21
1.0
11.3
0.3
0.01
-
10.3
0.01
-
No.27
10/24/98
78
91
28
1.5
5.2
1.0
0.5
-
4.2
0.7
100:5:0.2
No.28
10/31/98
65
71
13
3.6
11.5
3.8
2.2
-
10.1
3.7
-
No.29
11/7/98
73
83
15
2.0
10.7
2.4
0.6
-
9.3
2.2
-
No.30
11/14/98
-
-
-
-
-
-
0.4
-
10.7
1.0
-
No.31
11/23/98
-
-
-
-
-
-
0.3
-
5.0
1.8
-
No.32
11/30/98
72
91
71
1.2
6.2
1.5
0.4
-
5.3
0.5
100:5:0.3
No.33
12/7/98
70
91
46
2.5
10.1
2.8
0.6
-
8.2
0.7
100:5:0.4
No.34
12/14/98
-
-
-
-
-
-
0.3
3.0
22.5
0.8
-
No.35
12/21/98
-
-
-
-
-
-
-
-
-
-
-
No.36
12/28/98
-
-
-
-
-
-
-
-
-
-
-
No.37
1/4/99
-
-
-
-
-
-
0.2
0.8
12.6
0.4
-
No.38
1/11/99
54
73
18
3.7
7.4
2.0
0.9
1.8
4.6
1.4
100:3:0.2
No.39
1/18/99
73
91
19
1.2
6.0
1.6
0.3
0.7
5.1
0.9
100:4:0.2
No.40
1/25/99
79
98
26
1.1
5.6
0.9
0.5
0.6
5.0
0.5
100:5:0.2
No.41
2/1/99
56
69
23
1.1
4.9
2.3
0.5
1.2
4.3
1.2
100:4:0.2
No.42
218/99
83
103
21
1.3
5.4
0.9
0.7
0.7
4.7
0.8
100:3:0.1
No.43
2/15/99
63
75
21
5.1
8.9
1.4
1.0
1.1
4.8
0.9
100:2:0.1
No.44
2/22/99
70
86
18
2.5
6.0
1.7
3.0
1.0
6.5
0.9
100:4:0.3
No.45
30/99
63
83
22
4.1
5.9
3.9
1.6
3.7
3.5
3.4
100:4:0.1
No.46
3/8/99
36
54
22
1.4
3.3
5.6
0.3
4.6
2.1
4.4
100:8:0.3
No.47
3/15/99
77
95
20
1.6
5.7
1.9
0.2
0.5
4.3
0.8
100:5:0.2
No.48
3/22/99
-
-
-
-
-
-
0.1
0.6
9.6
0.3
-
No.49
3/29/99
-
-
-
-
_
-
-
0.1
3.2
4.2
3.6
-
No.50
4/5/99
83
90
10
1.0
3.8
3.8
0.1
2.1
3.0
2.9
100:7:0.2
No.51
4/12/99
76
91
12
1.2
4.4
0.8
0.6
1.5
3.7
1.5
100:4:0.1
No.52
4/19/99
69
84
39
0.4
11.2
1.0
0.3
-
11.2
1.1
100:5:0.6
No.53
4/26/99
-
-
-
0.1
13.6
1.1
0.6
-
14.1
1.4
-
No.54
513/99
70
92
12
1.4
14.4
0.6
0.2
-
13.1
1.2
100:6:0.8
No.55
5/10/99
51
70
14
1.9
11.2
1.4
0.3
-
9.6
1.8
100:4:0.6
No.56
5/17/99
79
92
15
1.2
4.3
2.4
0.4
2.3
3.5
2.4
100:4:0.1
No.57
5/24/99
49
60
18
0.3
5.0
2.4
0.1
1.2
4.9
1.7
100:2:0.2
No.58
5/31/99
105
116
24
1.1
9.3
1.5
0.7
0.8
8.9
0.6
100:5:0.4
No.59
6/7/99
51
63
11
0.6
9.4
0.6
0.2
2.2
9.0
1.2
100:5:0.7
No.60
6/14/99
57
69
65
1.6
11.0
4.2
0.3
1.4
9.6
1.6
100:4:0.5
No.61
6/21/99
27
40
15
1.2
10.8
0.8
1.8
1.9
11.3
1.8
100:2:0.6
No.62
6/28/99
65
80
33
1.6
12.7
0.8
0.3
1.2
11.4
1.0
100:4:0.6
No.63
715/99
-
-
-
-
-
-
0.2
2.2
9.4
1.2
-
No.64
7/12/99
64
80
29
1.3
13.6
1.1
0.5
0.7
12.8
0.9
100:4:0.5
No.65
7/19/99
66
77
28
1.8
10.5
1.1
0.4
-
9.1
0.6
100:4:0.5
No.66
7/26/99
50
64
15
0.8
6.4
1.5
0.2
0.2
5.9
0.7
100:4:0.3
No.67
812/99
80
93
21
1.1
4.4
2.0
0.3
1.4
3.5
1.7
100:5:0.2
No.68
8/9/99
-
-
-
-
-
-
0.5
1.6
3.4
1.8
-
Notes: 'Inconsistent and nonrepresentative data. Orthophosphate values much greater than Total Phosphorus values.
Possible color interference in phosphorus analyses beginning with Week No. 18 data through Week No. 22.
Excessive loading of phosphorus on Feb. 25-26 due to flushing scrubbers with phosphoric acid solution on 2/25
TNN = Total Nonrefractory Nitrogen = NH3 + NO2/NO3
27211s001
wk avg
Updated: 10125/99
Page 4 of 5

NUTRIENT DATA SUMMARY, WEEKLY AVERAGES
CROMPTON and KNOWLES COLORS Inc.
Week
Date
Secondary
Sludge Wasted
(Ib/d)
Primary Sludge
Wasted
(lb/d)
Total Sludge
Wasted
((b/d)
Sludge
Age (d)
Alum
Addition
No.3
5/11/98
-
-
-
-
No
No.4
5/18/98
-
-
-
-
No
No.5
5/25/98
-
-
-
-
No
No.6
5/30/98
-
-
-
-
No
No.7
6/6/98
-
-
-
-
No
No.8
6/13/98
-
-
-
-
No
No.9
6/20/98
-
-
-
-
No
No.10
6/27/98
-
-
-
-
No
No.11
7/4/98
-
-
-
-
No
No.12
7/11/98
-
-
-
-
No
No.13
7/18/98
-
-
-
-
No
No.14
7/25/98
-
-
-
-
No
No.15
8/1/98
-
-
-
-
No
No.16
8/8/98
-
-
-
-
No
No.17
8/15/98
-
-
-
-
No
No.18
8/22/98
-
-
-
-
No
No.19
8/29/98
782
-
782
42
No
No.20
9/5/98
938
-
938
38
No
No.21
9/12/98
1023
-
1023
37
No
No.22
9/19/98
1207
-
1207
33
No
No.23
9/26/98
1912
-
1912
20
Yes
No.24
10/3/98
1679
-
1679
19
Yes
No.25
10/10/98
1205
-
1205
24
Yes
No.26
10/17/98
763
-
763
36
Yes
No.27
10/24/98
1509
-
1509
18
No
No.28
10/31/98
1290
503
1721
20
No
No.29
11/7/98
1190
325
1515
23
No
No.30
11/14/98
1329
501
1831
22
No
No.31
11/23/98
706
721
1427
31
No
No.32
11/30/98
739
1201
1940
29
No
N o. 33
12/7/98
1440
474
1913
14
Yes
No.34
12/14/98
332
169
501
52
No
No.35
12/21/98
226
600
826
72
No
No.36
12/28/98
126
723
849
136
No
No.37
1/4/99
512
531
1043
37
No
No.38
1 /11 /99
992
199
1191
23
No
No.39
1/18/99
1496
252
1748
18
No
No.40
1/25/99
1361
521
1882
21
No
No.41
2/1/99
342
109
451
88
No
No.42
2/8/99
1459
915
2374
22
No
No.43
2/15/99
921
387
1308
35
No
No.44
2/22/99
1145
898
2043
27
No
No.45
3/1/99
1408
569
1977
20
No
No.46
3/8/99
452
1255
1707
51
No
No.47
3/15/99
1076
733
1809
21
No
No.48
3/22/99
750
421
1170
28
No
No.49
3/29/99
228
596
824
77
No
No.50
4/5/99
310
525
835
56
No
No.51
4/12/99
899
331
1231
22
No
No.52
4/19/99
810
480
1290
26
Yes
No.53
4/26/99
508
245
754
40
Yes
No.54
5/3/99
915
614
1529
22
Yes
No.55
5/10/99
802
435
1237
23
Yes
No.56
5/17/99
475
598
1074
41
No
No.57
5/24/99
575
404
979
35
Yes
No.58
5/31/99
702
719
1421
28
Yes
No.59
6/7/99
515
1039
1554
37
Yes
No.60
6/14/99
740
559
1298
26
Yes
No.61
6/21/99
450
1248
1698
42
Yes
No.62
6/28/99
697
663
1360
33
Yes
No.63
7/5/99
624
407
1031
36
Yes
No.64
7/12/99
455
1289
1744
49
Yes
No.65
7/19/99
755
928
1683
35
Yes
No.66
7/26/99
879
445
1324
28
No
No.67
8/2/99
705
130
836
36
No
No.68
8/9/99
699
417
1117
43
No
27211s001
wk avg
Updated 10/25/99
Page 5 of 5

1 1 1 1 1 1 1 D 1 1 1 1 1 1 1 1 1
CKCI: Weekly Comments from CKCI
First Day of
Week
Week No.
Comments •
5/11/98
3
Daily flow total includes 72000 gallons well water.
5/18/98
4
Daily flow total includes 72000 gallons well water.
May 22 - AWARE recommends an increase in phosphoric acid dosage.
5/25/98— -- -
5
Daily -flow total includes 72000gallonswell water. •
Production Building #9 is not operating.
6/6/98
7
Daily flow total includes 72000 gallons well water.
6/13/98
8
Daily flow total includes 72000 gallons well water. Significant gassing occurring in the secondary clarifier.
6/20/98
9
Daily flow total includes 28800 gallons well water through 24-Jun.
Changed to 75% Phosphoric acid due to crystallization problems.
6/27/98
10
All wastewater treated this week is carried over from last week.
July 4th Production Shutdown.
7/4/98
11
Returned to full production.
Daily flow total includes 43200 gallons well water starting 9-Jul.
Primary sludge volume total 55348 gallons collected 7/8/98.
Secondary sludge volume total 14770 gallons collected 7/10/98.
7/11/98
12
Reduced urea dosage 13-Jul due to denitrification gassing in secondary per calculations of B. Stein
Begin new polymer trial 14-Jul - Amerlfoc 425 EP Secondary
Spiked samples for Ammonia analysis had 6.5% difference from known value.
7/18/98
13
Continue polymer trial on both Primary and Secondary.
Revised Phosphorus dosing strategy to add 0.27 lbs. 75% Phosphoric acid per 1000 gallons of treated wastewater.
7/25/98
14
Polymer trial completed, returned to Betz -Dearborn polymer.
8/8/98
16
Reduced Urea addition to 0.4#/1000 gallons wastewater 10-Aug.
8/15/98
17
Blue B (6 lots) will result in elevated ammonia levels.
8/8/98-8/15/98
16-17
The elevated influent phosphorus levels (beginning Week 17) might be due to analytical color interference coming from the
Blue B product that we have been running throughout the duration of this anomaly. The laboratory has also reported
problem with the analysis.
Another source might be the scrubber that uses a phosphoric acid solution to remove excess amines from the Blue B
process.
8/22/98
18
Reduced phosphorus addition to 0.12#/1000 gallons wastewater beginning 26-Aug.
Suspended urea addition for the duration of the Blue B campaign starting 28-Aug.
8/29/98
19
Continue suspension of urea additions during Blue B campaign.
27211s001
Comments
Page 1 of 3
10/25/99

1 1 1 1 1 1 1 ➢ I 1 1 1 1 1 1 1 1 1 1
CKCI: Weekly Comments from CKCI
First Day of
Week
Week No.
Comments
9/5/98
20
Primary flash mixer developed leak, bypass primary to repair on 6-Sept. back on line 11-Sept.
Blue B campaign continues, no urea added.
High concentration of phosphorus, discontinued phosphoric acid on 11-Sept.
9/12/98
21
Resumed feeding phosphoric acid on Sept. 14.
9/19/98
22
Resumed feeding urea on Sept. 21.
No production Sept. 25 inventory.
Continued polymer trial through week.
9/26/98
23
Ended polymer trial Sept. 28
Plant upset, polymer ineffective, switched to alum.
Increased nutrients. Installed booms. Began reducing MSS.
10/17/98
26
New data indicates that BOD may be 25% of COD rather than 50%.
Switched polymer on October 22nd at 1300 hrs.
10/24/98
27
Blue B should result in elevated ammonia levels.
10/31/98
28
Continuous feed of phosphoric acid solution into primary effluent stream.
11/7/98
30
MLVSS=77%
Shutdown 11/19/98 to repair line to river
11/23/98
31
Thanksgiving Shutdown
12/7/98
33
Observed evidence of a lime in mixed liquor on 12/11.
Switched to alum, wasted 20000 gallons secondary sludge and installed booms.
Called B. Stein and revised phosphoric dosing chart of increase by 20%
12/14/98
34
Begin Christmas Shutdown
Interesting increase of orthophosphorus in aeration during the week.
12/21/98
35
Continue Christmas Shutdown
Increased urea dosing to 50# per day due to lack of color in influent.
12/28/98
36
Continue Christmas Shutdown
1/4/99
37
Production start-up
Switched from alum to polymer on secondary 1/8/99
There is evidence of increased demand for phosphorus with the start-up and higher COD loading.
1/25/99
40
Increased phosphorus additions 1/28/99 and 1/29/99 based on In House orthophosphate results
2/1/99
41
Suspended Urea additions 2/4/99
Resumed Urea additions 2/8/99
27211s001
Comments
Page 2 of 3
10/25/99

1 1 B 1 1 1 1 I 1 s 1 1 1 1 1 1 1 1 1
CKCI: Weekly Comments from CKCI
First Day of
Week
Week No.
Comments
2/22/99
44
Reduced Phosphoric and Urea dosage per B. Stein beginning 2/24/99
Excess phosphorus was added to system beginning 2/25/99 due to accidental flushing of scrubber that uses a phosphoric
acid solution.
371 /99
45
Suspended phosphorus additions on 3/5/99
3/8/99
46
Minimal production this week
Resumed phosphorus additions 3/10/99 after collecting samples.
3/15/99
47
Minimal production this week
Acetic acid prepared as food was added to EQ on 3/16/99
3/22/99
48
Minimal production this week.
Cleaned out EQ-A this week.
3/25/99 Additional phosphorus added after samples collected •
3/29/99
49
Minimal production this week.
Acetic acid prepared as food was added to EQ on 3/29/99
Suspended Urea addition and adjusted Phosphorus addition on 3/30/99
4/19/99
52
Switched to Alum 4/19/99. There is evidence that polymer produces float at higher doses
Added 6 extra gallons of phosphoric acid on 4/19/99. COD's are higher than normal at the beginning of the week.
Adding well water at secondary. Assumed alum nutrient dosing schedule.
4/26/99
53
Continued Alum Use on Secondary
Power Failure at plant SCADA off-line and treatment shutdown 4/30/99.
5/17/99
56
Switched to Polymer 5/17/99. Began nutrient dosing for polymer on 5/18/99
5/24/99
57
Switched to alum on secondary 5/27/99
Increased phosphoric dosage 5/28/99
5/31/99
58
Continue feeding alum on secondary.
Incident in spray dryer - 5000 lbs. Bordeaux 3BSF to drain 6/4/99.
6/21/99
61
Feeding alum
2500 lbs. Bentonite added to aeration tank 6/23/99
7/5/99
63
No Production this week
Plant maintained on prepared food and well water
EQ-A Emptied for Re -Coating
7/19/99
65
Heavy Rainfall 7/24/99
Quarterly sampling this week
27211s001
Comments
Page 3 of 3
10/25/99

Appendix C
NCDENR Site Visit Report

North
Art
PM-
MeV
Pvt-
Izak
ran
OFFICE OF WASTE REDUCTION
Carolina Department of Environment, Health, and Natural Resources
Site Visit Report
Crompton & Knowles Colors Incorporated
Lowell, North Carolina
Office of Waste Reduction
Industrial Pollution Prevention Program
David Williams
John R Burke
July 26,1996
Post Office Box 29569, Raleigh, North Carolina 27626-9569
Telephone: [phone]; FAX: [phone]

Disclaimer
This report is intended to offer information and guidance for identifying
opportunities and options for waste reduction. Compliance with
environmental and occupational safety and health laws is the sole
responsibility of each business. All legal and regulatory references
within this document are intended only for informational purposes and
are not to be taken as reliable sources of legal reference. Businesses
should contact the appropriate Legal and regulatory authorities for
current regulatory requirements as well as for interpretation and
implementation. All references and vendor materials (when available)
mentioned in the report are included. Mention of a vendor or
manufacturer does not represent an endorsement by the State of North
Carolina. Neither the State of North Carolina nor the authors of this
report are responsible for practices or procedures implemented by
individual firms.

,Executive Swnmary
The following summary outlines those techniques, programs, and technologies which can reduce waste
generation and operating costs. The report provides detailed examples and contacts for following up on
the feasibility of these options.
• In loading raw chemicals into the vessels from 55 gallon drums, the operators have to drop the drums
onto the floor, remove the Iid located on top of the drum and pour the contents into the vessel. This
practice probably also leads to considerable loss of the raw chemicals. If this procedure is practiced
frequently, CKCI should consider purchasing chemicals that are currently handled in this manner in
250 gallon intermediate bulk containers (IBCs).
.., • CKCI should make water conservation a priority in the chemical mixing area. Success in this area
will have a direct result in the expense of energy, polymer, and tap water. Where feasible, CKCI
should make it a priority to schedule similar dyes and shades to be produced in the same vessel.
Additionally, tie facility should consider scheduling from light to dark shades of similar dyes to
eliminate the need for boil out of the vessel. When boil out is required, the facility should transfer
where feasible Ito any other vessels requiring boil out or to a holding vessel to be reused. Because the
vessels are filled during boil out, this represent a significant amount of dilution water in the waste
treatment system.
• This facility should investigate the use of wet/dry vacuums to collect spilled dye material in the truck
and tray dryer area.
• To cut down on the processing time, amount of dyestuffs spilled, and labor required, CKCI should
design a better system to handle removing the dried dyestuff from the trays.
Each of these suggestions are detailed in the report. OWR will gladly assist in efforts to implement any
Pal of the previous suggestions.
aA

/04
INEM
1.0 Introduction
2.0 Plant Description
3.0 Wastewater Treatment Costs
4.0 Waste Reduction Options
Outline
4.1 Reaction 'Vessels
4.2 Dyestuff l in
Y IrY g
4.3 Wastewater Treatment
5.0 Waste Reduction Programs
Mat 5.1 Responsible Care
5.2 ETAD/EPA
5.3 CKCI Waste Minimization Program
5.4 Establishing and Maintaining an effective Recycling Program
5.5 Setting up a Buy -Recycled Program
6.1 Financial Incentives
6.1.1 Recycling Tax Incentives
6.1.2 Challenge Grants
6.1.3 Waste Reduction and Energy Conservation Grants
6.2 Climate Wise
6.3 Waste Exchange Programs
6.4 Energy Conservation Assessments
6.5 Manufactu ing Extension Partnership
6.6 Internet Access to Pollution Prevention Resources
6.7 Pollution Prevention Training
6.8 Focus Newsletter
7.0 Enclosures
com

CKCI: Waste Reduction Assessment
1.0 Introduction
CKCI requested on -site technical assistance from the Division of Pollution Prevention and
Environmental Assistance of the Department of Environment, Health, and Natural Resources (DEHNR)
to help the facili evaluate their current operations and waste reduction programs. On July 26, 1996,
John Burke and D vid Williams of the Industrial Pollution Prevention Section (IPPS) visited the dye
manufacturing pl nt. Rodney Lang, Manager - Environmental Operations, and Bobby Lamb,
Environmental Engineer, provided a detailed synopsis and plant tour .
soi
ran
tan
This report discusses potential pollution prevention techniques for reducing multimedia waste streams as
well as markets four recycling solid wastes.
2.0 Plant Description
CKCI produces mostly acid reactive, basic, and azo in powder and liquid form. These dyes are used in
the carpet, auto, and plastic industries. The facility currently operates 5 days per week.
The facility receives raw chemical ingredients for the manufacture of dyestuffs. The raw chemicals are
mixed in reaction vessels which are heated through a boiler system or cooled.with ice. The product
generated from th! reaction is processed through filter presses, if the dyestuff is to be distributed in
powder form. The filtered dyestuff is dried in an oven.or spray dryer and blended before packaging.
The facility operates a variety of emission control equipment to treat air emissions and remove pollutants
in the wastewater. Three wet scrubbers are used to control hydrochloric acid emissions and amine
emissions. CKCI ?perates one dust collection system. The facility operates a wastewater treatment
system composed of a flocculation and clarification system followed by activated sludge.
Several waste reduction and recycling techniques the facility has put in place include:
•1 Multi.lese of cl waters in . i • n:v_
' mplementation of a solid waste recycling program wi 1Oyer:tvven
reduction,
items lined fo��''p'~��►'i�7/clri
3.0 Wastewater Treatment Costs
CKCI discharges ' p average of 240,000 gallons per day of effluent.
Polymer costs run pproximately 40% of the•total cost to operate the wastewater treatment system.
Combined with sludge disposal and energy costs, the three categories make up 69% of the annual costs
of wastewater treatment. Thus, it should be a major goal of CKCI to;
1. Increase the efficiency and reduce the amount of polymer used by reducing the dilution waters.
entering the sy tem,
2. Reduce the sludge requiring disposal by reducing the pollutant loading to the system, and
3. Conserve energy by reducing total volume of effluent requiring pumping.
By reducing dilution waters the facility will also reduce tap water costs.
CKCI - 1 - September 11,1996

Gib
lee
POI
4.0 Waste Reduction Options
The following sections list areas where CKCI should target waste reduction efforts, provide waste •
reduction options for these areas, and Iist contacts and markets for recyclable materials.
4.1 Reaction Vessels
One of the first s eps in the manufacture of dyestuffs at CKCI is the reaction of raw chemicals to form
dye compounds. These reactions take place in pressurized and non pressurized reaction vessels housed
in one of two buildings. Some of the raw materials are added by hand from 55 gallons drums or buggies
for ice. After processing, the vessels are sometimes boiled out to removed color and residual chemicals.
Caustic is also used during this cleaning stage. The discharge from the reaction vessels is probably the
greatest source of pollutants in the wastewater requiring removal.
There are several options which CKCI may want to consider which could reduce pollutant loading,
reduce total effluent discharge, and increase worker safety:
• In loading ra'v chemicals into the vessels from.55 gallon drums, the operators have to drop the drums
onto the floor, remove the lid located on top of the drum and pour the contents into the vessel. If this
procedure is practiced frequently, CKCI should consider:
1. Purchasing chemicals that are currently handled in this manner in 250 gallon intermediate bulk
containers (IBCs). These containers drain from the bottom allowing for all but 4 ounces of
chemical to be removed. • These IBCs are usually returnable, thus eliminating the need to be
handled by a separate recycling firm. CKCI could purchase 55 gallon containers with sump •
bottoms which the chemical would be transferred in from the IBCs to the mixing vessel. The
sump drums could be transferred with a dolly to the vessel opening. The bottom cap would be
removed and the chemical would discharge into the vessel. A quick rinse in the top of the drum
would remove all residual material into the vessel leaving the sump drum ready for reuse.
Sonoco Products manufacturers sump bottom 55 gallon drums (800-841-7252).
Other faclities which have coverted to IBCs have experienced significant reduction in costs of
raw materials and drum management. Amital Spinning in New Bern, James Ipock 919-636-
g P g
3435, experienced a reduction in raw material costs of $0.04 per pound of chemical and $26,000
annually in handling and disposal of drums. In 1994, this facility saved $175,000 as a result of
converting to IBCs.
• CKCI should make water conservation a priority in .the chemical mixing area. Success in this area
will have a direct result in the expense of energy, polymer, and tap water.
CKCI should when possible and practical schedule similar dyes and shades to be produced in the
same vessel. Additionally, the facility should when possible and practical schedule from light to
dark shades of similar dyes to eliminate the need for boil out of the vessel. When boil out is
required, the facility should transfer when possible and practical. to any other vessels requiring boil
out. Becausekthe vessels are filled during boil out, this represent a significant amount of dilution
water in the waste treatment system.
If CKCI is currently practicing these techniques the information needs to be compiled and graphed to
identify shifts which are not performing efficiently, or days when these practices are not being
followed. In order to evaluate the use of rinse waters and boil outs. CKCI should consider having the
operators keep a running log of how many boil outs or rinses processed in a shift and compared to
the number of reactions processed.
1i°CKCI - 2 - September 11,1996

fairl
ORO
ISM
FOR
4.2Dyest of Drying
After the reactions occur in the mixing vessels, the resulting dyestuffs and other liquors are discharged to
filter presses where the precipitated dyestuff is removed and the waste liquid is discharged to the
treatment plant. Ir! case of liquid dyes, clarification filter presses are used to remove insoluble dyestuffs
and the liquid dye tuffs are distributed for packaging.
The filtered dyestuffs to be further dried are either processed in the truck and tray drying area or in the
spray drying area. In the truck and tray drying area, the filtered dyestuffs are transferred to trays which
are loaded into rac}cs to be placed in an oven for up to three days. The dried material is broken up with a
shovel on a table, removed from the tray, and placed in 55 gallon drums to be transferred to the blending
room. There are some low cost options for reducing the waste generated and the labor required in this
area:
• This facility should investigate the use of wet/dry vacuums to remove spilled dye material in the
trucks and tray room1. CKCI could purchase one vacuum and use for a trial period. The vacuum
would be used iprior to any rinsing of the floors. After a bulk of the spilled dyestuff is collected, the
operators could then used a high pressure low volume nozzle to clean the room2. The collected
dyestuffs could be filtered with a mesh screen and added to the product if it is deemed acceptable.
The amount of collected dyestuff during this trial period will determine if this practice is cost
effective. Several reasons for investigating this option include the value of the collected dyestuff as
a product, the cost of polymer to remove this dyestuff once it enters the effluent, and the disposal
costs of this amount of dyestuff in the sludge.
• . To cut down on the processing time, amount of dyestuffs spilled, and labor required, CKCI should
design a bettersystemlto handle removing the dried dyestuff from the trays. Currently, these trays
are removed from the racks, placed on a table and chopped up with shovels, and then loaded into 55
gallon drums. ;This movement of the dyestuff results in
considerable material loss. It may be feasible to design
a cheap but efficient system to remove dyestuffs from
the tray and deposit them into 55 gallon drums.
Diagram 1 depicts a simple schematic of a metal box
with chicken wire across the bottom and a cone section
underneath.
This set up would allow for the trays to be flipped and
the contents dropped into the metal container. After
several of these trays have been empty the operator
could use the shovel to press any remaining dyestuff
through the screen into the drum. With this simple
,I, device, no dyestuff would be dropped onto the floor during processing.
In the spray drying area, the filtered dyestuffs are mixed back into slurry form at a higher solids percent,
processed through a grinder, and then dried in the spray drying system. The solids content in the liquid
leaving the reaction vessel is roughly 10%, while the solids concentration needed in the spray drying
system is roughly 40%. In order to achieve this conversion, CKCI filters the dyestuffs out of the reaction
vessel discharge and adds water back to the dyestuffs to obtain the necessary 40% solids.
4.3 Wastewater Tratment
CKCI has already invested a significant amount of capital into its wastewater treatment system, but there
are few additions which will eventually provide a cost savings to the facility. One technology to
consider is nanofiltration3. Nanofiltration has the capability of filtering most pollutants accept chlorides.
CKCI - 3 - September 11,1996
Sig

ram
One textile facility, Sara Lee Knits (Donald Brown (910-519-5610)), is currently installing a
nanofiltration system to remove color and other auxiliary chemicals from the effluent while collecting
the filtered brine solution for dyebath reuse. One of the most significant savings which will be incurred
by the facility is tke reduction in polymer costs due to the significant concentration and reduction in
volume of the wastewater.
5.0 Waste Reduction Programs
Crompton & Knowles Colors Inc., participates in three formal programs with the goal of developing
procedures and projects to minimize or eliminate waste produced as part of the facility's manufacturing
operations.
5.1 Responsible Care®
CKCI, as a member of the Chemical Manufacturers Association, participates in the Responsible Care®
program which includes a Pollution Prevention Code of Management Practice. An annual report is
GICS completed and sent to the CMA on the status of the plant in regard to poIIution prevention activities
along with an overview report of the amounts hazardous and non -hazardous waste generated by the
facility.
5.2 ETAD/EPA
The dyestuff manufacturer's trade organization (ETAD) which CKCI is a member and the EPA's Office
4.0 of Pollution Prevention have entered into a joint effort to monitor. and encourage P2 and waste
minimization efforts in the dyestuff industry.
As an ETAD member, CI(CI has agreed to complete annual assessments of the number of pollution
prevention opportunities that are in place at the facility.
5.3 CKCI Waste Minimization Program
In coordination with the programs above, a broader program has been established at this facility. A
committee assembles on a quarterly basis to discuss all valid, ideas and suggestions for the reduction of
wastes in all areas, not only pollution prevention but also recycling and improving treatment
technologies.
As a result, CKCI has in place projects which reduce waste such as the following:
Pallet rebuilding
Steel drum recycling
Cardboard recycling
Office paper recycling
Press cake box reuse
O„ Unsolicited publication reduction
Aluminum can recycling
Wastewater-treatn ent sludge reduction •
Sonic dedusting to reduce spray dryer washing
5.4 Setting Up a Buy Recycled
CKCI's commitment to a comprehensive waste reduction program should also encompass a written buy -
recycled policy. The recycling loop is not complete until the materials collected for recycling are
manufactured into a new product and then sold. Setting up a buy -recycled program will not only reduce
raw material costs but increase market demand for waste products4.
af4f CKCI - 4 - September 11,1996
POD

6.0 Other Important Resources
6.1 Financial Incentives
6.1.1 Recycling Tax Incentives
Special tax credits for recycling and resource recovery are available5. These tax credits can help offset
capital investmenF cost and encourage management to endorse programs more willingly. If a business
purchases or constructs facilities or equipment used exclusively for recycling or resource recovery, it
•
may be entitled to special tax credits.
mat
6.1.2 Challenge Grant Program
The Office of Waste Reduction offer annual grants up to $20,000 to help companies develop and
•°' implement innovItive projects that eliminate, reduce, or recycle air emission, wastewater discharges or
solid and hazardo s wastes. Requests for proposal are mailed out in the spring and must be submitted in
May 6. If you recive�the FOCUS: Waste Minimization newsletter you will automaticallyreceive a
request for proposals. Call the Office of Waste Reduction for more information.
6.1.3 Waste Reduction and Energy Conservation Funding
dot The US Department of Energy provides funding for projects which reduce energy consumption and
waste generation. The National Industrial Competitiveness through Energy, Environment, and
Economics (NICE3) program provides up to $400,000 per project to industries who are investing in
technologies to reduce energy consumption and waste generation will improving competitiveness. In
1995, the NC Off I e of Waste Reduction will receive $106,000 for a brine reuse project to be
implemented by Sara Lee Knit Products. If CKCI has a potential project for submission, please contact
John Burke at the Office of Waste.Reduction before October. •
tolsP
PPM
fart
efEc
POI
6.2 Climate Wise
Climate Wise is a voluntary program that is jointly sponsored by Division of Energy and the EPA. The
program was established to improve technology transfer between industries concerning industrial
technologies which reduce greenhouse emissions, conserve energy and conserve natural resources while
enhancing a facility's bottom line. Participants in this program can benefit from;
• free on -site technical assistance which includes energy assessments and waste assessment,
• free guidance on financial assistance opportunities for process improvements or modifications,
• free access to technologies currently being investigated by other similar industries, and
• free national publicity for projects reducing waste generation and energy usage. • •
Participants are required only to list related projects which will be attempted and report on the success of
those projects in terms of waste reduced, energy conserved, and money saved'. Please contact John
Burke at [phone] for further information.
CKCI - 5 - September 11,1996

meg
pen
6.3 Waste Exchange Programs
Waste Exchange Programs are another avenue that CKCI can explore to identify P markets for its
recyclable wastes9. For example, the Southeast Waste Exchange (SEWE) in Charlotte is a non-profit
organization that works with industries and businesses to locate generators and users of waste products.
"One person's trash can become another person's raw material".
6.4 Energy Conservation Assessments
The North Carolina State University Industrial Extension Service and the North Carolina Energy
Division can provide energy audits and energy conservation courses for a small fee ($600). This
assistance targets nearly all basic unit operations of a manufacturing operation ranging from compressors
to HVAC units. W Iter Johnston at [phone] is the contact for additional information on energy
management.
Another program at North Carolina State University called the Industrial Assessment Center (IAC)
provides preliminary energy reduction audits free of charge for industries within a 150 mile radius of
Raleigh. For more information on this program call Steve Terry with the IAC at [phone].
6.5 Manufacturing Extension Partnership
The Industrial Extension Service at the N.C. State University recently introduced the North Carolina
Manufacturing Extension Partnership (NC MEP) Program. The. NC MEP team of engineering. specialists
offer technical assistance to North Carolina manufactures such as: industrial management, computer
applications, plant engineering, and material handling. Limited technical assistance, information, and
site visit are provided free of charge. More extensive support and consulting are price according to
project length and required resources. The NC MEP headquarters can be reached at [phone].
6.6 Internet Access
to Pollution Prevention Resources
Sample World Wide Web sites on the Internet:
http: /wastenot. inel.gov/envirosense/ssds/ssds.html
Information available includes, solvent substitition information, Department of Defense P2 technical
library.
http://venus.hyperkcom/chem.html
EPA Chemical Fact Sheet. MSDS for hundreds of chemicals, Environmental Health and Safety technical
reference library.
http://www.earthcycle.com/g/p/earthcycle/
National Material E change Network: Contains over 10,000 listing among 30 categories of material
available and wanted.
http://gopher.epa.gov/
EPA World Wide Web Server which includes releases, software, databases, public information center.
information locators.
http//www.er.doe.gov/production/esh/epic.html
US Department of Energy's pollution prevention information clearinghouse, federal law. regulations.
policy, and guidance
CKCI - 6 September 11,1996

.14 6.7 Pollution Prevention Training
Employee training is an integral aspect of any waste reduction program. Waste reduction/pollution
Fahprevention training that focuses on employee awareness and stress continuous improvement process can
lead to improve environmental programs and cost savings. The Office of Waste Reduction provides
various truing services. These include
Oft
Management Awareness Training - Training on the importance of waste reduction from an economic and
environmental standpoint, how to implement a waste reduction program, and,
Train -The -Trainer Training - Process specific or facility specific truing for waste reduction teams on
waste reduction options for the facility. These training includes:
1. facilitated brain storming session to identify and rank options,
2. fundamental of material balances and waste identification,
3. discussion of potential barriers to implementation, and
4. implementation plan development.
6.8 Focus Newsletter
The Office of Waste Reduction publishes a newsletter entitle FOCUS: Waste Minimization. The
quarterly newsletter containing waste reduction information, case studies, and related regulatory topic.
Please call our office if you would like to receive the resource.
7.0 Enclosures
1 Vendor of Wet Vacs
2 Information of High Pressure Low Volume Spray Nozzles.
3 Tip of Membrane Filtration Systems.
4 OWR's Setting Up a By -Recycled Program.
5 State and Federal Grant, Loan, and Tax Programs for Waste Reduction.
6 NC OWR's Challenge Grant Application.
7 State and Federal Grant, Loan, and Tax Programs for Waste Reduction.
8 The Department of Energy's Climatewise Program
9 Material Exchffnge Programs in North America.
CKCI - 7 - September 1I,1996

Appendix D
Summary of BOD5 and COD Utilization Rates

CROMPTON & KNOWLES COLORS INC.:
Calculations for k (BOD removal rates)
Week
Date
BOD (mg/L)
COD (mg/L)
MLSS
(mg/L)
Detention
Time (days)
Removal Rate
Using MLSS (d"')
Polysaccharide
Adjusted Removal
Rate (d'')
Inf. BOD
Eff.
BOD
Inf.
COD
Eff.
COD
MLSS
Aer. Basin
k (COD)
k (BOD)
k (COD)
k (BOD)
No.3
5/11/98
52.3
2885
700
3656
1.91
_
1.3
6.1
No.4
5/18/98
90.6
2115
425
3765
2.83
0.79
3.8
No.5
5/25/98
18.3
2360
613
3877
2.62
0.7
3.1
No.6
5/30/98
18.6
2636
585
4048
2.68
0.9
4.1
No.7
6/6/98
23.6
2430
531
4018
2.38
0.9
4.3
No.8
6/13/98
24.2
2116
577
4175
2.35
0.6
2.7
No.9
6/20/98
13.6
1712
393
4309
2.85
0.5
2.2
No.10
6/27/98
10.4
1734
4777
10.16
No.11
7/4/98
21.6
1938
564
4386
2.59
0.4
2.0
No.12
7/11/98
12.6
1446
345
4083
2.08
0.5
2.6
No.13
7/18/98
45.2
2118
547
4259
2.08
0.7
3.3
No.14
7/25/98
15.4
2714
813
5538
2.53
0.5
2.2
No.15
8/1/98
15.6
3432
373
6132
2.55
1.8
8.6
No.16
8/8/98
19.2
2321
318
6770
2.94
0.7
3.5
No.17
8/15/98
13.3
1585
510
6239
2.01
0.3
1.3
No.18
8/22/98
i
12.2
1662
448
6849
2.07
0.3
1.5
No.19
8/29/98
15.2
1962
_
556
6759
2.04
0.4
1.7
No.20
9/5/98
8.0
1980
535
7354
2.87
0.3
1.2
No.21
9/12/98
'
4.4
2342
584
7814
2.42
0.4
1.8
No.22
9/19/98
7.0
2177
691
8191
2.42
0.2
1.1
No.23
9/26/98
14.8
1945
622
7833
2.27
0.2
1.1
No.24
10/3/98
16.2
2800
968
6633 '
2.13
0.4
1.8
No.25
10/10/98
11.2
1804
. 6101
2.12
No.26
10/17/98
4.2
2210
5691
2.84
No.27
10/24/98
1972
5750
2.35
No.28
10/31/98
7.2
1333
5444
1.86
No.29
11/7/98
4.2
1812
5768
2.38
No.30
11/14/98
5.7
1687
473
6106
3.11
0.2
1.1
No.31
11/23/98
'
5.6
2097
455
4617
4.57
0.4
1.7
No.32
11/30/98
6.0
2019
468
4467
2.99
0.5
2.4
No.33
12/7/98
14.9
1897
520
4197
3.37
0.4
1.7
No.34
12/14/98
28.7
1813
700
3600
4.79
0.2
0.8
No.35
12/21/98
16.5
1727
425
3393 '
4.82
0.3
1.5
No.36
12/28/98
7.0
1986
613
3572
4.13
0.3
1.4
No.37
1/4/99
4.4
2337
411
3916
2.15
1.3
6.2
No.38
1 /11 /99
531
7.1
2606
598
4782 '
2.44
0.7
3.4
3.6
16
No.39
1/18/99
770
6.4
2561
720
5515
2.05
0.6
8.1
2.8
39
No.40
1/25/99
670
8.4
2001
538
6008
2.07
0.4
4.2
2.1
20
No.41
2/1/99
573
6.3
1713
176
6258
1.95
1.2
4.2
5.8
20
No.42
2/8/99
1049
6.6
3187
545
6657
2.73
0.9
9.1
4.1
43
No.43
2/15/99
9.3
3378
517
6630
3.13
0.9
4.3
No.44
2/22/99
10.4
2506
473
6414
2.69
0.6
3.0
No.45
3/1/99
3.6
2363
395
5741
3.75
0.5
2.6
No.46
3/8/99
2.6
782
405
4762
3.25
0.05
0.2
No.47
3/15/99
5.5
1892
297
4775
2.92
0.7
3.5
27211s001
k Rates
10/26/99
Page 1 of 2

SO
Ora
a.o
Week
Date
BOD (mg/L)
COD (mg/L)
MLSS
(mg/L)
Detention
Time (days)
Removal Rate
Using MLSS (d'')
Polysaccharide
Adjusted Removal
Rate (d"')
Inf. BOD
Eff.
BOD
Inf.
COD
Eff.
COD
MLSS
Aer. Basin
k (COD)
k (BOD)
k (COD)
k (BOD)
No.48
3/22/99
5.5
2599
279
4306
7.58
0.7
3.2
No.49
3/29/99
2.8
1885
226
3659
7.55
0.5
2.4
No.50
4/5/99
2.5
1424
174
3593
3.97
0.7
3.4
No.51
4/12/99
10.6
2607
334
4104
2.82
1.5
7.3
No.52
4/19/99
10.0
1925
497
4438
3.24
0.4
1.8
No.53
4/26/99
11.4
1629
526
4209
2.24
0.4
1.7
No.54
5/3/99
137
3.0
1639
546
4142
2.54
0.3
0.6
1.5
3
No.55
5/10/99
2.8
1672
750
3833
2.68
0.2
1.0
No.56
5/17/99
634
3.2
2352
685
4081
3.52
0.4
8.6
1.9
41
No.57
5/24/99
619
2.8
2549
757
4152
3.51
0.4
9.4
2.0
45
No.58
5/31/99
434
4.9
2199
793
4138
2.17
0.4
4.2
2.1
20
No.59
6/7/99
2.0
1374
806
3978
2.46
0.1
0.5
No.60
6/14/99
832
3.5 '
1836
368
3963
2.23
0.8
22.5
4.0
107
No.61
6/21/99
780
14.6
1792
250
3960
2.46
1.1
4.2
5.4
20
No.62
6/28/99
806
11.6
1885
388
4745
2.31
0.7
5.0
3.2
24
No.63
7/5/99
7.5
1616
147
4669
4.49
0.8
3.7
No.64
7/12/99
684
15.0
2363
364
4658
2.79
1.0
2.3
4.8
11
No.65
7/19/99
13.4
2011
522
5478
2.77
0.4
1.8
No.66
7/26/99
283
7.0
1798
5165
1.93
1.1
5
No.67
8/2/99
12.8
1960
412
5297
1.85
0.8
3.6
No.68
8/9/99
5.8
1940
6288
2.51
No.70
8/23/99
17.6
2688
6900
3.15
LT Average
629
12.5
2087
504
5095
2.99
0.43
2.04
2.05
10
Polysaccharide analyses (anthrone test) were performed
on the CKCI mixed liquor. These results indicated lower
than normal polysaccharide and therefore lower
_„ than normal bacterial density.
fame
Polysaccharide Results
12/3/97 2.3%
12/19/97 2.3%
12/31/97 4.7%
4/26/99 3.3%
Average 3.2%
Avg. k
Median
Min. k
Max. k
0.6 6.2 2.8 30
0.5 4.2 2.4 20
0.05 0.6 0.22 2.7
1.8 22.5 8.6 107
Typical Avg. Polysaccharide (10%-20%) = 15%
Average/Typical = 0.21
as
Otherwise Healthy Mudge (polysaccharide analyses indicate MLVSS < 21 % of MLSS)
Utilization Rates calculated using MLSS are lower than would be expected.
A•,
Wit
Utilization Rate:
Utilization Rate:
k = (Inf. BOD) * (BOD removed)
(Eff BOD) * (MLSS) * (detention time)
k = (Inf. BOD) * (BOD removed)
(Polysaccharide Adjusted) (Eff BOD) * (MLSS*0.21) * (detention time)
27211s001
k Rates
10/26/99
Page 2 of 2

Appendix E
Statistical Analysis of Nutrient Discharges

Paw
1601
010
Statistical Plots: Data from Weeks 24-68, except Weeks 45, 46, 50.
Using Weekly Avgs.
Figure 1: Effluent TP (mg/L)
i Prob % Prob
1 0.03 3.0
2 0.06 6.1
3 0.09 9.1
4 0.12 12.1
5 0.15 15.2
6 0.18 18.2
7 0.21 21.2
8 0.24 24.2
9 0.27 27.3
10 0.30 30.3
11 0.33 33.3
12 0.36 36.4
13 0.39 39.4
14 0.42 42.4
15 0.45 45.5
16 0.48 48.5
17 0.52 51.5
18 0.55 54.5
19 0.58 57.6
20 0.61 60.6
21 0.64 63.6
22 0.67 66.7
23 0.70 69.7
24 0.73 72.7
25 0.76 75.8
26 0.79 78.8
27 0.82 81.8
28 0.85 84.8
29 0.88 87.9
30 0.91 90.9
31 0.94 93.9
32 0.97 97.0
TP (mg/L1
0.23
0.27
0.62
0.64
0.66
0.79
0.81
0.84
0.85
0.94
0.95
0.97
1.1
1.1
1.14
1.4
1.4
1.5
1.5
1.5
1.6
1.7
1.9
2
2
2.3
2.4
2.4
2.4
2.8
3.8
4.2
Prob = i/(n+1)
% Prob = Prob*100
Here: n = 32
"' Incident with wet packed toweer scrubber 2/25/99
(data not included in statistical analysis)
ar
..e
27211s001
P Stats (2)
DATA
Date
Week No.
TP mg/L
- 10/3/98
No.24
0.7
10/10/98
No.25
0.2
10/17/98
No.26
0.3
10/24/98
No.27
1.0
10/31/98
No.28
3.8
11/7/98
No.29
2.4
11/14/98
No.30
11/23/98
No.31
11/30/98
No.32
1.5
12/7/98
No.33
2.8
12/14/98
No.34
12/21/98
No.35
12/28/98
No.36
1/4/99
No.37
1/11/99
No.38
2.0
1/18/99
No.39
1.6
1/25/99
No.40
0.9
2/1/99
No.41
2.3
2/8/99
No.42
0.9
2/15/99
No.43
1.4
2/22/99
No.44
1.7
3/1/99
3/8/99
3/15/99
No.47
1.9
3/22/99
No.48
3/29/99
No.49
4/5/99
4/12/99
No.51
0.8
4/19/99
No.52
1.0
4/26/99
No.53
1.1
5/3/99
No.54
0.6
5/10/99
No.55
1.4
5/17/99
No.56
2.4
5/24/99
No.57
2.4
5/31/99
No.58
1.5
6R/99
No.59
0.6
6/14/99
No.60
4.2
6/21/99
No.61
0.8
6/28/99
No.62
0.8
7/5/99
No.63
7/12/99
No.64
1.1
7/19/99
No.65
1.1
7/26/99
No.66
1.5
8/2/99
No.67
2.0
8/9/99
No.68
95th Percentile (calculated):
10/3/98 - 8/2/99 = 3.3
Average:
10/3/98 - 8/2/99 =
1.5
41,
10/25/99

Ole
ORM
oama
r..
a.n
pal
Statistical Plots: Data from Weeks 30 - 68 (All data included)
Using weekly averages
Figure 2: Effluent TN (mg/L)
i PI4.b %Prob TN (mg/0
1 0.03 3.4 14.2
2 0.07 6.9 16.1
3 0.10 10.3 16.1
4 0.14 13.8 18.1
5 0.17 17.2 18.2
6 0.21 20.7 18.6
7 0.24 24.1 19.1
8 0.28 27.6 19.1
9 0.31 31.0 21.1
10 0.34 34.5 21.1
11 0.38 37.9 22.1
12 0.41 41.4 23.0
13 0.45 44.8 23.1
14 0.48 48.3 25.1
15 0.52 51.7 25.1
16 0.55 55.2 28.1
17 0.59 58.6 29.1
18 0.62 62.1 30.2
19 0.66 65.5 30.9
20 0.69 69.0 31.4
21 0.72 72.4 37.1
22 0.76 75.9 37.6
23 0.79 79.3 46.0
24 0.83 82.8 46.2
25 0.86 86.2 50.1
26 0.90 89.7 50.2
27 0.93 93.1 68.5
28 0.97 96.6 73.1
Prob = i/(n+1)
% Prob = Prob*100
Here: n = 28
DATA
Date
Week No.
TN mg/L
11/14/98
No.30
11/23/98
No.31
11/30/98
No.32
73.1
12/7/98
No.33
50.1
12/14/98
No.34
12/21/98
No.35
12/28/98
No.36
1/4/99
No.37
1/11/99
No.38
18.6
1/18/99
No.39 _
25.1
1/25/99
No.40
29.1
2/1/99
_
No.41
37.6
2/8/99
No.42
21.1
2/15/99
No.43
21.1
2/22/99
No.44
_
18.1
3/1/99
No.45
23.1
3/8/99
No.46
50.2
3/15/99
No.47
28.1
3/22/99
No.48
3/29/99
No.49
4/5/99
No.50
18.2
4/12/99
No.51
22.1
4/19/99
No.52
__
46.2
4/26/99
No.53
5/3/99
No.54
14.2
5/10/99
No.55
23.0
5/17/99
No.56 _
_ 16.1
5/24/99
No.57
19.1
5/31/99
No.58
30.9
6/7/99
No.59
46.0 `
6/14/99
No.60
68.5
6/21/99
No.61
19.1
6/28/99
No.62
_
37.1
7/5/99
No.63
7/12/99
No.64
30.2
7/19/99
No.65
31.4
7/26/99
No.66
16.1
8/2/99
No.67
25.1
95th Percentile (calculated):
11/14/98 - 8/2/99 = 62.1
4/5/99 - 8/2/99 = 51.8
Average:
11/14/98 - 8/2/99 =
4/5/99 - 8/2/99 =
30.7
28.9
27211s001 10/25/99
N stats (2) Page 1 of 2

rr
MIR
ara
ama
RNA
Statistical Plots: Data from Weeks 30 - 68 (All data included)
Using weekly averages
Figure 3: Effluent TNN (mg/L)
i Prob % Prob
1 0.03 3.4
2 0.07 6.9
3 0.10 10.3
4 0.14 13.8
5 0.17 17.2
6 0.21 20.7
7 0.24 24.1
8 0.28 27.6
9 0.31 31.0
10 0.34 34.5
11 0.38 37.9
12 0.41 41.4
13 0.45 44.8
14 0.48 48.3
15 0.52 51.7
16 0.55 55.2
17 0.59 58.6
18 0.62 62.1
19 0.66 65.5
20 0.69 69.0
21 0.72 72.4
22 0.76 75.9
23 0.79 79.3
24 0.83 82.8
25 0.86 86.2
26 0.90 89.7
27 0.93 93.1
28 0.97 96.6
TNN (mg/L1
0.4
0.4
0.5
0.6
1.1
1.2
1.3
1.3
1.6
1.9
2.5
2.7
3.1
3.3
3.7
4.0
4.2
4.3
6.0
7.3
7.6
7.7
8.3
8.6
9.7
14.5
28.0
34.9
Prob = i/(n+1)
% Prob = Prob*100
Here: n = 28
"D (TNN = Total Nonrefractory Nitrogen =
a
NO2/NO3-N + NH3-N)
DATA
Date
Week No.
TNN (mg/L)
11/14/98
No.30
11/23/98
No.31
11/30/98
No.32
2.5
12/7/98
No.33
4.0
12/14/98
No.34
12/21 /98
No.35
12/28/98
No.36
1/4/99
No.37
1/11/99
No.38
_
1.1
1/18/99
No.39
6.0
1/25/99
No.40 _
2.7
2/1/99
No.41
14.5
2/8/99
No.42
0.4
2/15/99
No.43
0.5
2/22/99
No.44
0.4
3/1/99
No.45 __
n 1.3
3/8/99
No.46
28.0
3/15/99
No.47
7.7
3/22/99
No.48
3/29/99
No.49
4/5/99
No.50
8.3
4/12/99
No.51
9.7 __
4/19/99
No.52
7.6
4/26/99
No.53
5/3/99
No.54
1.9
5/10/99
No.55
8.6
5/17/99
No.56
_
1.2
5/24/99
No.57
0.6
5/31/99
No.58
7.3
6/7/99
No.59
34.9
6/14/99
No.60
3.3
6/21/99
No.61
3.7
6/28/99
No.62
4.2
7/5/99
No.63
7/12/99
No.64
1.3
7/19/99
No.65
3.1
7/26/99
No.66
1.6
8/2/99
No.67
4.3
95th Percentile (calculated):
11/14/98 - 8/2/99 = 23.2
4/5/99 - 8/2/99 = 16.0
Average:
11/14/98 - 8/2/99 =
4/5/99 - 8/2/99 =
6.1
6.3
27211 s001 10/25/99
N stats (2) Page 2 of 2

1
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
otal Phosphorous mg/L
9.0
8.0
7.0
6.0
5.0
4.0
3.0
2.0
1.0
0
FIGURE 1
Statistical Analysis of WWTP Effluent— TP (mg/L)
mi ,n ii i�v; r'llllll!
I��ii��1111 1111111 i
Mil1"1""i1111"111111111111111111 I1'liiiitit"'iiI, ii ii 111111111i 11111111111111
i,,,ll,lll illl11l, I;ill 0 I1; 1 1
�I IIJilli1l Illiiiiiii1iiillilil��llll Illl1llllllll I111`1111'i1°_ iiii
11
1E11 111
1II11;11� 111111111111111111011111111 i� �pi1till
11111�n�1�1�mmIl�IlM� :aiiIlIIIiiIiIlII1IIIIIUII1IllhIl1IIIUiiiI1iiiIIii ,ll11il1IIII IIIIII�I Illll�!�!,il� I 1I1I1IU11III1I1IIUIIIlUIIIItIIIIlII1
0.01 1 2 5 10 20 30 40 50 60 70 80 90 95 99 99.9 99.99
PROBABILITY (%) AWARE -

1 1 1 l 1 1 1 1 1 1 1 1 1 l
90
80
70
J
60
E
50
0
L.
40
O
30
20
10
0
FIGURE 2
Statistical Analysis of WWTP Effluent— TN (mg/L)
r
..._ rr. .n ._.
•
•
'NM Molnar
0.01
r
r
i
r
• A
•
•
• •
• •
NOI
r
4-1
I I
r r.
!
"T
NMI
•
.-4
•
•
mr
•
ra.r..r.rr
2 5 10 20 30 40 50 60 70 80
PROBABILITY (%)
90 95
.44
99
99.9
99.99
All INC

1 1 1 1 1 1 1 1 ➢
1 1 1
1
1
1
1
1
1
1
•
CA
1 onrefractor itro u e
0
45
FIGURE 3
Statistical Analysis of WWTP Effluent— TNN (mg/L)
r
40
IF
35
30
25
20
15
10
5
0
•
Mir
•
•
4-
F.
••
IF NMI
Irmo ra
"merlon •
•
r
FIF
-
A
INN
•
ri r.rm rim
FI FF.
1
IF I
•
•
•
•
r
0.01 1 2 5 10 20 30 40 50 60 70 80 90 95 99 99.9 99.99
PROBABILITY (%) AWARE-

Appendix F
Alternative Treatment Design and Cost Estimates

CROMPTON & KNOWLES - TERTIARY TREATMENT FOR PHOSPHORUS REMOVAL
SUMMARY OF PRECIPITATION DESIGN
DESCRIPTION
VALUE
Permitted Average Monthly Flow
0.40 MGD
Phosphorus
Secondary
Estimated
Effluent
Removal
Clarifier Effluent TP
Phosphorus Removal
Phosphorus
2.75 mg/L
1.75 mg/L
1 mg/L
Estimated Ferric Chloride Addition
Ferric' Chloride Dose
Daily Addition of 40% Ferric Chloride
75 mg/L
625 Ib/d (54 gal/d)
Estimated Polymer Addition
Polymer Dose
Daily olkddition of Polymer
75 mg/L
250 Ib/d (26 galld)
Estimated NaOH
NaOH
Daily Addition
Addition (based on addition of 20 mg/L FeCI3)
Dose
of 25% NaOH
55 mg/L
736 Ib/d (70 gal/d)
Estimated Sludge Generation, based on FePO4 produced
Dry Sludge Produced
Dewatered Sludge (est. 25% solids)
Settled Sludge (est. 1%solids)
334 Ib/d
1336 Ib/d (21 ft3)
4000 gal/d (167 gph)
Flash Mix Tank
Capacity
Detention
Dimensions,
Materials
Mixer,
Time
square
of Construction
Hp
200 gallons
0.75 min
3'x3'x3'
Concrete
0.75 Hp
Flocculation
Capacity
Detention
Diameter
Heighti
Materials
Mixer,
Tank
Time
of Construction
Hp
4,350 gallons
15 min
7.5 ft
13.2 ft
Concrete
1.0 Hp
Tertiary Clarifier
Diameter
Side Water Depth
Hydraulic Loading Rate
50 ft
14 ft
200 gpolft2
Neutralization Tank
Capacity
Detention Time
Diameter
Heights
Materials of Construction
Mixer, Hp
1,500 gallons
5 minutes
6 ft
7 ft
Concrete
1.0 Hp
27211s005
Summary
10/25/99

CROMPTON KNOWLES
PRECIPITATION SYSTEM - BUDGETARY COST ESTIMATE
ESTIMATOR: L.Gellner Date: 10/6/99
DESCRIPTION
(Design Basis - Site grading not included. Assume no
extensive excavation necessary.)
Quantity
Material & Labor
No. of
Units
Unit of
Meas.
Per Unit
TOTAL
Magnetic Flow Meter w/ Additional Transmitter
1
LS
$4,000
- $4,000
Installation
$1,000
$1,000
Flash Mix Tank - 200 gallon square (3'x3'x3', LxWxH)
Concrete
Slab: 1' thick, 6" overhang
2
yd3
$250
$500
Walls: 1' thick, 1' freeboard
3
yd3
$400
$1,200
Excavation: 2:1 slope
50
yd3
$3
$200
0.75 Hp Mixer j
1
ea.
$2,000
$2,000
Mixer Installation
$500
$500
FeCI3 Metering Punp: 0-8 gph, w/ Enclosure
2
LS
$1,900
$3,800
Installation j
LS
$500
$500
Polymer Blend & Feed System w/Enclosure: 0-4.5 gph
1
LS
$7,900
$7,900
Installation
$500
$500
Flocculation Tank 4350 gallon cylindrical
Concrete
Slab: 1' thick, 6" overhang
3
yd3
$250
$800
Walls: 1' thick, 1' freeboard
15
yd3
$400
$6,000
Excavation: 2:1 slope
1150
yd3
$3
$3,500
1.0 Hp Mixer
1
ea.
$5,700
$5,700
_
Mixer Installation
$500
$500
Tertiary Clarifier - 50 ft Dia., 14 ft. Sidewall
Equipment: Mechanism and Bridge
1
LS
$166,000
$166,000
Concrete
Slab: 1' thick, 6" overhang
82
yd3
$250
$20,500
Walls: 1' thick, 1' freeboard
95
yd3
$400
$38,000
Excavation: 2:1 Slope
3845
yd3
$3
$11,600
Tertiary Clarifier Solids Pumps
3
LS
$3,600
$10,800
Installation
$1,000
$1,000
Neutralization Tank - 1500 Y
9 , alloncylindrical
Concrete
Slab: 1' thick, 6" overhang
3
yd3
$250
$800
Walls: 1' thick, 1' freeboard
8
yd3
$400
$3,200
Excavation: 2:1 slope
276
yd3
$3
$900
1.0 Hp Mixer
1
ea.
$5,700
$5,700
Mixer Installation
$500
$500
Major Processes Subtotal Page 1:
$297,600
27211s005
CoagFloc
10/25/99

CROMPTON KNOWLES
,,., PRECIPITATION SYSTEM - BUDGETARY COST ESTIMATE
[ESTIMATOR: L.Gellner Date: 10/6/99
DESCRIPTION
(Design Basis - Site grading not included. Assume no
extensive excavation necessary.)
Quantity
Material & Labor
No. of
Units
Unit of
Meas.
Per Unit
TOTAL
NaOH Metering Pumps: 0-8 gph, w/ Enclosure
2
LS
$1,900
$3,800
Installation
LS
$500
$500
pH Controller w/Self-Cleaning Probe, Chart Recorder and Enc.
1
LS
$5,500
$5,500
Installation !
LS
$500
$500
NaOH Storage llank - 4000 gallon w/ Nexus Veil
1
LS
$14,000
$14,000
Chemical Feed Building: 12'x20', 12' High, Insulated
1
LS
$22,000
$22,000
I -beams for Mounting Mixers
Rapid Mix Tank
115
Ib.
$1
$115
Flocculation Tank _
219
Ib.
$1
$219
Neutralization Tank
184
Ib.
$1
$184
Piping and Tubing - Distances Assumed
Wastewater Ond Tertiary Solids: 4" Sch. 40 Pipe - Below Groun
600
ft.
$25
$15,000
Trenching
600
ft.
$25
$15,000
Fittings and Valves
LS
$4,000
$4,000
NaOH Tubing: 0.5" O.D. Heat Trace Tubing
300
ft.
$20
$6,000
FeCI3 Tubing: 0.5" O.D. Teflon Heat Trace Tubing
300
ft.
$20
$6,000
Polymer Tubing: 0.5" Teflon Heat Trace Tubing
300
ft.
$20
$6,000
Tubing Carrier Pipe: 4" Sch 40 (Underground)
300
ft.
$50
$15,000
Major Processes Subtotal Page 2:
9
$113,818
Major Processes Subtotal Page 1:
$297,600
Major Processes Cost Total:
$411,418
Electrical:
10%
$41,100
_ _
Engineering:
10%
$41,100
Contingency:
30%
$123,400
Contractor OH+P:
18%
$74,100
Total Project Cost:
$691,118
Equivalent Annual Capital Cost (a):
$107,700
Daily Cost of Chemicals
FeCI3
625
Ib.
$0.18
$113
NaOH
736
Ib.
$0.10
$100
Polymer
250
Ib.
$0.84
$300
Total Annual Cost of Chemicals:
$182,500
Annual Power Requirements:
23070
kW-H
$0.07
$1,600
Equivalent Annual Total Cost:
$291,800
27211s005
CoagFloc
10/25/99

CROMPTON & KNOWLES - TERTIARY TREATMENT FOR NITROGEN REMOVAL
SUMMARY OF RESIN ADSORPTION SYSTEM
DESCRIPTION
VALUE
Permitted Average Monthly Flow
0.40 MGD
Nitrogen Removal
Influent TN
Influent Organic N
Influent Inorganic N
Organic Nitrogen Removed (April 1 - Nov. 1)
Total Nitrogen Removed (April 1 - Nov. 1)
52.5 mg/L
36.5 mg/L
16.0 mg/L
63% (23 mg/L)
23 mg/L (63 Ib/d)
Resin Columns
Number
Volume, ea
Diameter,
Depth, ea
ea
3
556 ft3
12 ft
5 ft
Hydraulic Loading
Loading Rate
Cycle
0.25 gpm/ft3
94 BV
Regeneration
Regenerant
Loading Rate
Regeneration Cycle
Time to Regenerate
Frequency
Volume Spent Regenerant
Methanol
0.25 gpm/ft3
3 BV
1 hour
every 94 BV
12,500 gal
Methanol Recovery System
Process
Volume Regenerant Processed
Time to Rgcover Methanol
Solvent Still Processing Rate
Methanol Loss per Cycle
Distillation
12,500 gal
18 hrs.
700 gal/h
10% (1250 gal)
BV = Bed Volume
Assumptions: Resin would need to be replaced every 10 years.
27211s005
Summary (2)
10/25/99

PIM
FIMN
..o
CROMPTON KNOWLES
RESIN ADSORPTION SYSTEM - BUDGETARY COST ESTIMATE
ESTIMATOR: L.Gellner Date: 10/11/99
DESCRIPTION
(Design Basis - Site grading not included. Assume no
extensive excavation necessary.)
Quantity
Material & Labor
No. of
Units
Unit of
Meas.
Per Unit
TOTAL
Resin Columns - 3
Resin Volume for 3 Columns
1668
ft3
$565
$942,420
Columns and Equipment
1
LS
$750,000
$750,000
Installation '
25%
$187,500
Methanol and Methanol Storage
Methanol
20,000
gal
$0.60
$12,000
20,000-gallon Storage Tank (Clean/Distilled Methanol)
1
LS
$20,000
$20,000
Installation
25%
$5,000
Spent Methanol Storage Tank - 20,000 gal
1
LS
$20,000
$20,000
Installation
25%
$5,000
Solvent Recovery System
1
LS
$250,000
$250,000
Installation
25%
$62,500
Still Bottom Holding Tank - 10,000 gal
1
LS
$10,000
$10,000
Installation
25%
$2,500
Major Processes Cost Total:
$2,267,000
Electrical:
10%
$131,000
Engineering:
10%
$131,000
Contingency:
_
30%
$394,000
Contractor OH+P:
18%
$236,000
Total Project Cost:
$3,159,000
Equivalent Annual Capital Cost:
$492,200
Daily Methanol Costs
1250
gal
$0.60
$750
Daily Disposal Costs
1250
gal
$1.81
$2,263
7-month Chemical Costs:
$641,400
Equivalent Annual Total Cost:
$1,133,600
fintl Notes:
Equivalent annual cost based on 9% interest over 10 years.
Electrical, Engineering, Contingency, OH&P cost does not include resin cost and methanol cost
Chemical and disposal costs are based on 7 months of operation (Apr. 1 - Nov. 1)
to comply with Nitrogen limit
27211s005
Resin
10/14/99