NC0004375_Report_20010110

NPDES DOCUHENT :MCANNINO COVER MEET
NPDES Permit:
NC0004375
Clariant Corporation
Document Type:
Permit Issuance
Wasteload Allocation
Authorization to Construct (AtC)
Permit Modification
Complete File - Historical
Engineering Alternatives (EAA)
Correspondence
Owner Name Change
eporrt
Instream Assessment (67b)
Speculative Limits
Environmental Assessment (EA)
Document Date:
January 10, 2001
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BROWN AND
CALDWELL
January 10, 2001
_._r. Kerr T. Stevens
Director
NC Division of Water Quality
1617 Mail Service Center
Raleigh, North Carolina 27699-1617
Subject: Treatability Testing of Combined
Charlotte Mecklenburg Utilities and
Clariant Corporation Wastewaters
Final Report
NPDES No. BC 0004375
CMU PN: 622-00-553
Dear Mr. Stevens:
19047-05/01
Enclosed is a copy of our final report on the treatability testing of the combined treatment of
wastewater from the Charlotte -Mecklenburg Utilities Long Creek basin at the Clariant
Corporation's East Site Wastewater Treatment Plant (NPDES No. NC 0004375). We are
pleased to report that the combined wastewater can be treated to consistently meet the current
Clariant NPDES limits with minimal modifications to the existing treatment plant.
We will call you next week to set up a meeting to discuss your review comments. In the
meantime, please do not hesitate to contact us if you have any questions or require additional
information.
Very truly yours,
BROWN AND CALDWELL
Richard A. Carrier, P.E.
Project Manager
RAC:dm
Enclosure
D uARO, NP
SEAL 'p
d
'' /7163r'( o L 4
cdt_ ?e,7a.
Peter F. Schuler, P.E':'
ProjeGt;Engineer
cc: Wes Eckenfelder, Brown and Caldwell
David Goodrich, NC Division of Water Quality
Gary Sanderson, Clariant Corporation
Barry Shearin, Charlotte -Mecklenburg Utilities
Environmental Engineering And Consulting
200 PROVIDENCE ROAD, SUITE 204, CHARLOTTE, NC 28207
[phone] FAX [phone]
G:119047 - Clariant Treatability\WP\Letters1L006 -Stevens - final report.doc

MI
rawl
Fon
TABLE OF CONTENTS
CHAPTER 1. BACKGROUND / PURPOSE 1-1
r'C' CHAPTER 2. METHODOLOGY / PROCEDURES OF TREATABILITY TESTS 2-1
Batch Treatability Tests 2-1
Continuous Flow Pilot Scale Treatability Tests 2-2
prI
Bench Scale Peroxidation Experiments 2-4
CHAPTER 3. DISCUSSION OF RESULTS 3-1
I1
Results of Bench Scale Treatability Tests 3-1
Results of Continuous Flow Pilot Tests - CMU / Clariant Combined Unit 3-5
BOD / COD 3-5
MI
TSS 3-7
TKN / Organic Nitrogen / Ammonia 3-7
Nitrite and Nitrate 3-9
MI
Phosphorous 3-10
Volatiles, Semi-volatiles, Inorganics and Metals 3-10
furlChronic Toxicity: 3-12
Disinfection Studies 3-12
Results of Continuous Flow Pilot Tests - Clariant Only Unit 3-13
p., BOD / COD 3-13
TSS 3-15
TKN / Organic Nitrogen / Ammonia: TKN / Organic Nitrogen / Ammonia 3-15
WI Nitrite and Nitrate 3-17
Phosphorous 3-18
Volatiles, Semi-volatiles, Inorganics and Metals: 3-19
F.1 Results of Bench Scale Peroxidation Experiments 3-20
CHAPTER 4. PROPOSED MODIFICATIONS TO EXISTING CLARIANT WWTF 4-1
FM Description of Existing Clariant WWTF 4-1
Proposed Modifications to Clariant's WWTF 4-2
Proposed Permit Limits for Combined Treatment of CMU / Clariant Wastewater 4-3
PEI
CHAPTER 5. CONCLUSIONS AND RECOMI4EENDATIONS 5-1
Conclusions 5-1
WO Recommendations 5-2
F, APPENDIX A. Operational / Analytical Data for Combined CMU / Clariant Pilot Unit
APPENDIX B. Operational / Analytical Data for Clariant Only Pilot Unit
APPENDIX C. Meeting Minutes of Meeting with NC DENR / DWQ
rm
MI
BROWN AND CDWUJ!J
owl G.\19047 - Clariant Treatability\WP\Roports\Contents - Pilot Study Report.doc

LIST OF TABLES
1=1 Number Page
2-1 Continuous Flow Pilot Unit Operational Criteria 2-3
2-2 Analytical Testing Schedule for Continuous Flow Treatability Study 2-3
3.1 Characteristics of Wastestreams Evaluated in Batch Treatability Testing 3-1
"`' 3-2 Batch Activated Sludge Test Results 3-2
3-3 Calculated Rate Constants for BOD and NH3-N Removal 3-4
3-4 Summary Of Organic / Inorganic Scan Of Pilot Unit Effluent 3-11
3-5 Summary of Organic / Inorganic Scan of Clariant Only Pilot Unit Effluent 3-19
4-1 Current NPDES Discharge Limits (winter monthly averages) 4-4
IWO
LIST OF FIGURES
0.1
Number Page
1-1 Existing Flow Diagram 1-2
3-1 Removal of SCBOD in Batch Treatability Tests 3-3
3-2 Removal of Ammonia in Batch Treatability Testing 3-3
3-3 Combined CMU / Clariant Pilot Unit - BOD Removal 3-6
3-4 Combined CMU / Clariant Pilot Unit - COD Removal 3-6
3-5 Combined CMU / Clariant Pilot Unit - TSS Removal 3-7
3-6 Combined CMU / Clariant Pilot Unit - TKN Removal 3-8
3-7 Combined CMU / Clariant Pilot Unit - Ammonia Removal 3-9
r=' 3-8 Combined CMU / Clariant Pilot Unit Nitrate / Nitrite Removal 3-10
3-9 Combined CMU / Clariant Pilot Unit - Phosphorous Removal 3-11
3-10 UV Dose Response Curve for Combined CMU / Clariant Pilot Unit 3-12
PE' 3-11 Clariant Only Pilot Unit - BOD Removal 3-14
3-12 Clariant Only Pilot Unit - COD Removal 3-14
3-13 Clariant Only Pilot Unit - TSS Removal 3-15
3-14 Clariant Only Pilot Unit - TKN Removal 3-16
3-15 Clariant Only Pilot Unit - Ammonia Removal 3-16
3-16 Clariant Only Pilot Unit - Nitrate / Nitrite Removal 3-18
3-17 Clariant Only Pilot Unit - Phosphorous Removal 3-19
3-18 Bench Scale Demonstration of Nitrification Inhibition 3-20
3-19 Bench Scale Demonstration of Peroxide Addition 3-21
4-1 Proposed Flow Diagram 4-2*
4-2 Current and Proposed Permit Limits 4-5
*Figure follows page number noted.
BROWN AND CL/FJ!Jb
GU9047 - Clarissa Trcatabtlity\WP\Rcports\Coateats - Pilot Study Report.doc

CLARIANT
GROUNDWATER
CLARIANT
ALKALINE SEWER
LIME
CLARIANT -�
ACID SEWER
NEUTRALIZATION
I PRIMARY CLARIFIER
NO 1 I ___—
ACID
-
T
SECONDARY CLARIFIER
NO 1
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PHOSPHORIC ACID
FLOATING AERATORS
------------------
FLOATING AERATORS
JET MIXING
• --� ae ae c1a db ��/-\
y v arc v anLv v_//
EQUALIZATION LAGOON ACTIVATED SLUDGE LAGOON
(Z-03) (Z-04)
POLYMER
T
i
T T
SECONDARY CLARIFIER
N0 2
I
1
FlLTRATE
BELT PRESSES
LEY' FEED PUMP
FEED TANK
WAS / RAS PUMPS
T
SOLIDS - TO ONSITE
--- ---
LANDFILL ___
— — -- 1 AERATION ---- -
PARSHALL FLUME
BROWN AND
CALDWELL
SUBMITTED:
APPROVED:
APPROVED:
NW[OT YMUBOI
MOM MO CALOWILL
DATE:
DATE:
DATE
UNE IS 2 INCHES
AT FULL SIZE
GF NOT Y-SCM. ACCORDINGLY)
ALE CMUD\19047\CAD
DRAWN J P ORTER
DESIGNED P SCHULER
CHECKED P SCHULER
CHECKED R CARRIER
REVISIONS
DESCRIPTION
BY
DATE
APP.
CLARIANT CORPORATION
CLARIANT
WASTEWATER TREATMENT FACILITY
IMPROVEMENTS
TO CATAWBA
RIVER
TO 300MC
RESERVOIR_
TRANSFER PUMP
CLARIANT WWTF
EXISTING FLOW DIAGRAM
PRO.ECT NUMBER
19047
DRAWING NUMBER
1-1
SHEET NUMBER

CHAPTER 1. BACKGROUND / PURPOSE
WI
foci
fiLl
faml
rim
Charlotte Mecklenburg Utilities (CMU) currently pumps wastewater from the Long Creek
finpumping station located adjacent to the Clariant facility to the McAlpine Creek WWTF for
treatment and disposal. The Long Creek basin is undergoing rapid development and CMU is
considering several long-term treatment options including combined treatment at the existing
,M Clariant WWTF. CMU wants to ultimately pump 2.0 MGD of Long Creek basin wastewater to
Clariant for treatment and disposal.
Clariant Corporation (Clariant) discharges process and sanitary wastewater to an onsite
wastewater treatment facility (WWTF) which consists of neutralization, primary clarification,
activated sludge treatment, final settling, and post aeration (see Figure 1-1). Activated sludge
treatment consists of two aeration basins connected in series with reported volumes of 4.0 MG
(Z-03) and 2.5 MG (Z-04), respectively. Clariant manufactures specialty organic chemicals and
has a National Pollutant Discharge Elimination System (NPDES) permit (NC 0004375) to
discharge 3.9 MGD of treated wastewater to the Catawba River in western Mecklenburg County.
Last year Clariant treated an average of 1.1 MGD. In the future, Clariant projects that the
amount of wastewater treated in the WWTF will decrease due to changes in production. These
same changes are also anticipated to result in a 70 percent reduction in BOD load. Consequently,
Clariant anticipates operating only the smaller aeration basin in the future. The larger aeration
basin will be maintained as a standby equalization basin or aerobic sludge digester.
Effluent from the WWTF has discharge limits and/or monitoring requirements for pH, BOD,
NH3-N, TSS, fecal coliform, total nitrogen, total phosphorus, total phenolics, total sulfate,
MBAS, manganese, iron, chlorides, mercury, volatile organic compounds, semi -volatile organic
compounds, and chronic toxicity.
,r, The combined treatment plant would likely have effluent limits and/or monitoring requirements
for those parameters currently listed in the Clariant discharge permit plus the additional
parameters listed for the McAlpine Creek WWTF (e.g., total residual chlorine). Additionally,
m, the North Carolina Department Environmental and Natural Resources / Division of Water
Quality (NC DENR / DWQ) has indicated that the combined treatment plant may be required to
meet monthly average effluent limits for total nitrogen and total phosphorus of 6 mg/L and
,, 1 mg/L, respectively. Thus, the treatment plant may be required to provide denitrification,
nitrification and phosphorus removal.
run It is likely that the existing Clariant WWTF will require capital improvements for combined
treatment to be successful. The purpose of this study was to determine whether or not the
combined treatment could meet expected effluent limits and the degree of improvements
r., necessary at the Clariant WWTF. This treatability study combined both bench scale batch and
on -site continuous flow through pilot scale tests. The methodologies, data, and conclusions from
both the bench scale and pilot scale tests are discussed in the following sections of the report.
WI
a.,
G:119047 - Clarient Trcatability\WP\Reports\Chapter 1 - Pilot Study Report.doc
BROWN AND CflIWfli
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CHAPTER 2. METHODOLOGY / PROCEDURES
OF TREATABILITY TESTS
,_, This chapter of the report describes the methodologies and procedures used for the bench scale
and pilot scale treatability tests. Three different types of tests were conducted during this study:
(1) Batch Treatability Tests, (2) Continuous Flow Pilot Scale Treatability Tests, and (3) Bench
ran Scale Peroxidation Experiments. The first step in this investigation was to conduct batch
treatability testing to determine if combined treatment of the future Clariant and Long Creek
wastewaters could support appreciable nitrification and biochemical oxygen demand (BOD)
�., removal. Once these tests were complete, a pilot scale apparatus was constructed to verify the
results of the batch tests with 10 weeks of continuous flow tests. Bench scale peroxidation
experiments were also conducted to determine if the addition of hydrogen peroxide would
enhance the nitrification rate.
Batch Treatability Tests
Flow proportioned, composite samples of the three Clariant wastestreams (groundwater, acid
sewer, and alkaline sewer) and the Long Creek wastewater were collected along with Clariant
return activated sludge (RAS), packed on ice and shipped to Brown and Caldwell's laboratory in
Nashville, Tennessee. The three Clariant wastewaters were blended to create a hypothetical
,.,, combined future Clariant wastestream. The combined wastestream and the Long Creek
wastewater were analyzed for pH, total dissolved solids (TDS), total Kjeldahl nitrogen (TKN),
ammonia (NH3-N), nitrite (NO2-N) plus nitrate (NO3-N), carbonaceous biochemical oxygen
rim demand (CBOD), and alkalinity. This analysis indicated a 960 mg/L NH3-N concentration in the
combined Clariant wastestream instead of the anticipated 50 to 100 mg/L NH3-N concentration.
Clariant reported this was due to accidental release of waters from an ammonium sulfate
fall scrubber. These waters are typically captured and held for subsequent disposal as a fertilizer.
Consequently, the combined wastewater was increased to pH 11 by adding sodium hydroxide
and air stripped to reduce the NH3-N concentration and then readjusted to pH 8.0 using sulfuric
acid. Discussions with Clariant indicated that this air stripping step would not significantly alter
the organic composition of the wastewater.
r.9 Three batch activated sludge tests were conducted. Reactor A was used to evaluate the
degradability of combined future Clariant wastewater only. Reactor B was used to evaluate the
degradability of Long Creek wastewater only. Reactor C was used to evaluate the degradability
ran of a blend of 33 percent by volume Clariant wastewater and 67 percent by volume Long Creek
wastewater. In each test, the Clariant RAS was concentrated up to 30,000 mg/L mixed liquor
volatile suspended solids (MLVSS), conditioned with 2.2 percent (by weight MLVSS) pure
culture nitrifiers, and spiked into wastewater at 20 percent by volume.
The contents of Reactors A, B, and C were aerated for 6 hours at room temperature (22 +/- 1 °C)
„a, during which time they were monitored for soluble chemical oxygen demand (SCOD), soluble
carbonaceous biochemical oxygen demand (SCBOD), NH3-N, and NO2-N plus NO3-N. The rate
of CBOD removal and nitrification were compared among the reactors to determine the relative
degradability of Clariant and Long Creek wastewaters.
G.\19047 - Clerical Trcatability\WP\Reports\Chaptcr 2- Pilot Study Repoitdoc BROWN A N 1) C A L D W E L L

2-2
la, The results of the bench scale testing were used to develop the sizing criteria and flow rates for
the pilot scale units to treat both Clariant wastewater and combined Clariant / Long Creek
wastewater.
r�l
Continuous Flow Pilot Scale Treatability Tests
The continuous flow treatability study was conducted onsite in a process / pilot laboratory at the
Clariant facility. Two pilot scale units were constructed that consisted of an anoxic zone,
internal recycle loop, aerobic zone, and clarifier. One pilot plant unit treated Clariant only
wastewater and the other pilot plant was used to treat a Combined CMU / Clariant wastewater.
Both pilot scale units were located within a water bath that was used to adjust the temperature of
the wastewater in the pilot units to 12° C to simulate winter operation.
Flow -proportioned chilled composite samplers were located on Clariant's acid and alkaline sewer
discharges. Samples were collected from these locations on Mondays, Wednesdays and Fridays
along with a grab sample of the "treated" groundwater from the air stripping tank. This process
wastewater was then blended on a flow proportional basis and adjusted to a pH of between 7 and
fag 8 to formulate the "future" Clariant wastewater. Typical "blends" were approximately 2 parts
groundwater (138 gpm), 2 parts alkaline wastewater (150 gpm), and 1 part acid wastewater
(75 gpm). This "future" Clariant wastewater was used as the feed for the Clariant Only pilot unit
and it was also blended with CMU wastewater as described below.
The "representative future" Long Creek wastewater was collected on Mondays, Wednesdays and
Fridays using a flow -weighted chilled composite sampler located at the existing CMU Long
Creek Pump Station wet well. CMU Long Creek wastewater was passed through a fine screen to
simulate treatment through a bar screen and grit chamber prior to combining with the "future"
Clariant wastewater. Long Creek wastewater was blended with the "future" Clariant wastewater
based on a flow of 2.0-mgd for the municipal wastewater and the measured flow at each of the
Clariant waste streams, which usually totaled around 0.5 to 0.6-mgd. This blend was fed to the
combined CMU / Clariant pilot unit.
Two activated sludge treatability units were started up with Clariant mixed liquor spiked with an
`w' appropriate quantity of nitrifiers. Unit No. 1 was operated at a 1.3 day hydraulic retention time
(HRT) and treated the Clariant/Long Creek wastewater blend. Unit No. 2 was operated at a
4.5 day HRT and treated only Clariant wastewater. Both were operated at an anoxic zone HRT,
ran aerobic zone HRT, internal recycle rate, and food to mass ratio (F/M) selected from the batch
treatability testing. These values are given in Table 2-1.
During the study period, Brown and Caldwell with assistance from the Clariant WWTF operators
monitored numerous operational parameters as outlined in Table 2-2. Field measurements
included pH, temperature, dissolved oxygen (D.O.) levels, flowrates, oxygen uptake rates
(OURs), and sludge volume index (SVI). In addition, numerous samples were collected by
Brown and Caldwell and analyzed by CMU for chemical oxygen demand (COD), SCOD, BOD,
G:119047 - Clariant Treatability\WP\Reports\Chaptor 2 - Pilot Study Report.doc
BROWN AND CAIJ1EL

PRI
2-3
r•1 SCBOD, total suspended solids (TSS), TDS, volatile suspended solids (VSS), NH3-N, NO2-N
plus NO3-N, total and soluble phosphorous (P), and TKN.
Brown and Caldwell also collected one sample to analyze the effluent from each of the pilot
units for all of the parameters covered under Clariant's existing NPDES permit. Other
experiments that were conducted during this phase of the study included jar testing to determine
chemical dosages to achieve compliance with a total phosphorous (TP) limit of 1 mg/L, zone
settling velocity (ZSV) tests, and ultraviolet (UV) disinfection tests.
ram' Table 2-1. Continuous Flow Pilot Unit Operational Criteria
Pal
I1
farl
Operational
Parameter
CMU / Clariant
Combined Pilot Unit
Clariant Only Pilot
Unit
Hydraulic Retention Time
1.3 days
4.5 days
Anoxic Zone HRT
0.6 days
2.0 days
Aerobic Zone HRT
0.7 days
2.5 days
Internal Recycle Rate
9:1
9:1
F/M (lb BOD / lb MLVSS per aerobic day)
0.090
0.070
Mean Cell Residence Time
50 days
40 days
Table 2-2. Analytical Testing Schedule for
Continuous Flow Treatability Study
Parameter
Days of the Week
S
M
T
W
T
F
S
Influent
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
COD, CBOD, TSS, VSS
TKN, NH3-N, NO2-N + NO3-N
Flowrate
Anoxic Zone Effluent
NO2-N + NO3-N, SCOD,SCBOD
pH, DO, and Temperature
G:119047 - Clariant Troatability\WP\Reports\Chapter 2 - Pilot Study Report.doc
llI(QWI AND CII/IJIJ
fit

f=1
2-4
rat
Parameter
Aeration Basin Mixed Liquor
pH, DO, and Temperature
MLSS and MLVSS
OUR
ZSV, SVI, Microscopic
MEI
Effluent
�► TCOD, TCBOD
SCOD, SCBOD
TKN, NH3-N, NO2-N plus NO3-N
TDS, TSS and VSS
Total and Soluble Phosphorus
sal
Total Phenolics, Total Sulfate,
O&G, MBAS, Mn, Fe, chlorides,
VOC's, and SVOC's
Chronic Toxicity
UV Disinfection
1=1
Sol
Pal
Wri
Days of the Week
S
X
X
M
X
X
X
X
X
X
T
X
X
W
X
X
X
X
X
X
X
X
X
T
X
X
Once during study
Once during study
Once during study
F
X
X
X
X
X
X
Bench Scale Peroxidation Experiments
Bench scale experiments were conducted to demonstrate whether or not the addition of hydrogen
peroxide would make the different process wastewaters more amenable to nitrification. Flow -
weighted composite samples from the Clariant acid and alkaline sewers, as well as grab samples
of MLVSS from the combined CMU / Clariant pilot unit and the Long Creek sewer were
collected, packed on ice and shipped overnight to Brown and Caldwell's Nashville treatability
laboratory.
At the laboratory, the MLVSS from the CMU / Clariant pilot unit was concentrated to
20,000 mg/L and 150 ml of concentrate was transferred to sample bottles A, B, C, D, E, and F.
Seven solutions were prepared as detailed below and added to these sample bottles along with
micro -nutrients. The pH was then adjusted to 7.5 +/- 0.5 s.u. and the solutions were aerated
overnight.
• Bottle A - Long Creek Wastewater - 600 ml of Long Creek Wastewater.
• Bottle B - Alkaline Sewer Wastewater - 60 ml Alkaline Sewer Wastewater and
540 ml of BOD dilution water (distilled water).
G \19047 - Clarient Troataisility\WP\Ropotts\Chapter 2 - Pilot Study Report.doc
BROWN AND CALDWELL
rat

fml
2-5
• Bottle C - Acid Sewer Wastewater - 32 ml Acid Sewer Wastewater and 568 ml of
BOD dilution water.
fml • Bottle D - CMU / Clariant Combined Wastewater - 508 ml of Long Creek
Wastewaterr, 60 m1 Alkaline Sewer Wastewater, and 32 ml_ Acid Sewer Wastewater.
• Bottle E - Acid Sewer Peroxidized - 32 ml of "Acid Sewer Peroxidized" and 568 ml
of BOD dilution water.
for, • Bottle F - Clariant Peroxidized - 92 ml of "Clariant Peroxidized" and 508 ml of BOD
dilution water.
'"' "Acid Sewer Peroxidized" was prepared by placing 400 ml of acid sewer wastewater in a 500 ml
bottle and adjusting the pH to less than 3 s.u. with 1 N NaOH. Then 1.35 ml of 30 percent
hydrogen peroxide and 6.6 ml of iron slurry (5 g FeSO4*7H20 in 0.1 ml DI water) was added
and the mixture was shaken for 60 minutes. The pH was then adjusted to 7 s.u. with 1 N NaOH.
"Clariant Peroxidized" was prepared by placing 140 ml of acid sewer wastewater plus 260 ml of
''r' alkaline wastewater in a 500 ml bottle and adjusting the pH to less than 3 s.u. with 1 N NaOH.
Then 0.5 ml of 30 percent hydrogen peroxide and 2.3 ml of iron slurry (1.75 g FeSO4*7H20 in
0.1 ml DI water) was added and the mixture was shaken for 60 minutes. The pH was then
(09 adjusted to 7 s.u. with 1 NNaOH.
The next morning the samples A, B, C, D, E, and F were centrifuged down and 350 ml of decant
1.' was poured off and saved for nitrification tests. 250 ml of each decant is placed in sample
bottles marked A, B, C, D, E, and F and aerated. Sample bottles G and H were then .prepared as
follows:
I1
• Bottle G - Combined CMU / Clariant Biomass - 350 ml of BOD dilution water was
added to Sample D's concentrated mixed liquor from centrifugation. The mixture was
re -slurried, aerated for an hour and re -concentrated to 50 ml. 50 ml of concentrated
biomass and 200 ml of BOD dilution water was then placed in sample Bottle G.
• Bottle H - Control - 250 mi of BOD dilution water placed in sample Bottle H.
Nitrogen -rich slurry was then formulated by mixing 1 g NH4C1 and 3 g NaHCO3 in 1000 ml of
distilled water. Each of the sample bottles was then spiked with 50 mi of nitrogen -rich slurry
and 10 ml of nitrifier concentrate and aerated for one minute. The pH of the mixtures was then
for, adjusted to a pH of 7.5 +/- with H2SO4. Samples were collected, filtered through 1.5 um filter
paper, and analyzed for ammonia at 30 minutes and 3 hours. The results were reported in mg of
ammonia removed per day per mg of MLVSS.
CY\19047 - Clariant Trostability\WP\Reports\Chapter 2 - Pilot Study Report.doc
BROWN AND CLIIJIJ
PEI

PEI
CHAPTER 3. DISCUSSION OF RESULTS
This chapter of the report summarizes the findings of the bench and pilot scale experiments
conducted on the Clariant Only and CMU / Clariant Combined wastewater.
Results of Bench Scale Treatability Tests
Wastewater characteristics for the future combined Clariant wastewater and Long Creek
�► wastewater that were measured during the bench scale treatability tests are summarized in Table
3-1. These characteristics indicate that without alkaline air stripping, the CBOD of the combined
future Clariant wastewater will be more concentrated than the CMU Long Creek wastewater
(290 vs 215 mg/L). In addition, approximately one-half of the future Clariant wastewater CBOD
can be removed through vigorous alkaline air stripping. This BOD removal will likely occur in
the activated sludge system due to air stripping and/or degradation of the low molecular weight,
volatile organics.
The Long Creek wastewater exhibited typical medium -strength domestic sewage characteristics
1.1 for all parameters excluding TSS and VSS. The concentrations of these two parameters are
elevated in comparison to typical medium -strength domestic sewage.
Table 3-1. Characteristics of Wastestreams Evaluated in Batch Treatability Testing
Wastewater
Characteristic
Future Clariant
Wastewater
Before Air Stripping
Future Clariant
Wastewater
After Air Stripping
Long Creek
Wastewater
CBOD (mg/L)
290
150
215
COD (mg/L)
390
190
790
TKN (mg/L)
960
70
35
NH3-N (mg/L)
960
70
29
NO2-N + NO3-N (mg/L)
18
11
5
TSS (mg/L)
16
Not Analyzed
580
VSS (mg/L)
12
Not Analyzed
360
TDS (mg/L)
7,050
Not Analyzed
350
TDFSa (mg/L)
2,770
Not Analyzed
180
a Tnta1 dissolved fixed snlids is equal to the inorganic nortion of the total dissolved solids.
Results of the Batch Activated Sludge (BAS) tests are summarized in Table 3-2. Figures 3-1 and
3-2 also illustrate the removal of BOD and ammonia, respectively. These figures show rapid
removal of BOD and ammonia for all of the wastewaters studied during the bench scale
treatability tests.
G:119047 - Clariant Treatability\WP\Reports\Chapter 3 - Pilot Study Report.doc
BROWN AND CtllLEId

3-2
Table 3-2. Batch Activated Sludge Test Results
Reactor
Batch
Aeration
Time
(hours)
MLVSS
(mg/L)
SCBOD
(mg/L)
SCOD
(mg/L)
TKN
(mg/L)
NH3-N
(mg/L)
NO2 N
plus NO3-
N (mg/L)
Oxygen
Uptake
(mg/L • hr)
A. Future Clariant Wastewater Only
Oa
6350
120
150
56
56
8
NAb
1
36
95
NA
40
20
54
4
9
68
NA
24
30
48
8
8
52
NA
3
40
29
19
5
54
<10
0.6
38
13
B. Long Creek Wastewater only
Oa
7100
170
630
28
24
4
NA
1
29
95
NA
23
<1
43
4
11
82
NA
9.5
20
46
8
11
49
NA
<1
22
15
19
6
54
<1
0.4
24
16
C. Future Clariant and Long Creek
Wastewater
Oa
7200
154
470
48
48
5
NA
1
24
68
NA
35
8
50
4
10
68
NA
14
18
46
8
8
46
NA
2
30
18
19
7
68
<1
0.8
<30
18
a Calculated values based on known concentrations of wastewaters prior to test.
b Not analyzed.
Ci:\19047 - Clariant Treatability\WP\Reports\Chapter 3 - Pilot Study Raport.doc
BROWN HD CLDiItL

Figure 3-1. Removal of SCBOD in Batch Treatability Tests
Figure 3-2. Removal of Ammonia in Batch Treatability Testing
�—Clariant—CMU CMU / Clariant
G:\19047 - Clariant Treatability\WP\Reports\Chapter 3 - Pilot Study Report.doc
3-3
BROWN AND CALDWELL

fort
Carl
fowl
12,1
PEI
3-4
These results were analyzed to develop CBOD removal and nitrification rates using the
equations presented below.
So (So — Se) = k Se
Xvt
Nr =
Xvnt
Nt2 — Ntl
(korNi) T1=(korNr)T2
Definition of Variables:
Where So, Se
Xv
t
k
Nr
N1,Nt2
X„s
T1,T2
(Equation used to calculate BOD removal rate constant)
(Equation used to calculate Nitrification rate constant)
x 1.06 (T1:17) (Equation used to correct for temperature)
= Influent TCBOD and effluent SCBOD, respectively, mg/L
= MLVSS concentration, mg/L
= Hydraulic retention time, days
= BOD removal rate constant, 1/days
Nitrification rate constant, 1/days
= Nitrite plus nitrate concentrations at time (ti and t2), mg/L
= Nitrifier MLVSS concentrations, mg/L
= Temperatures Ti and T2,
The values of the two rate constants, k (BOD removal) and NR (ammonia removal), provide an
indication of the degradability of the two substrates during the bench scale treatability tests. A
'mo' summary of these calculated results is presented in Table 3-3 and a discussion of the significance
of these results appears below.
farl
Clot
RBI
Table 3-3. Calculated Rate Constants for BOD and NH3-N Removal
Wastewater
BOD Removal Rate Constant
(k)
Nitrification Rate Constant
(Nr)
at 21 °C
at 12 °C
at 21 °C
at 12 °C
Clariant Only - Air Stripped
1.1
0.7
0.69
0.41
Clariant Only without Air
4.8
2.8
NA
NA
Stripping (estimated)
CMU Long Creek Only
2.8
1.7
0.61
0.36
Combined CMU /Clariant
2.8
1.7
0.47
0.28
The future Clariant wastewater that had been subjected to air stripping exhibited a k of 1.1/day at
21°C. If the pre -stripped influent had been used, a k of 4.8/day at 21°C would have likely been
observed. This is a more realistic k value given the constituency of the Clariant wastewater.
Since microbes are less active at lower temperatures, this k value would drop to approximately
2.81bs/day at 12°C.
G:\I9047 - Clerical Troatability\WP\Roports\Chapter 3 - Pilot Study Report.doc
8R0 AND CADIJIJ

3-5
The Long Creek wastewater exhibited a k of 2.8/day at 21°C or 1.7/day at 12°C. This rate is
lower than expected for domestic sewage (typically 8/day), indicating one of two things. Either
the Clariant activated sludge is not well acclimated to domestic sewage, or the Long Creek
wastewater contains organics that are difficult to degrade, possibly contributed by industrial or
commercial dischargers. Given the limited number of industrial and commercial users in the
Long Creek Basin, the reduced degradation rate is most likely due to the poor acclimation to
domestic sewage. Full acclimation of Clariant activated sludge to domestic sewage should occur
quickly during the continuous flow study (less than 2 weeks). If the reduced rate is due to other
organics in the Long Creek Basin, the time required to acclimate will depend upon the
complexity of the organics and could take as long as 6 weeks.
The combined future Clariant and Long Creek wastewater exhibited a k of 2.8/day at 21°C or
1.7/day at 12°C, which is identical to the k for the Long Creek wastewater only. Brown and
Caldwell believes that an acclimated pilot plant will degrade BOD faster than was demonstrated
in the bench scale studies.
The future Clariant wastewater exhibited a Nr of 0.69/day at 21°C or 0.41/day at 12°C. The
Long Creek wastewater exhibited a Nr of 0.61/day at 21°C or 0.36/day at 12°C, which is
comparable to the nitrification rate observed for the Clariant wastewater only. The combined
future Clariant and Long Creek wastewater exhibited a Nr of 0.47/day at 21°C or 0.28/day at
12°C. This nitrification rate is slightly lower than that exhibited in either of the two individual
wastestreams. However, it is within the range of Nr values exhibited at other WWTFs.
Results of Continuous Flow Pilot Tests - CMU / Clariant Combined Unit
The continuous flow studies were started on June 26, 2000 and continued for approximately
10 weeks until September 6, 2000. It should be noted that around the 1711-19t of July, Clariant
switched the type of herbicide being manufactured in Building 45. This change in production
processes affected the treatment efficiency of not only the pilot scale units, but also Clariant's
full-scale WWTF. More in-depth discussion of the impact of production processes is given
below. Normal daily analytical results and operational measurements for the CMU / Clariant
Combined pilot scale unit are presented in Tables A-1 and A-2 in Appendix A, respectively.
BOD / COD. The combined CMU / Clariant continuous flow pilot unit reduced the influent
BOD from 100 - 300 mg/L to less than 10 mg/L and often less than 5 mg/L during the first
several weeks of the study as shown on Figure 3-3. Although BOD removal efficiency was
impacted by the mid -July production process changes, the effluent BOD was maintained below
25 mg/L and would have met the existing permit requirements. It should be noted that the high
variability of influent BOD / COD observed during the pilot study is typical for a batch chemical
manufacturing facility.
COD removal was more impacted by the mid -July production changes than BOD removal as
illustrated on Figure 3-4. The influent COD was reduced from 300-600 mg/L to approximately
30-40 mg/L during the first 3 weeks of the study. This corresponds to a removal percentage of
>90 percent. However, after the process changes in Building 45 the removal percentage was
reduced to about 60-70 percent and the COD in the effluent became much more erratic. It should
BROWN AND CALDWELL
G:119047 - Clariant 'freatability\WP\Reports\Chapter 3 - Pilot Study Report.doc

3-6
Figure 3-3. Combined CMU / Clariant Pilot Unit - SOD Removal
50-
Date
"."IIOD-iu TSIIOD-out
Figure 3-4. Combined CMU / Clariant Pilot Unit - COD Removal
E
O
2000
1800
1600 -
1400 -
1200
1000
800 -
600
400 -
•
200 -
0
\
6/26/2000 7/10/2000
7/24/2000
Date
•
•1
-4
8/7/2000
I" '0 —0—SCOD-out
8/21/2000
9/4/2000
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BROWN AND CALDWELL

IMO
3-7
be noted that the detention time in the combined unit was approximately 36-48 hours and peaks
observed in the effluent were directly attributable to earlier spikes in the influent COD load.
TSS. The removal of total suspended solids by the combined CMU / Clariant continuous flow
pilot unit was unsatisfactory as shown on Figure 3-5. Although the addition of polymer after
August 8 reduced the effluent TSS, inherent limitations of the pilot system's final clarifier design
made it impossible for the existing pilot facilities effluent to meet existing permit limits. It is
Brown and Caldwell's opinion that optimization of the polymer addition combined with the
existing 80-ft diameter secondary clarifiers at Clariant's WWTF will be able to meet Clariant's
existing NPDES permit requirements. It should be noted that the hydraulic capacity of the
secondary clarifiers is 5.0-mgd and the proposed flow rate is only 3.1-mgd. At a hydraulic
loading rate of 3.1-mgd the surface -loading rate on the secondary clarifiers will be 310 gpm/sf,
compared to a typical design range of 800 to 1,000 gpm/sf.
Figure 3-5. Combined CMU / Clariant Pilot Unit - TSS Removal
E
1000
900
800
700
600
500
400
300
200
100
7/10/2000
7/24/2000
Date
8/7/2000
"TSS-in —TSS-out
8/21/2000
9/4/2000
TKN / Organic Nitrogen / Ammonia. Total Kjeldahl nitrogen (TKN) is the total of the organic
nitrogen and ammonia nitrogen (NH3-N) present in a wastewater. Organic nitrogen is converted
to ammonia in the first step of the activated sludge process. NH3-N is then converted by
nitrifiers in a process called nitrification to nitrite (NO2-N) and nitrate (NO3-N). This process
was negatively impacted by the mid -July process changes. Prior to July 19, the influent TKN
averaged 29 mg/L, the influent ammonia averaged 22 mg/L and the influent organic nitrogen
G.\19047 - Clariant Treatability\WP\Reports\Chapter 3 -Pilot Study Report.doc
BROWN AND CALDWELL

■w
MEI
REM
3-8
averaged approximately 7 mg/L. As the combined CMU / Clariant continuous flow pilot unit
became acclimated to the wastewater the effluent TKN and ammonia was reduced as shown on
Figures 3-6 and 3-7, respectively. The effluent ammonia was reduced to less than 1 mg/L and
from July 10 to July 17 the effluent ammonia was measured at 0.2 mg/L. The pilot unit was
removing approximately 22-24 mg/L of ammonia. Although approximately 5 mg/L of soluble
TKN (organic nitrogen) remained in the effluent, the majority of this nitrogen would most likely
be in a non-bioavailable state in the Catawba River because the biota in the WWTF could not
break it down.
Figure 3-6. Combined CMU / Clariant Pilot Unit - TKN Removal
z
"'0 "TKN-in -TKN-out
The mid -July process modifications significantly increased the TKN and organic nitrogen loads
in the pilot plant influent. After Julyl9, the influent TKN averaged 55 mg/L, the influent
ammonia averaged 30 mg/L and the influent organic nitrogen averaged approximately 25 mg/L.
The influent loading rates of TKN, ammonia, and organic nitrogen also became more variable.
These loading rates impaired the ability of the nitrifiers to breakdown the ammonia and the
effluent ammonia concentration increased to an average of between 25 - 30 mg/L. It was
determined that chemicals present in the wastewater after July 19 inhibited nitrification (see
discussion of bench scale pre -oxidation experiments). It should also be noted that the pilot unit
was still removing approximately 16 mg/L of ammonia with the inhibition and relatively cold
temperature of 12 °C. It is estimated that the WWTF would remove approximately 26 mg/L of
ammonia at 21 °C and the effluent ammonia concentration would be reduced to around
15-20 mg/L.
G:119047 - Clariant Treatability\WP\Reports,Cbapter 3 - Pilot Study Report.doc
BROWN AND CALDWELL

MOWN
raMI
RIMA
3-9
Figure 3-7. Combined CMU / Clariant Pilot Unit - Ammonia Removal
140
t
i1
120 - j l
11
I I
100 - 1 I !
I 1 it
I I ! 1
80 - I I I 1
c
I 1 1 1
1 1 4 , / 1
7_ 60 I !.1 �- -••j 1
I I 1 1 a- -i `j(-� 1
I 1 ! •1 1
40 .•A. ! I . , •1 / l
Iife / •
20 - �•� r_ \
i
0
6/26/2000 7/10/2000
7/24/2000
Date
8/7/2000
-•-'N113-in —6—NH3-out—-"TKN-in
8/21/2000
9/4/2000
The pilot plant effluent would consistently meet Clariant's existing NPDES permit for ammonia
during the spring, summer, and fall no matter what chemicals were being produced. However,
without pre -oxidation of the Clariant wastewater from herbicide production with the WWTF
might not consistently achieve the permit limits during the winter months.
It should be noted that Clariant maintains a 300-million gallon off-line reservoir that could be
used to contain the "off -spec" treated effluent. Brown and Caldwell's opinion is that the
installation and use of hydrogen peroxide feed facilities and the effective use of the 300-million
gallon post treatment storage reservoir can be used to consistently meet the existing NPDES
permit limits for ammonia.
Nitrite and Nitrate. The breakdown and removal of nitrogen continues with a process called
de -nitrification that occurs in the anoxic zone of the WWTF. In this process, NO2-N and NO3-N
are broken down into nitrogen gas. Figure 3-8 is an over -simplification of the removal of nitrites
and nitrates because it does not show the amount of nitrite and nitrate formed by the nitrification
of ammonia. The figure illustrates that early in the study when the dissolved oxygen level in the
"anoxic zone" was greater than 0.5 mg/L the NO2-N and NO3-N created by the nitrifiers was not
being broken down into N2 gas by the de-nitrifiers. This resulted in a higher effluent
concentration of NO2-N and NO3-N than the influent concentration. However, once the anoxic
zone D.O. levels were maintained at less than 0.5 mg/L of 02 the effluent concentration of nitrite
and nitrate was less than 1 mg/L. The conversion rate of NO2-N and NO3-N to N2 gas was fairly
consistent throughout the pilot study and averaged around 15 mg/L. Currently, Clariant is only
required to monitor for NO2-N and NO3-N. It should be noted that the effluent nitrite / nitrate
G:119047 - Clariant Treatability\W P\Reports\Chapter 3 - Pilot Study Report.doc
BROWN AND CALDWELL

ill
mork
3-10
Figure 3-8. Combined CMU / Clariant Pilot Unit - Nitrate / Nitrite Removal
35
30
25
20
tV 15
10
5
0
6/26/2000
7/10/2000
7/24/2000
Date
8/7/2000
' • . ' N itrate-N itrite-in T N itrate-N itrite-out
8/21 /2000
9/4/2000
spiked on several occasions. These high effluent values around the 9th and 28th of August were
caused by high D.O. concentrations in the anoxic zone. In addition, the anoxic zone was
removed from the pilot plant on August 30.
Phosphorous. The phosphorous present in the wastewater is essentially all contributed by the
CMU Long Creek wastewater. Although no measurements of influent phosphorous were taken,
the Long Creek wastewater can be considered medium strength municipal wastewater and the
influent total phosphorous concentration is most likely between 5 and 8 mg/L. Over the course
of the study, the soluble effluent total phosphorous ranged from 0.7 to 5.4 mg/L and averaged
3.0 mg/L. The goal of this study was to determine how much chemical additive was necessary to
achieve an effluent total phosphorous concentration of 1.0 mg/L.
Bench scale chemical addition studies were conducted in Brown and Caldwell's treatability
laboratory and the results are summarized on Figure 3-9. The metal salts tested were
Al2(SO4)3 * 18H20 (alum) and FeC13*6H20 (ferric chloride) at dosages of 14.1 and 22.3 mg/L,
respectively. In addition, 2 mg/L of Cytec 1598C (a high molecular weight cationic polymer)
was added. The insoluble amount of phosphorous is based on an effluent TSS of 20 mg/L with a
phosphorous content of 0.026 mg / mg of TSS. Although it appears that a total phosphorous
limit of 1 mg/L can be met by optimizing the addition of aluminum or iron salts, the total
phosphorous in the untreated effluent was only 1.2 mg/L on the day these tests were run.
Volatiles, Semi-volatiles, Inorganics and Metals. A sample of the effluent from the combined
CMU / Clariant pilot unit was collected on August 29, 2000, packed on ice and transported to
G:\19047 - Clariant Treatability\WP\Reports\Chapter 3 - Pilot Study Report.dac
BROWN AND CALDWELL

IRMA
3-11
Figure 3-9. Combined CMU / Clariant Pilot Unit - Phosphorous Removal
Prism Laboratories for analysis. EPA methods 624, 625, 200.7, 245.1, 300, 420.1 and 425.1
were used to analyze the pilot unit effluent to scan for all of the constituents found on Clariant's
existing NPDES permit. A summary of the detected compounds is presented in Table 3-4 and
the raw laboratory data is attached in Appendix A.
Table 3-4. Summary of Organic / Inorganic Scan of Pilot Unit Effluent
Chemical Compound
Analyzed for
Reporting
Limit
(mg/L)
Analytical
Result
(mg/L)
Monthly Avg.
Permit Limit
(#/day)
Discharge
@ 3.1 mgd
(#/day)
Chromium, Total
0.005
0.018
N/A
0.5
Iron, Total
0.10
1.0
Monitor
26
Manganese, Total
0.10
1.5
Monitor
39
Sulfate
10
230
Monitor
5950
Chloride
4.0
140
Monitor
3620
Phenol
0.05
0.24
3.9
6.2
MBAS, Surfactants
0.2
0.2
Monitor
5.2
Essentially no volatile or semi -volatile organic compounds were present in the effluent with the
exception of phenol. Although phenol was present in quantities that would have exceeded
Clariant's existing permit limit on a monthly average basis, the daily maximum limit was not
exceeded. Clariant plans to discontinue the production process that produces the phenol
wastestream in the near future.
G:\19047 - Clariant Treatability\WP\Reports\Chapter 3 - Pilot Study Rcport.doc
BROWN AND CALDWELL

3-12
,., The other chemical compounds that were detected are either not in Clariant's existing permit
(Chromium) or only require monitoring and do not have specific discharge limits. Thus, it
would appear that the proposed addition of CMU Long Creek wastewater will not have any
effect on the ability of Clariant to meet their existing NPDES permit for a wide range of organic
and inorganic compounds.
PROP
OMNI
Chronic Toxicity. Samples of the effluent from the combined CMU / Clariant pilot unit was
collected on August 15 and 18, 2000, packed on ice and transported to Burlington Research
Laboratories for Chronic Toxicity analysis using Ceriodaphnia. The results showed that at a
dilution of 12.5 percent exhibited a chronic value and >50 percent inhibition to reproduction.
However, the laboratory results were inconclusive because the lowest dilution ran was
12.5 percent, which is significantly higher than the actual dilution of the Clariant wastewater
discharge by the Catawba River. The Clariant wastewater discharge only represents
approximately 1.8 percent of the Catawba River flow during drought conditions. Since Clariant
currently has no problems consistently passing the chronic toxicity test, it is Brown and
Caldwell's opinion that the addition of municipal wastewater will have little effect on Clariant
continuing to pass this test in the future
Disinfection Studies. On August 28, 2000, samples of the effluent were collected, packed on ice
and transported to Trojan Technologies, Inc. for ultraviolet (UV) disinfection experiments. The
samples were analyzed for UV transmittance (as collected and filtered), TSS, particle size
analyses, and UV dose response (collimated beam tests). The results of the collimated beam
tests are presented on Figure 3-10.
Figure 3-10. UV Dose Response Curve for Combined CMU / Clariant Pilot Unit
Fecal Col forms! 100 ml
10000000
1000000
100000
10000
1000
100
10
0 10
20 30 40 50 60
UV Dose (mWslcm2)
--Effluent -Disinfection Limit j
GPR.\19047 - Clariant Treatability\WP\Reports\Chapter 3-1'ilot Study Report.doc
BROWN AND CALDWELL

fan
tin4
3-13
fay, Over the range of UV dosages applied, the number of fecal coliforms could not be reduced to
less than 200 per 100 ml as will most likely be required by the NPDES permit. In addition, the
transmittance of UV light was only 35 percent for the unfiltered effluent and 46 percent for
�► filtered effluent. These low values of transmittance and associated low kill rates were due to a
high concentration of total suspended solids (TSS = 61 mg/L), a high number of large particles
(65 percent were larger than 31 microns) and the presence of black sulfur dye residue in the
�+ wastewater.
Secondary clarification in the full-scale facility should be greatly enhanced in comparison to the
�► pilot unit. This will most likely reduce the TSS in the effluent to less than 20 mg/L. In addition,
Clariant has stated that the production of sulfur dyes is scheduled to be reduced in the future,
which will reduce the color of the wastewater and increase the observed UV transmittance.
Brown and Caldwell recommends that additional testing be conducted in the spring after the dye
production is reduced to further refine the feasibility of UV disinfection. These tests should be
conducted by blending effluents from both CMU's McAlpine WWTP and Clariant's WWTF in
the proportions expected in full-scale treatment.
Results of Continuous Flow Pilot Tests - Clariant Only Unit
The continuous flow studies were started on June 26, 2000, and continued for approximately
'"' 10 weeks until September 6, 2000. It should be noted that around the 17-19 of July, Clariant
switched the type of herbicides being produced in Building 45. This change in production
processes affected the treatment efficiency of not only the pilot scale units, but also Clariant's
full-scale WWTF. More in-depth discussion of the impact of production processes is given
below. Normal daily analytical results and operational measurements for the Clariant Only pilot
scale unit are presented in Tables B-1 and B-2 in Appendix B, respectively.
BOD / COD. The Clariant Only continuous flow pilot unit reduced the influent BOD from
100 — 300 mg/L to less than 10 mg/L and often less than 2 mg/L during the first several weeks of
the study as shown on Figure 3-11. Although BOD removal efficiency was impacted by the
mid -July production process changes, the effluent BOD was usually maintained below 25 mg/L
and would have met the existing permit requirements.
COD removal was much more impacted by the mid -July production changes than BOD removal
as illustrated on Figure 3-12. The influent COD was reduced from approximately 500 mg/L to
an average of around 90 mg/L during the first three weeks of the study. This corresponds to a
removal percentage of greater than 80 percent. However, after the process changes in Building
45 the removal percentage was reduced to about 50-60 percent and the COD in the effluent
became much more erratic. It should be noted that the detention time in the Clariant Only pilot
unit was approximately five days and peaks observed in the effluent were directly attributable to
,,RI earlier spikes in the influent COD load. However, the pilot unit was acting like a continuously
stirred tank reactor (CSTR) rather than a plug flow reactor so the spikes would emerge in
roughly seven days and be somewhat attenuated.
Pal
G.\19047 - Clariant Treatability\WP\Reports\Chapter 3- Pilot Study Repott.doc BROWN A N ll C A L D W E L L
Ast

3-14
Figure 3-11. Clariant Only Pilot Unit - BOD Removal
400
350 -
300
250 -
200
C
150 -
100 -
50 -
•
0 • — — —
6/26/2000 7/10/2000
4
7/24/2000
Date
8/7/2000
-BOD-in T—SBOD-out
8/21/2000 9/4/2000
Figure 3-12. Clariant Only Pilot Unit - COD Removal
6/26/2000
7/10/2000
7/24/2000
D ate
8/7/2000
• •COD -in —SCOD-out
8/21/2000
9/4/2000
G \19047 - Clariant Treatability\WP\Reports\Chapter 3 - Pilot Study Report doc
BROWN AND CALDWELL

OEM
t•
MIN
NNW
maa
3-15
TSS. The removal of total suspended solids (TSS) by the Clariant Only continuous flow pilot
unit was unsatisfactory prior to the addition of polymer on August 8 as shown on Figure 3-13.
After the addition of polymer the pilot unit would have met the existing permit limits for
discharge flows of less than 1.0-mgd. Brown and Caldwell is confident that optimization of the
polymer addition combined with the existing 80-ft diameter secondary clarifiers at Clariant's
WWTF will enable Clariant to meet the existing NPDES permit requirements. It should be noted
that the hydraulic capacity of the secondary clarifiers is 5.0-mgd and the proposed flow rate is of
a Clariant Only facility is around 0.6-mgd. At a hydraulic loading rate of 0.6-mgd, one of the
secondary clarifiers will only see a surface -loading rate of 125 gpm/sf, which is much less than
the 800 gpm/sf normally used for design. Thus, for a Clariant Only facility only one of the
secondary clarifiers will need to be operated.
Figure 3-13. Clariant Only Pilot Unit - TSS Removal
E
2000
1800 -
1600
1400 .
1200 -
1000 -
800 -
600
400
200 -
0 -•
6/26/2000 7/10/2000
7/24/2000 8/7/2000
D ato
("•"'TSS-in —TSS-outj
8/21/2000
9/4/2000
TKN / Organic Nitrogen / Ammonia: TKN / Organic Nitrogen / Ammonia. Total Kjeldahl
nitrogen (TKN) is the total of the organic nitrogen and ammonia nitrogen (NH3-N) present in a
wastewater. Organic nitrogen is converted to ammonia in the first step of the activated sludge
process. Ammonia is then converted by nitrifiers in a process called nitrification to nitrite (NO2-
N) and nitrate (NO3-N). This process was negatively impacted by the mid -July process changes.
Prior to July 19, influent TKN averaged 16 mg/L, influent ammonia averaged 10 mg/L and the
influent organic nitrogen averaged approximately 6 mg/L. As the Clariant Only continuous flow
pilot unit became acclimated to the wastewater, the effluent TKN and ammonia was reduced as
shown on Figures 3-14 and 3-15, respectively. The effluent ammonia was reduced to less than
G:119047 - Clariant Truatability\WP\Rcports\Chaptcr 3 - Pilot Study Rcport_doc
BROWN AND CALDWELL

3-16
Figure 3-14. Clariant Only Pilot Unit - TKN Removal
7
6/26/2000
7/10/2000
7/24/2000
Date
8/7/2000
L+ "TKN-in —TKN-out
8/21/2000
9/4/2000
Figure 3-15. Clariant Only Pilot Unit - Ammonia Removal
160
140
120
100
80
7
60
40
20
0
6/26/2000
7/10/2000
7/24/2000
Date
8/7/2000
"•-"Ammonia-in —II—Ammonia-out
8/21/2000
9/4/2000
G:\19047 - Clariant Treatability\WP\Reports\Chapter 3 - Pilot Study Report.doc
BROWN AND CALDWELL

full
3-17
0.2 mg/L from June 28 to July 17. During the time period, the pilot unit was removing
approximately 13 mg/L of ammonia. Although approximately 3 mg/L of soluble TKN (mostly
organic nitrogen) remained in the effluent, the majority of this nitrogen would most likely be in a
non-bioavailable state in the Catawba River because the biota of the WWTF could not break it
down.
The mid -July process modifications significantly increased the TKN and organic nitrogen loads
in the pilot plant influent. After July 19, influent TKN averaged 110 mg/L, the influent ammonia
averaged 49 mg/L and the influent organic nitrogen averaged approximately 61 mg/L. These
averages exclude observed influent values from August 18 to August 31 when the acid sewer
0.1
wastewater was not included in the future Clariant mix. The acid sewer was excluded during this
2-week period in an attempt to stabilize the pilot plant.
0.1 After July 19, the influent loading rates of TKN, ammonia, and organic nitrogen also became
much more variable. These loading rates surpassed the ability of the nitrifiers to breakdown the
ammonia and the effluent ammonia concentration rose to an average of between 35 - 40 mg/L. It
was determined that chemicals present in the wastewater after July 19 inhibited nitrification (see
discussion of bench scale pre -oxidation experiments). It should also be noted that the pilot unit
was still removing approximately 50 mg/L of ammonia -- even in it's inhibited state at cold
temperatures of 12 °C. Thus, the pilot unit would remove approximately 80 mg/L of ammonia
at 21 °C and the effluent ammonia concentration would be reduced to around 10-15 mg/L.
Although the Clariant Only pilot plant effluent had high ammonia concentrations, the full-scale
WWTF will most likely consistently meet Clariant's existing NPDES permit for ammonia due to
the reduced flow rate and long hydraulic retention time in the WWTF. However, pre -oxidation
fml of the Clariant wastewater from herbicide production may be necessary at times to ensure permit
limits are met during the winter months. It should be noted that Clariant maintains a 300-million
gallon off-line reservoir that could be used to contain the "off -spec" treated effluent. It is Brown
and Caldwell's opinion that the installation and use of hydrogen peroxide feed facilities and the
effective use of the 300-million gallon post treatment storage reservoir can be used to meet the
existing NPDES permit limits for ammonia.
1
Nitrite and Nitrate. The breakdown and removal of nitrogen continues with a process called de -
nitrification that occurs in the anoxic zone of the WWTF. In this process, NO2 N and NO3-N are
broken down into nitrogen gas. Figure 3-16 is an over -simplification of NOZ N and NO3-N
removal, because it does not show NO2-N and NO3 N created during nitrification. The figure
does illustrate that early in the study when the dissolved oxygen level in the "anoxic zone" was
rm, greater than 0.5 mg/L, the NO2-N and NO3 N created by the nitrifiers was not being broken
down into N2 gas by the de-nitrifiers. This resulted in a higher effluent concentration of NO2 N
and NO3-N than the influent concentration. Once the anoxic zone D.O. levels were maintained
,_, at less than 0.5 mg/L of O2, the effluent concentration of nitrite and nitrate was usually less than
3 mg/L. There were several days where the amount of ammonia converted overwhelmed the
ability of the de-nitrifiers to produce nitrogen gas. The conversion rate of NO2-N and NO3 N to
,_, N2 gas was highly variable due to the large variation in ammonia conversion throughout the pilot
study. The conversion averaged around 13 mg/L before July 19 and approximately 50 mg/L
after July 19. Currently, Clariant is only required to monitor for NO2-N and NO3 N so elevated
�, levels of nitrite and nitrate in the effluent would not violate their existing permit. It should be
G \19047 - Clariant Trcatability\WP\Reports\Chaptor 3 - Pilot Study Report.doc
BROWN AND Cl/Id

Figure 3-16. Clariant Only Pilot Unit - Nitrate / Nitrite Removal
111
Mel
3-18
Nitrate - Nitrite. tng/l.
Date
"•"Nitrate -Nitrite -in — Nitrate -Nitrite -out
9/4/2000
noted that the effluent nitrite/nitrate spiked on several occasions. These high effluent values
around the 1St and 28Ut of August were caused by high D.O. concentrations in the anoxic zone. In
addition, the anoxic zone was removed from the pilot plant on August 30.
Phosphorous. The Clariant Only wastewater does not contain significant amounts of
phosphorous. In fact, Clariant currently adds phosphorous to the WWTF to provide sufficient
levels for microbial growth. Although no measurements of influent phosphorous were taken, the
Clariant only influent was most likely no more than 1 or 2 mg/L. Over the course of the study,
the soluble effluent total phosphorous ranged from 0.1 to 3 mg/L and averaged 0.9 mg/L. The
goal of this study was to determine how much chemical additive was necessary to achieve an
effluent total phosphorous concentration of 1.0 mg/L.
Bench scale chemical addition studies were conducted in Brown and Caldwell's Nashville
treatability laboratory and the results are summarized on Figure 3-17. The metal salts tested
were Al2(SO4)3*18H20 (alum) and FeC13*6H20 (ferric chloride) at dosages of 14.1 and
22.3 mg/L, respectively. In addition, 2 mg/L of Cytec 1598C (a high molecular weight cationic
polymer) was added. The insoluble amount of phosphorous is based on an effluent TSS of
20 mg/L with a phosphorous content of 0.026 mg / mg of TSS. Although it appears that a total
phosphorous limit of 1 mg/L can be met, the total phosphorous in the untreated effluent was only
0.23 mg/L on the day these tests were run. In addition, phosphorous was not added during the
pilot study to enhance microbial degradation.
G:\19047 - Clariant Trcatability\WP\Reports\Chapter 3 - Pilot Study Report.doc
BROWN AND CALDWELL

3-19
Figure 3-17. Clariant Only Pilot Unit - Phosphorous Removal
Volatiles, Semi-volatiles, Inorganics and Metals. A sample of the effluent from the Clariant
Only pilot unit was collected on August 29, 2000, packed on ice and transported to Prism
Laboratories for analysis. EPA methods 624, 625, 200.7, 245.1, 300, 420.1 and 425.1 were used
to analyze the pilot unit effluent to scan for all of the constituents found on Clariant's existing
NPDES permit. A summary of the detected compounds is presented in Table 3-5 and the raw
laboratory data is attached in Appendix B. Essentially no volatile or semi -volatile organic
compounds were present in the effluent with the exception of phenol. Phenol was not present in
quantities that would have exceeded Clariant's existing permit limit. The other chemical
compounds that were detected are either not in Clariant's existing permit (Chromium) or only
require monitoring and do not have specific discharge limits.
Table 3-5. Summary of Organic / Inorganic Scan of Clariant Only Pilot Unit Effluent
Chemical Compound
Analyzed for
Reporting
Limit
(mg/L)
Analytical
Result
(mg/L)
Monthly Avg.
Permit Limit
(#/day)
Discharge
@ 0.6 mgd
(#/day)
Chromium, Total
0.005
0.006
N/A
0.03
Manganese, Total
0.10
5.5
Monitor
28
Sulfate
10
1400
Monitor
7000
Chloride
4.0
500
Monitor
2500
Phenol
0.05
0.11
3.9
0.55
MBAS, Surfactants
0.2
0.4
Monitor
2.0
G:\19047 - Clariant Treatability\WP\Reports\Chapter 3 - Pilot Study Rcport.doc
BROWN AND CALDWELL

PRIM
-
MOM
3-20
Results of Bench Scale Peroxidation Experiments
The objective of the bench scale peroxidation experiments was to determine if chemical
compounds remained in the wastewater after treatment that inhibited nitrification and if the
addition of peroxide would reduce the inhibition. Figure 3-18 illustrates that a chemical
compound remains in the wastewater after activated sludge treatment that inhibits nitrification,
because the control had a higher nitrification rate than the supernatants from each of the
activated sludge treated wastewaters. These results demonstrate that even the Long Creek sewer
can at times contain pollutants that can inhibit nitrification. It should be noted that this sample
was a grab sample and that composite samples are not expected to cause the same level of
inhibition. Subsequent samples from the Long Creek sewer did not exhibit similar levels of
inhibition.
Figure 3-18. Bench Scale Demonstration of Nitrification Inhibition
mg N removed per mg VSS per day
0.25
0.2
0.15
0.1
0.05
0.11
0.05
0-
Long Creek Sewer
Alkaline Sewer Acid Sewer
0.04
0.24
CMU/Clariant C'ontwl
Figure 3-19 demonstrates the effectiveness of pretreating the acid wastewater and the combined
alkaline / acid wastewater with hydrogen peroxide. The addition of 1000 ppm of hydrogen
peroxide improved the nitrification rate of the acid sewer wastewater by a factor of almost four
and increased the nitrification rate from 21 to 79 percent of the control. The addition of 375 ppm
of hydrogen peroxide improved the nitrification rate of the combined acid / alkaline wastewater
from approximately 12 to 50 percent of the nitrification rate of the control. Therefore, the bench
scale tests demonstrated that the addition of hydrogen peroxide significantly enhances the
nitrification rate of the Clariant wastewater. Brown and Caldwell recommends that the
combined CMU / Clariant WWTF provide hydrogen peroxide feed facilities to improve
nitrification rates when necessary.
G:119047 - Clariant Treatability\W P\Reports\Chapter 3 - Pilot Study Report.doc
BROWN AND CALDWELL

3-21
Figure 3-19. Bench Scale Demonstration of Peroxide Addition
0 .^_ 5
0.2 —/
k• 0.15�
2-
0.05 J
0.02
Alkaline Sewer
0 .05
Acid Sew cr
0.1
Acid Peroxidized
0 I:
i
Acid Alkaline Control
Peroxidized
G\19047 - Clariant Treatability\WP\Reports\Chapter 3 - Pilot Study Report.doc
BRAWN AND CALDWELL

rat
Rol
fat
CHAPTER 4. PROPOSED MODIFICATIONS
TO EXISTING CLAIMANT WWTF
This chapter of the report provides a discussion of the existing process units at the existing
Clariant WWTF and modifications required to treat blended CMU / Clariant wastewater. This
chapter also includes a discussion of permit limits that might be applicable for the combined
treatment of municipal and industrial wastewater at this facility.
Description of Existing Clariant WWTF
Clariant currently discharges process and sanitary wastewater to an onsite WWTF for treatment
prior to discharge to the Catawba River (see Figure 1-1). Sanitary wastewater is combined with
t-, acid process wastewater ahead of the WWTF to disinfect the influent wastewater and eliminate
the need for post -treatment disinfection. These wastewaters are then blended with lime to
neutralize the acid and passed through primary clarifiers to settle out the resulting calcium
sulfate. Contaminated groundwater and alkaline process wastewater is mixed with the effluent
from the primary clarifiers in the 4.0 MG equalization basin (Z-03). Basin Z-03 has several
floating aerators and mixers to maintain the solids in suspension and prevent the incoming
wastewater from becoming anoxic. Phosphoric acid is added to Z-03, because Clariant's existing
wastewater has insufficient phosphorous for microbial growth.
The wastewater passes from Z-03 into the 2.5 MG activated sludge basin (Z-04). This basin is
currently undergoing rehabilitation. Seven 40 Hp floating aerators and one 40 Hp floating mixer
previously provided air for the activated sludge process and to maintain the solids in suspension.
However, the insufficient mixing intensity of the existing system allowed a significant amount of
solids to settle within the basin. These solids have been removed every two years in what has
become a time consuming and expensive project. Currently, Clariant is in the process of
installing a new jet mixer system in Z-04 and should be operational by spring 2001. This system
will consist four 50 Hp jet mixers, associated headers with jet nozzles, and liquid distribution
�., pipes. In addition, six of the existing floating aerators will be re -installed in the basin.
The wastewater then overflows from basin Z-04, polymer is added and the treated effluent is
settled in two 80-foot diameter secondary clarifiers that have a rated hydraulic capacity of
5-mgd. Supernatant from the secondary clarifiers flows through a Parshall flume that records the
discharge flow rate and a discharge canal where re -aeration occurs prior to discharge into the
Catawba River.
Settled solids from the secondary clarifiers are recycled back to the influent of basin Z-04 and
are mixed with primary solids in the feed tank for the belt presses. The blended primary and
secondary solids are dewatered by the belt presses and disposed of in Clariant's onsite landfill.
The filtrate from the belt presses is returned to the head of basin Z-03.
G \19047 - Clariant Treatability\WP\Reports\Chapter 4 - Pilot Study Repott.doc
BROWN AND CADEbt
twol

4-2
Clariant is currently planning several minor modifications to the existing WWTF that will be
complete prior to the installation of facilities required for treating CMU's Long Creek
wastewater. These modifications include the installation of the jet mixers described previously,
use of MgOH rather than lime for acid neutralization and installation of a new phosphoric acid
feed system for Z-04.
The use of MgOH rather than lime for acid neutralization will greatly reduce the amount of
inorganic solids formed. Thus, Clariant will be able to eliminate the existing primary clarifiers
and allow the acid / sanitary wastewater to flow directly to the equalization basin. Another
FalIR added benefit will be the reduction in solids that require dewatering and disposal in the onsite
landfill.
The new phosphoric acid feed system is to be installed in Building 50A at the same time as the
jet mixers. The current system consists of a 300-gallon tote containing phosphoric acid that is
elevated on a platform and a manual valve that allows the operator to add phosphorous as
necessary. The new phosphoric acid feed system will consist of a 300-gallon tote placed on a
scale and a small metering pump with a capacity of 24-gpd. The metering pump will allow the
feed rate to be more closely controlled to match the influent wastewater flowrate and the scale
will allow the operator to monitor the phosphoric acid use rate.
Proposed Modifications to Clariant's WWTF
Brown and Caldwell and CMU have finalized the design of the new Long Creek Pumping
Station that will be located adjacent to the existing and outdated Long Creek Pumping Station on
land currently owned by Clariant. Construction of the new pumping station is scheduled to begin
during the summer of 2001 and be complete by the end of 2002. The new pumping station has
space allocated for the future installation of two 4-mgd pumps with variable frequency drives to
supply CMU wastewater to the Clariant WWTF. Wastewater will be pumped through a 14-inch
diameter force main and discharged into new headworks at the Clariant facility. Installation of
the pumps and the force main are required as part of this project. Figure 4-1 illustrates all of the
proposed modifications to the existing Clariant WWTF in bold highlight.
The new headworks to "pre treat" the municipal wastewater will consist of a parshall flume,
grinder and grit removal. The Parshall flume will allow Clariant to independently monitor the
amount of CMU Long Creek wastewater that receives treatment at the WWTF. The grinder will
rim reduce the size of rags and other debris that is typically contained in municipal sewerage to
protect rotating equipment within the Clariant facility. Grit removal will remove dense heavy
solids that would settle within basin Z-04. Although Clariant and Brown and Caldwell are
planning to investigate the feasibility of using the existing primary clarifiers to provide this "pre-
treatment", it is unlikely that this alternative will be selected because Clariant has no facilities to
handle primary sludge from a municipal wastewater.
Bench scale studies by Brown and Caldwell and Millennium Science and Engineering, Inc. have
demonstrated that the addition of hydrogen peroxide will at times significantly improve the
G.\19047 - Clariant Treatability\WP\Reports\Chapter 4- Pilot Study Report.doc BROWN H N ll C A L D W L L L

CLARIANT
GROUNDWATER
CLARIANT C
ALKALINE SEWER
Mg0H -
CLARIANT
AqD SEWER
CMUD
WASTEWATER
PARSHALL FLUME
ACID
NEUTRALIZATION
GRINDER
T -1
GRIT
REMOVAL
H202
CLARIFIER CLARIFIER
NO 1 I � NO 2
•
ANOXIC ZONE
v v
FLOATING AERATORS
JET MIXING
1 1
AEROB C ZONE
_L_V_ NLY V_ L_V V_ _V_ _1LSL �L_ ]L��'.' RECYCLE PUMPS
ACTIVATED SLUDGE LAGOON
(Z-04)
WAS / RAS PUMPS
i
FEED TANK
, FERRIC
POLYMER
BELT PRESSES
FEED PUMP
-1
DISINFECTION • - = • • -v AERATION -
PARSHALL FLUME-------.�
L
FILTRATE
SOLIDS
(
TRANSFER PUMP
BROWN AND
CALDWELL
UNE IS 2 INCHES
AT FULL SIZE
IF NOT Y-SCALE ACLMGN0.1)
SUBMITTED:
APPROVED:.
APPROVED:
FROICOr ONO=
NDW NO CAMEL
DATE
DATE
DATE:
FILE CMUD\19047\CAD
DRAWN J PORTER
DESIGNED P- SCHULER
CHECKED P SCHULER
CHECKED R CARRIER
ZONE REV.
REVISIONS
DESCRIPTION
BY 1 DATE
APP.
CLARIANT CORPORATION
CLARIANT
WASTEWATER TREATMENT FACILITY
IMPROVEMENTS
CLARIANT WWTF
TO ONSITE
LANDFILL
TO CATAMA
RIVER ---D
TO 300MG
RESERVOIR
PROPOSED FLOW DIAGRAM
PROJECT NUMBER
19047
DRAWING NUMBER
4-1
MEET NUMBER

ton
4-3
r, performance of Clariant's WWTF. Thus, Brown and Caldwell recommends that hydrogen
peroxide storage and feed facilities be installed to allow pre-treatment of the acid and / or
alkaline wastewater prior to blending with the municipal wastewater on an as -needed basis.
1..1 Although the addition of hydrogen peroxide will not usually be required, Clariant should have
the capability of adding H202 if the BOD or ammonia removal rate is affected by changes in
production. Additional bench scale studies are recommended to better define the dosage of
hydrogen peroxide required to effectively "pre treat" the acid and alkaline wastewater.
Effluent from the new headworks could be blended with Clariant's acid and alkaline wastewater
�•, in a new anoxic zone in basin Z-04 to remove nitrite/nitrate through de -nitrification. Installation
of a curtain wall in Z-04 could be used to cost-effectively form the anoxic zone. De-nitrifiers
present in the anoxic zone will reduce the nitrate / nitrite formed from the biological degradation
fowl of organic nitrogen and ammonia to nitrogen gas. During the pilot study the anoxic zone
removed between 13 and 50 mg/L of total nitrogen. Wastewater would be recycled from the
aerobic zone at a rate of up to 9:1 by a combination of the jet mixers and new speed external
recycle pumps with variable frequency drives.
Limited bench scale studies during this pilot study demonstrated that the addition of aluminum or
rwl iron salts would reduce the amount of soluble total phosphorous in the discharge. If the addition
of municipal wastewater results in a total phosphorous limit being added to the existing NPDES
permit, Clariant could install storage and feed facilities for iron salts.
The addition of significant quantities of municipal wastewater to Clariant's WWTF will
necessitate the installation of additional disinfection facilities. UV disinfection is the
'.' recommended process, because it will not create chlorinated hydrocarbons (chlorination) or
produce post treatment BOD (ozonation). Although the existing pilot study did not demonstrate
that UV disinfection was effective at "normal" UV dosages, Brown and Caldwell has designed
(.' systems to effectively disinfect wastewater with even lower UV transmissivities than were
witnessed during this study. Successful demonstration and implementation of UV disinfection of
the combined effluent will require conducting additional studies. These studies should
commence in the spring after Clariant's existing sulfur dye production is scaled back to future
levels.
Proposed Permit Limits for Combined Treatment of CMU / Clariant Wastewater
(.' Effluent from the existing Clariant WWTF is discharged into the Catawba River under the permit
limits established in NPDES permit number NC 0004375. This permit has discharge limits and /
or monitoring requirements for pH, BOD, COD, NH3-N, TSS, fecal coliform, total nitrogen, total
phosphorous, total phenolics, total sulfate, MBAS, manganese, iron, chlorides, mercury, volatile
organic compounds (VOCs), semi -volatile organic compounds, and chronic toxicity. It should
be noted that the discharge limits listed in Clariant's existing permit are all mass -based limits and
Fr
are based on an average flow of 1.4-mgd and a peak flow of 3.9-mgd. These permit limits have
been established to provide Clariant the flexibility necessary to protect the environment and
operate a batch chemical production facility with wastewater discharges of variable strength and
Cr.119047 - Clariant Troatability\WP\Rcports\Chapter 4- Pilot Study Repoit.doc BROWN AND C A 1! L W E L L
t�1

tog
4-4
constituents. Although Clariant normally discharges significantly less BOD, TSS, and ammonia
than is currently permitted, the flexibility must be maintained or Clariant will not be able to
continue operations.
The combined CMU / Clariant treatment plant would likely have effluent limits and/or
monitoring requirements for those parameters currently listed in the Clariant discharge permit
rim plus additional parameters listed for the McAlpine Creek WWTP where the Long Creek
wastewater is ultimately treated. The discharge from the McAlpine Creek WWTP is McAlpine
Creek, which is a small tributary of the Catawba River.
1
Key pollutants that may be impacted by the addition of a medium strength domestic sewage such
as the Long Creek wastewater are BOD, COD, NH3-N, TSS, fecal coliform, total nitrogen and
mit total phosphorous. In addition, possible increases in the monitored OCPSF volatile and semi -
volatile organic compounds that may result from industrial users in the publicly owned collection
system. Currently, the Long Creek Basin has very few industrial dischargers with the exception
�► of a commercial laundry at the head of the basin. A comparison of the present NPDES limits at
both the McAlpine Creek and Clariant WWTP's is presented in Table 4-1.
Mot
Sal
Table 4-1. Current NPDES Discharge Limits (winter monthly averages)
Effluent Characteristic
Clariant Limits
(NC 0004375)
McAlpine Creek Limits
(NC 0024970)
BOD
852 lbs
8 mg/L (carbonaceous)
Ammonia
651 lbs
1.9 mg/L
TSS
976 lbs
15.0 mg/L
Fecal Coliform
Monitor and Report Only
200 / 100 ml
Total Nitrogen
Monitor and Report Only
Monitor and Report Only
Total Phosphorous
Monitor and Report Only
Monitor and Report Only
Flow
3.9 mgd
64.0 mgd
The wastewater proposed for treatment in the combined facility is currently discharged from the
McAlpine Creek and Clariant WWTPs. The permitted total discharge from both facilities for
BOD, TSS, and ammonia are shown on Figure 4-2 as "Current Combined Load." These values
,,F, are based on a flow of 2.0-mgd from the Long Creek sewer and the current mass -based limits at
Clariant. The pilot study demonstrated that with the proposed modifications Clariant's WWTF
can successfully treat the future combination of municipal and industrial wastewater to meet
Clariant's existing NPDES permit limits. Brown and Caldwell recommends that Clariant's
existing NPDES permit discharge limits for BOD, TSS, and ammonia remain unchanged. This
results in a net reduction of the permitted discharge of 133 lbs/day BOD, 252 lbs/day of TSS and
,na, 32 lbs/day of ammonia into the Catawba River Basin. In addition, the load that is currently
discharged into McAlpine Creek will be discharged into a much larger waterway with resultant
higher assimilative capacity. It should also be noted that the actual mass of ammonia, TSS arid
rim BOD will be significantly less than the permit limits most of the time.
GA19047 - Clariant Trcatability\WP\Reports\Chaptcr 4 - Pilot Study Report.doc
llIUD AND Cfl.IIbL

ra.
4-5
The installation of a disinfection system will allow the modified Clariant WWTF to accept
municipal wastewater and achieve the fecal coliform standard of 200 / 100 ml that is expected to
�. be added to their existing NPDES permit. The pilot study also appears to suggest that the
modified Clariant WWTF can meet moderate to low total phosphorous levels with the addition
of metal salts. However, the institution of a strict total nitrogen limit would be very difficult if
not impossible for the Clariant WWTF to meet whether or not CMU wastewater is added.
Ike
Int
Figure 4-2. Current and Proposed Permit Limits
1400 1
1200
1000
800
600
400
200
0
1: 5
1226
TSS
Current Combined Load •Proposed Load
651
Ammonia
G\19047 - Clariant Trcatabi ity\WP\Reports\Chapter 4 • Pilot Study Report.doc
BROWN AND CALDWELL
w

1=1
furl
CHAPTER 5. CONCLUSIONS AND RECOMMENDATIONS
This chapter of the report summarizes the findings that have been discussed in previous chapters
and provides a list of recommendations to implement. These conclusions and recommendations
are as follows:
Conclusions
• Combined CMU / Clariant wastewater can be treated to meet Clariant's existing permit
limits for BOD and TSS under all conditions experienced during the pilot study,
including during the production of herbicides.
• Combined CMU / Clariant wastewater can be treated to meet Clariant's existing permit
limits for ammonia during the spring, summer and fall (but not winter) under all
conditions experienced during the pilot study, including the production of herbicides.
• The addition of hydrogen peroxide to "pre -treat" the acid and alkaline wastewater greatly
increases the nitrification rate. The addition of hydrogen peroxide should allow
combined CMU / Clariant wastewater to be treated to meet Clariant's existing permit
limits for ammonia during cold weather conditions when herbicides are being produced.
1.1
• The installation of an anoxic zone will greatly reduce the amount of nitrate -nitrite and
total nitrogen present in the effluent from the Clariant WWTF no matter what
'#`' combination of wastewater is being treated.
• The addition of iron salts prior to the secondary clarifiers should allow Clariant's WWTF
`.' to meet a moderate to low total phosphorous limit.
• No significant amounts of inorganic or organic compounds currently listed on Clariant's
existing NPDES permit were measured during a scan of the pilot unit effluent.
• Additional testing will be required to confirm the feasibility of UV disinfection and to
1.1
determine dosage requirements.
• The modifications to the Clariant WWTF should include a new headwork, hydrogen
peroxide storage and feed facilities, an anoxic zone with recycle pumps, metal salt
storage and feed facilities, and a disinfection system.
• Significant reductions in Clariant's permitted discharge limits or low total nitrogen limits
will severely limit Clariant's ability to operate this chemical manufacturing facility and
r=1 would require additional pilot work to demonstrate whether or not they can be feasibly
achieved.
G\19047 - Clariant Treatability\WP\Rcports\Chapter 5 - Pilot Study Rcport.doc
IIkO CALDEIJIJ

fm1
Recommendations
5-2
• The results of this study should be presented to NC DENR's Division of Water Quality.
fl After NC DENR has sufficient time for review, a meeting should be held to discuss these
results and determine permit limits that would be anticipated.
pm • Additional bench scale studies should be conducted to determine the range of hydrogen
peroxide that may be required to eliminate the nitrification inhibition present during
herbicide production.
• After the production of sulfur dye is reduced to future levels, additional bench scale
studies should be conducted to demonstrate the feasibility of UV disinfection, to
determine the dosage requirements, and to size the required equipment.
G:119047 - Clariant Treatability\WP\Rcports\Chapter 5 - Pilot Study Report.doc
BROWN AND Cflll'E1J

Table A-1. Combined CMU/Clariant Pilot Unit Analytical Results
_
INFLUENT
_
MIXED LIQUOR
ANOXIC ZONE
Date
COD
(mg/L)
CBOD
(m8/L)
TSS
(mg/L)
VSS
(mg/L)
TKN
(mg/L) .
Nitrate-
Nitrite
(mg/L)
Ammonia
(mglL)
Ammonia
Prism
Results
_ (mg/L)
TSS
(WA)
VSS
(mg/L)
SCOD
(mg/L)
SCBOD
(mg/L)
Nitrate -
Nitrite
(mg/L]
SCO:
(moll
6/26/2000
269
139.1
68
62
35
1.6
25
4400
1400
_
6/27/2(100
6/28/2000,
379
113.2
120
112
26
1.4
17
4320
2160
6/29/2000
6/30/2000
519
192.4_
284
208
32
<0.5
24
3300
1100
7/1/2000
7/2/2000
-
7/3/2000
607
274
215
175
40
1.0
29
3420
1260
7/4/2000
7/5/2000
308
128
116
_ - 80
133
1.4
23
3800
2400
7/6/2000
7/7/2000
433
133
188
140
27
<0.5
20
3700
2150
_
"
7/8/2000
7/9/2000
7/10/2000
435
166
180
150
28,
<0.5
23
4350
2650
7/11/2000
7/12/2000
430
1128
360
280
26
<0.5
20
_
5650
3450
7/13/2000
7/14/2000
424
63
108
64
22
<0.5
19
4280
2440
7/15/2000
_
7/16/2000
7/17/2000
400
_ 164
180
140
27
<0.5
22
4600
2580
7/18/2000
7/19/2000
1000
179
405
265
65
5.3
43
1200
580
47
<2
9.3
7/20/2000
-
7/21/2000
495
191.2
155
115
26
6 <0.5
18
4100
2350
428
r 58.7
0.57
7/22/2000
7/23/2000
_
7/24/2000
_ 538
137
185
150
22
<0.5
17
3680
2120
112
6.6
1.7
7/25/2000
7/26/2000
547
120.2
220
200
37
0.55
25
3900
2250
100
"
9.5
<0.5
7/27/2000
7/28/2000
482
107
190
120
26
0.64
20
_
1350
700
102
6.3
<0.5
7/29/2000
7/30/2000
7/31/2000
1745
92
300
260-
51
1.8
34
3800
2350
127
<2
<0.5
8/1/2000
8/2/2000
687
195
360
290
51
<0.5
50
3650
2400
798
26
2.1
8/3/2000
-
8/4/2000
580
93
, 350
140
64~
1.92
21
2350,
1800
693
4.8
5.5
8/5/2000
'
_
8/6/2000
8/7/2000
573
206
370
240
50
0.84
29
4250
2550
150
30
<0.5
8/8/2000
8/9/2000
r 8/10/2000
865
237
340
2480
220
1680
59
1.27
26
_ 24
-
5400
2950
158
54
1.0
8/11/2000
810
190
360
270
58
<0.5
26
25
3300
2000
254
30
<0.5
8/12/2000
820
420
8/13/2000
_
8/14/2000
717
150
340
240
59
1.12
23_
21
3767
2233
"
286
55
<0.5
8/15/2000
8/16/2000
1512
148
920
640
>100
3.1
_ 32
34
3833
2567
248
15
<0.5
8/17/2000
8/18/2000
792
96
180
120
33
<0.5
21
5.6
4950
3350
174
9.4
<0.5
8/19/2000
_
8/20/2000
8/21/2000
327
107.5
205
160
27
<0.5
17
5650 _
3650
157
9
'
<0.5
8/22/2000_
` 8/23/2000
349
128.3
185
125
18
<0.5
14
6.9
2600
1850
63
15.7
<0.5
8/24/2000
8/25/2000
424
133.2
180
140
34
<0.5
18'
16
3350
2050
61
<9
<0.5
8/26/2000
8/27/2000
8/28/2000
246
114
r
103
90
37
<0.5
9.3
3900
2550
62
<8.4
8/29/2000
8/30/2000
592
150
305
265
39
<0.5
_ 21
4750
3200
8/31/2000
~
9/1/2000
1102
304
370
230
116
2.36
48
4500
2850
9/2/2000
`
9/3/2000`
9/4/2000
864
309
305
155
85
I.88
33
_4360
2580
9/5/2000
_
-
_ 9/6/2000
617
258
213
187
56,
0.58
26
4190
2510
-
9/7/2000
-
9/8/2000
SCBOD TSS
(mj/L) [mom )
41 5.1 220
63 6.9 76
50 5.9 92
39 4.2- 67
101 9.1 147
<10 3.3 100
31 2.6 110
34 2.9 100
29 <2 125
<10 <2 89
33 <2 80
313 - >21 340
330 17 350
115
4 150
86 5.7 115
VSS
(m8/L)
60
46
40
50
73
64
140
60
60
52
50
260
250
110
55
TDS
(m811-)
1776
872
510
668
778
968
594
562
648
448
640
1000
1200
EFFLUENT
Nitrate-
TKN Nitrite
(m8JL) (m8/L)
18.0
•
18.0 5.3
12.0 9.0
6.7 16.0
11.0 3.2
9.2 3.2
7.0 4.9
2.3 4.8
6.3 7.7
4.9 11.0
Ammonia
_ (meeL)
11
9.1
6.2
0.4
2.2
0.8
0.2
0.2
<0.2
<0.2
2.6 13.0 2.4
44.0 1.2 31
40.0 <0.5 29
12.0 1.2 11
13.0 1.7 13
Ammonia
Prism
Results
(ne811.}
•
Total
COD CBOD Phosphorus
(mglL) r (mg/L) (mpi1L)
161 >35 3.9
<100
35 3.5
34 <2 2.5
no sample <2 no sample
86 7.7
17
3.0
274 37.4 4.9
98
<2 280
755 27 300
252 19 380
64 20 240
95 26 56
240
200
250
130
26
1332
1732
1006
1722
18.0
0.6 19
37.0 1.0 28
49.7 <0.5 35
28.1 - 0.6 - 20
30.6 14.5 26
26
992
279
35 5.4
24 0.7
44 11 68
9 _ 13 130
75 - 14 68
45
75
50
1862
1856
1652
32.4 <0.5 26
50.9
0.7 30
58.1 <0.5 29
25
28
29
368
11
39 2.6
66
12 172
03 13.9 48
79 15.7 52
65; 7.2 30
68
62
6�
9.8 64
<8 32
6B
93 >48 170
08 >100 176
120
40
28
22
60
22
45
110
128
1540
810
1886
1006
924
676
648
2442
2846
52.9 <0.5 34
24.8 <0.5 34
18.4 <0.5 19
20.6 <1.5 14
22.2 - 30.0 16
21.6 5.8 16
17.0 5.3 15
73.1
1.2 35
63.9 1.8 42
36
21
110 13.9 1.8
15
81 12.7 1.7
no sample 32, no sample
no sample no sample no sample
633 <65
no sample

Table A-2. Combined CMU/Clariant Pilot Unit Daily Operational Measurements
Aerobic
Date -TWe
PH
Flowrate
pH
DO
(mfJL)
Temp.
(C)
Recycle
Flowrate
pH
DO
Temp.
OUR
OUR
PHVolume
Il-)
Comments
6/24/2000 2:30
10.30.8
17.8
80
6/25/2000 8:00
7.4
10.50
9
17.2
6/26/2000 8:23
15
7.3
0.3
16.7
130
6/27/2000 6:38
7.4
11
7.3
0.7
14.4
91
7.4
7
15.0
7.414.2
6/28/2000 9:15
0.3
14.4
99
7.4
4
14.4
0.05
165
I r
1
9513.7
r
9.5
IhIff1
11.8
Ir1-iiI]
9612.0
11
7.3
10.20.5
13.995
14.5
7/4/2000 8:50
7.1
10.51
7/5/2000 9:45
7
10.71
0.4
7/6/2000 7:55
7.4
10.21
r
Moved Long Creek sampler to pump station site.
7/7/2000 10:15
1
16.5TookaBrabsempleofLon_8CreekwastewatertomeetaliquotvolumeraluircmniD
1
7/8/2000 9:00
8
10.8
7.2
0.4
16.0
7/9/2000 8:50
8
10.57.3
0.6
16.0
93
7.3
6.5
14.5
7.1
14.0
7
]0.5
1
Tooka_grab sample of Long Creelswastewatertomeet aliquot volume rcgatumen1s.
r117.2
115
1
1
]l
1 -
11
17.2
115
1
r1
12
1
1
11
1offe.
Used DI water in place of sample volume.
Irjh"
r l
6.9
] 0.8
1
1
rBegan
addmnpolmer to Clariant Only unit
7.8
12
17.3
12
1
iAcid
sampler back in service.
7.6
11
1
iri
1
7.4
11
11
1
11
1
Reduced recycle flow to 3:1 ratio.
12A5
i
33
7.8
::
13.0
0 8
13.0
30
7.8
7
11.0
7.4
115
7/22/2000 9:00
��II:11EI
M3.1
7/D/2000 9:00
1 r i 8:00
1
1
1 r
Clariant staffhad not replaced influent buckets over the weekend B souluable nisi. • en series samples.
P Began _ a
111
1/1 1
7.1
11
7.6
12
14.0
30
7.1
7.3
13.0
0.2
12
7.1
14.0
111 1
7.8
9.6
7.6
1 7
15.6
1
1 1 1 1'
7.4
0 3
12.0
32
7.4
8.75
13.0
Took a grab sample of Long Creek wastewater to meet aliquot volume regvuements.
• 111 11
7.6
10
I
1 1 r
10.8
1 1 1 1 1 1
®®®�����®®�®
1
1
1
1
12.0
Took a grab sample of Long Creek wastewater and alkaline stream to meet aliquot volume requirements. Acid sewer much darker than ussual with
s • . •odor.
ri
0.7
15.0
30
7.8
7
12.0
1 1 i' 9:00
6.7
11
7.1
1
1
31
7.4
6.9
15.0
1
1
Took grab sample of acidand alkaline waste stream.
8/3/2000 11
• fir 11
10.5
30
7.6
8.9
14.0
0.1
7.2
17.0
Took a grab sample of Long Creek wastewater to meet aliquot volume requirements. Very large storm the night before (2 in. of rain). The long Creek
sample was much darker than usual.
111 1
1111
1I$
1
1IN]_1
1
11 1 11:00
7.1
10.20.4
17.8
40
7.9
9.1
15.0
7.3
15.5
Added 450 mL ofnibifiers to each unit. Removed and settled 450 mL before addition. Returned solids to reactors. Began adding new polymer to
reactors.
11i 9:00
1 111
1
1
8.4
1 1 1
1 •
76
0.8
14.0
93
7.8
7.2
13.0
0.2
12
7.5
13.0
Groundwater unit offline. Used DI water in place of sample volume. Boosted recycle rate to 9:1 ratio.
I r 0 8:05
7.
10.10.7
13.0
97
8
1.
12.0
7.8
11.5
Added 450 mL of nitrifiers to each unit Removed and settled 450 mL before addition. Returned solids to reactors. Began adding new polymer to
reactors.
rri 1
7.8
9
8.1
0.7
15.0
95
8.4
7.6
12.0
8.5
14.0
1 1 i 9:00
7.4
11
7.5
0.5
I4.D
100
7.8
5.9
13.0
0.1
7.3
15.0
Groundwater unit offline. Used DI water in place of sample volume.
. I r 1 9:00
Gorundwater unit offline. Used DI water in place of sample volume.
111r_lJ
:
Stoppedrunning pilot studywith acid samples. Used DI waterto makeup forvolume1
Irih'1
1 1 ' r
r :
1
1
1
1
Took a grab sample of Long Creek wastewaterto meet aliquotvolume requirements.
IIr 11
91
1 111
10.4
1Ls41
1 •It1
1IIU
Took a grab sample of Long Creek wastewaterto meet aliquotvolume requirements
.:
11
•
01
11
7
11
0.1
6
7.2
15.0
8/26/200011:40®_
8/27/20000:30
310
r ]®ll3111E1®21��-®i
7.4
0.6
16.1
95
7.1
5.4
15.0
Added 450 rnL of nitrifiers to each unit. Removed and settled 450 mL before addition. Returned solids to reactors. Plant upset by over dose of
polymer.
)31
8/28/2000 9:30
���
�
®
93
7.4
7.6
®i
'A®®Took
a grab sample of Long Creek wastewater to meet aliquot volume requirements.
8/29/200010:10
7.3
10.51
_ 92
1
6/10/000D 7:30
r
r
95
®�
®��
14.0
Took a grab sample of Long Creak wastewater and alkaline waste stream to meet aliquot volume requirements.
8/31120D013:15
®���-��
�__®
MI
. 111 ' 1
9/3/2000 9:45
10
9
MIMICT
7
®-��
7.5
12
77131
Et
• rrl rr
2
12
9/6/2000 10:00
7.4
5
7.3
9.5
12
7.3
5
C:119047\CeaLch RepcRelCtariant • LC Combined •• Daily Log Record

,-, Lab ,Report
- 1 •
I.ABA>4lPRA
, INC.
ran
MEI
9/1100
Browi&Caldwell
Attn:Jay Fulmer
200 Providence Rd.
Suite204
Chabtte, NC 28207
Customer Project ID:
Customer Sample ID:
Prism Sample ID:
Login Group:
Sample Collection Date/Time:
Lab Submittal Date/Time:
Full Service Analytical & Environmental Solutions
Page 1 of 8
Project Clariant Study
CLARIANTICMU
AB79771
2819G2
8/29/00 08:00
8/29/00 10:00
The flowing analytical results have been obtained for the indicated sample which was submitted to this laboratory
•
TEST
PARAMETER
TEST
RESULT
REPORTING METHOD
UNITS LIMIT REFERENCE
DATEI TIME
STARTED ANALYST
ACENAPHTHENE
ACENAPHTHYLENE
ANTHPACENE
BENZO(A)ANTHRACENE
B E NZO(B)FLU O RANTH E N E
BENZO(K)FLUORANTHENE
BENZO(A)PYRENE
BENZO(GHI)PERYLENE
BI S(2-CHLOROETHOXY)METHANE
BIS(2-CHLOROETHYL)ETHER
BIS(2-01LOROISOPROPYL)ETHER
BI S(2-ETHYLHEXYL)PHTHALATE
4-BRONOPHENYL PHENYL ETHER
BUTYLBENZYL PHTHALATE
4-CHLOR0-3-METHYLPHENOL
2-CHLORONAPHTHALENE
2-CHLOROPHENOL
4-CHLOROPHENYL PHENYL ETHER
CHRYSENE
DIBENZO(A.H)ANTHRACENE
DI-N-BUTYLPHTHALATE
1,2-DICHLOROBENZENE
1,3-DICHLOROBENZENE
1,4-0I0ILOROBENZENE
2,4-DICHLOROPHENOL
DIETHYL PHTHALATE
2,4-DIhETHYLPHENOL
DIMETHYL PHTHALATE
2,4-DINITROPHENOL
2,4-DINITROTOLUENE
Not detected ug/L 10 625 9/6/00 14:59 HWC
Not detected ug/L 10 625 9/6/00 14:59 HWC
Not detected ug/L 10 625 9/6/00 14:59 HWC
Not detected ug/L 10 625 9/6/00 14:59 HWC
Not detected ug/L 10 625 9/6/0014:59 HWC
Not detected ug/L 10 625 9/6/00 14:59 HWC
Not detected ug/L 10 625 9/6/00 14:59 HWC
Not detected ug/L 10 625 9/6/00 14:59 HWC
Not detected ug/L 10 625 9/6/0014:59 HWC
Not detected ug/L 10 625 9/6/00 14:59 HWC
Not detected ug/L 10 625 9/6/0014:59 HWC
Not detected ug/L 10 625 9/6/00 14:59 HWC
Not detected ug/L 10 625 9/6/00 14:59 HWC
Not detected ug/L 10 625 9/6/00 14:59 HWC
Not detected ug/L 10 625 9/6/00 14:59 HWC
Not detected ug/L 10 625 9/6/00 14:59 HWC
Not detected ug/L 10 625 9/6/00 14:59 HWC
Not detected ug/L 10 625 916/00 14:59 HWC
Not detected ug/L 10 625 9/6/00 14:59 HWC
Not detected ug/L 10 625 9/6/00 14:59 HWC
Not detected ug/L 10 625 9/6/00 14:59 HWC
Not detected ug/L 10 625 9/6/00 14:59 HWC
Not detected ug/L 10 625 9/6/00 14:59 HWC
Not detected ug/L 10 625 9/6/00 14:59 HWC
Not detected ug/L 10 625 9/6/00 14:59 HWC
Not detected ug/L 10 625 9/6/00 14:59 HWC
Not detected ug/L 10 625 9/6/00 14:59 HWC
Not detected ug/L 10 625 9/6/00 14:59 HWC
Not detected ug/L 50 625 9/6/00 14:59 HWC
Not detected ug/L 10 625 9/6/00 14:59 HWC
NC Certification No. 402 - SC Certification No. 99012 - NC Drinking Water Cert. No. 37735 - FL Certification No. E87519
449 Springbrook Road .. P.O. Box 240543 Charlotte, NC 28224-0543
Phone: [phone] ..Toll Free Number: 1-800/529-6364 Fax: [phone]

Lab. Report
t.A8ORAT itliS, INC.
9/11/00
Brown&Caldwell
Attn: Jay Fulmer
200 Providence Rd.
Suite 204
Charlotte, NC 28207
Customer Project ID:
Customer Sample ID:
Prism Sample ID:
Login Group:
Sample Collection Date/Ttme:
Lab Submittal DatelTime:
Full Service Analytical & Environmental Solutions
Page 2 of 8
Project Ciariant Study
CLARIANT/CMU
AB79771
2819G2
8129/00 08:00
8/29/00 10:00
nl The following analytical results have been obtained for the indicated sample which was submitted to this laboratory
fin
TEST
PARAMETER
TEST
RESULT
REPORTING METHOD
UNITS LIMIT REFERENCE
DATE/TIME
STARTED ANALYST
2,6-OI14ITROTOLUENE
DI-N-OCTYLPHTHALATE
FLUORANTHENE
FLUORENE
HEXACHLOROBENZENE
HEXACHLOROBUTADIENE
HEXACHLOROCYCLOPENTADIENE
HEXACHLOROETHANE
I NDENO(1,2,3-CD)PYRENE
ISOPHORONE
2-METHYL-4,6-DIN ITROPHENOL
NAPHTHALENE
NITROBENZENE
2-NITROPHENOL
4-NITROPHENOL
N-NITRO SO D I PH E NYLAM I N E
N-NITROSODI-N-PROPYLAMINE
PENTACHLOROPHENOL
PHENANTHRENE
PHENOL
PYRENE
1,2,4-TRICHLOROBENZENE
2,4, 6•TRI CHLOROPHENOL
BENZIOINE
1,2-0IPHENYLHYDRAZINE
PREP. METHOD 625
METALS DIGESTION
SILVER, TOTAL
ARSENIC, TOTAL
Not detected ug/L 10 625 9/6/00 14:59 HWC
Not detected ug/L 10 625 9/6/00 14:59 HWC
Not detected ug/L 10 625 9/6/00 14:59 HWC
Not detected ug/L 10 625 9/6/00 14:59 HWC
Not detected ug/L 10 625 9/6/00 14:59 HWC
Not detected ug/L 10 625 9/6/00 14:59 HWC
Not detected ug/L 10 625 9/6/00 14:59 HWC
Not detected ug/L 10 625 9/6/00 14:59 HWC
Not detected ug/L 10 625 9/6/00 14:59 HWC
Not detected ug/L 10 625 9/6/00 14:59 HWC
Not detected ug/L 50 625 9/6/00 14:59 HWC
Not detected ug/L 10 625 9/6/00 14:59 HWC
Not detected ug/L 10 625 9/6/00 14:59 HWC
Not detected ug/L 10 625 9/6/00 14:59 HWC
Not detected ug/L 50 625 9/6/00 14:59 HWC
Not detected ug/L 10 625 9/6/00 14:59 HWC
Not detected ug/L 10 625 9/6/00 14:59. HWC
Not detected ug/L 50 625 9/6/00 14:59 HWC
Not detected ug/L 10 625 9/6/00 14:59 HWC
Not detected ug/L 10 625 9/6/00 14:59 HWC
Not detected ug/L 10 625 9/6/00 14:59 HWC
Not detected ug/L 10 625 9/6/00 14:59 HWC
Not detected ug/L 10 625 9/6/00 14:59 HWC
Not detected ug/L 100 625 9/6/00 14:59 HWC
Not detected ug/L 100 625 9/6100 14:59 HWC
Completed 625 9/5/00 07:30 GRR
Completed EPA 200.7 8/31/00 11:00 PRF
Less than mg/L 0.005 EPA 200.7 8/31/00 18:22 MSP
Less than mg/L 0.010 EPA 200.7 8/31/00 18:22 MSP
NC Certification No. 402 - SC Certification No. 99012 - NC Drinking Water Cert. No. 37735 - FL Certification No. E87519
449 Springbrook Road .. P.O. Box 240543 ...Charlotte, NC 28224-0543
Phone: [phone] ...Toll Free Number: 1-8001529-6364 .. Fax: [phone]

Lab. Report
PIM
Psi
Pal
9/11/00
Brown&Caldwell
Attn: Jay Fulmer
200 Providence Rd.
fir Suite 204
Charlotte, NC 28207
Customer Project ID:
Customer Sample ID:
Prism Sample ID:
Login Group:
Sample Collection Date/Time:
Lab Submittal Date/me:
Full Service Analytical & Environmental Solution:
Page 3 of 8
Project: Clariant Study
CLARIANT/CMU
AB79771
2819G2
8/29/00 08:00
8/29/00 10:00
The following analytical results have been obtained for the indicated sample which was submitted to this laboratory
TEST
PARAMETER
TEST
RESULT
UNITS
REPORTING METHOD
UMIT REFERENCE
DATE/TIME
STARTED ANALYST
BARIUM, TOTAL
CADMIUM, TOTAL
CHROMIUM, TOTAL
LEAD. TOTAL
SELENIUM, TOTAL
IRON. TOTAL
MANGANESE, TOTAL
MERCURY. TOTAL
MERCURY DIGESTION
SULFATE
CHLORIDE
PHENOL
PHENOL DISTILLATION
MBAS, SURFACTANTS
BENZENE
BROMODICHLOROMETHANE
BROMOFORM
BROMOMETHANE
CARBON TETRACHLORIDE
CHLOROBENZENE
CHLOROETHANE
2-CHLOROETHYLVINYL ETHER
CHLOROFORM
CHLOROMETHANE
DIBROMOCHLOROMETHANE
1 ,2-DICHLOROBENZENE
1,3-DICHLOROBENZENE
1,4-01CHLOROBENZENE
1,1-DICHLOROETHANE
1,2-DICHLOROETHANE
NC Certification No. 402 - SC
449
Phone:
Less than
Less than
0.018
Less than
Less than
1.0
1.5
Less than
Completed
230
140
0.24
Completed
0.2
Not detected
Not detected
Not detected
Not detected
Not detected
Not detected
Not detected
Not detected
Not detected
Not detected
Not detected
Not detected
Not detected
Not detected
Not detected
Not detected
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L 0.2
ug/L 5
ug/L 5
ug/L 5
ug/L 10
ug/L 5
ug/L 5
ug/L 10
ug/L 10
ug/L 5
ug/L to
ug/L 5
ug/L 5
ug/L 5
ug/L 5
ug/L 5
ug/L 5
0.1 EPA 200.7
0.005 EPA 200.7
0.005 EPA 200.7
0.005 EPA 200.7
0.010 EPA 200.7
0.10 EPA 200.7
0.10 EPA 200.7
0.0002 EPA 245.1
EPA 245.1
10 EPA 300
4.0 EPA 300.0
0.05 EPA 420.1
EPA 420.1
EPA 425.1
EPA 624
EPA 624
EPA 624
EPA 624
EPA 624
EPA 624
EPA 624
EPA 624
EPA 624
EPA 624
EPA 624
EPA 624
EPA 624
EPA 624
EPA 624
EPA 624
Certification No. 99012 - NC Drinking Water Cert. No. 37735
Springbrook Road . P.O. Box 240543 Charlotte, NC 28224-0543
704/529-6364 ...Toll Free Number: 1-800/529-6364 .• Fax:[phone]
8/31/0018:22 MSP
8/31/00 18:22 MSP
8/31/00 18:22 MSP
8/31/0018:22 MSP
8/31/0018:22 MSP
8/31/00 18:22 MSP
13/31/0018:22 MSP
8/30/0015:58 PRF
8/30/0011:00 PRF
9/7/00 14:01 PBF
9/6/00 21:11 PBF
8/30/00 22:55 KAP
8/30/00 16:00 KAP
8/29/00 17:00 EHT
8/30/00 21:50 MP
8/30/00 21:50 MP
8/30/00 21:50 MP
8/30/00 21:50 MP
8/30/00 21:50 MP
8/30/00 21:50 MP
8/30/00 21:50 MP
8/30/00 21:50 MP
8/30/00 21:50 MP
8/30/00 21:50 MP
8/30/00 21:50 MP
8/30/00 21:50 MP
8/30/00 21:50 MP
8/30/00 21:50 MP
8/30/00 21:50 MP
8/30/00 21:50 MP
FL Certification No. E87519

mil Lab Report
f�1
9/11/00
Brown&Caldwetl
Attn: Jay Fulmer
200 Providence Rd.
r=, Suite 204
Charlotte, NC 28207
Customer Project ID:
Customer Sample ID:
Prism Sample ID:
Login Group:
Sample Collection Date/Time:
Lab Submittal Date/Time:
Full Service Analytical & Environmental Solutions
Page 4 of 8
Project Clariant Study
CLARIANT!CMU
AB79T71
2819G2
8/29/00 08:00
8/29/00 10:00
The following analytical results have been obtained for the indicated sample which was submitted to this laboratory
TEST
PARAMETER
TEST
RESULT
REPORTING METHOD
UNITS UMIT REFERENCE
DATE/TIME
STARTED ANALYST
1,1-DICHLOROETHENE
TRANS-1,2-DICHLOROETHENE
r#L 1,2-DICHLOROPROPANE
CIS-1,3-DICHLOROPROPENE
TRANS-1,3-DICHLOROPROPENE
ETHYLBENZENE
METHYLENE CHLORIDE
1,1,22 TETRACHLOROETHANE
TETRACHLOROETHENE
TOLUENE
1,1,1 TRICHLOROETHANE
1,1,2-TRICHLOROETHANE
TRICHLOROETHENE
TRICHLOROFLUOROMETHANE
VINYL CHLORIDE
ACROLEIN
ACRYLONITRILE
Not detected uglL 5
Not detected ug/L 5
Not detected ug/L 5
Not detected ug/L 5
Not detected ug/L 5
Not detected uglL 5
Not detected ug/L 5
Not detected ug/L 5
Not detected ug/L 5
Not detected ug/L 5
Not detected ug/L 5
Not detected ug/L 5
Not detected ug/L 5
Not detected uglL 5
Not detected ug/L 10
Not detected uglL 100
Not detected ug/L 100
EPA 624 8130/00 21:50 MP
EPA 624 8/30/00 21:50 MP
EPA 624 8/30/00 21:50 MP
EPA 624 8/30/00 21:50 MP
EPA 624 8/30100 21:50 MP
EPA 624 8/30/00 21:50 MP
EPA 624 8/30100 21:50 MP
EPA 624 8/30/00 21:50 MP
EPA 624 8/30/00 21:50 MP
EPA 624 8/30/00 21:50 MP
EPA 624 8/30/00 21:50 MP
EPA 624 8/30/00 21:50 MP
EPA 624 8/30/00 21:50 MP
EPA 624 8/30/00 21:50 MP
EPA 624 8/30/00 21:50 MP
EPA 624 8/30/00 21:50 MP
EPA 624 8/30/00 21:50 MP
Sample Comments:
L
Angela D. Overcash, V.P. Laboratory Services
NC Certification No. 402 - SC Certification No. 99012 - NC Drinking Water Cert. No. 37735 - FL Certification No. E87519
449 Springbronk Road P.O. Box 240543 ...Charlotte, NC 28224-0543
Phone: [phone] ...Toll Free Number. 1-800/529-6364 .. Fax: [phone]

Table B-1. Clariant Only Pilot Unit Analytical Results
Date
COD
(m8 L}
CBOD
(mg/L)
TSS
(mg/1
6/26/2000
_ 170
78.5
6/27/2000
6/28/2000
129
78.8
188.5
6/29/2000
6/30/2000
478
7/1/2000
_ 7/2/2000
7/3/2000
483
346
7/4/2000
_
7/5/2000
461
229
7/6/2000
7/7/2000
590
240
7/8/2000
7/9/2000
7/10/2000
430.
228
7/11/2000
7/12/2000
418
_!k.
7/13/2000
_
7/14/2000
424
69
7/15/2000
_
7/16/2000
7/17/2000
178
195
7/18/2000
7/19/2000
2600
319
7/20/2000
_
7/21/2000
600
208.3
7/22/2000
7/23/2000
7/24/21300
570
180
7/25/2000
_ 7/26/2000
406
<22
7/27/2000
7/28/2000
1150
138
7/29/2000
7/30/2000
7/31/2000
3506
113
8/1/2000
8/2/2000
299
22
8/3/2000
8/4/2000
682
88
8/5/2000
8/6/2000
8/7/2000
1260
340
8/8/2000
8/9/2000
nosample
no sample
8/10/2000
1.
8/11/2000
no sample
no sample
8/12/2000
8/13/2000
8/14/2000
1508
231
8/15/2000
8/16/2000
1610
275
8/17/2000
8/18/2000
129
<120
8/19/2000
8/20/2000
8/21/2000
172
l 39.9
8/22/2000
8/23/2000
202
64.1
8/24/2000
8/25/2000
194
57.7
8/26/2000
8/27/2000
8/28/2000
160
62
1
8/29/2000
8/30/2000
147
42
1
8/31/2000
9/1/2000
2247
200
.
9/2/2000
9/3/2000
9/4/2000
1584
187
_
,
9/5/2000
9/6/2000
1244
_
223
1
116
170
120
155
785
200
00
160
00
00
50
30
70
60
20
80
70
70
10
40
50
60
50
75
Ammonia
Nitrate- Prism
VSS TICN Nitrite Ammonia Results
(mL1 (m:1. (m- 1, m L1 ]m•/L
SCOD SCBOD
On I. m•/L)
EFFLUENT
TSS VSS TDS
40
70 11 2.2 3800 1400 37 Q
28 11 4.8 3420 1260 323 2-0
70 54 7.6 2800 1000 21 Q
111
ME® 2.2 8.0 _ 2300 900 �mi_ 28 <l 116 28
120 13 10 In ') 700 166 Q 820 500
20 14 11 1051) 550 127 <2 1900 110D
10 2.4 1.6 0.75 - 860 360 ---+
MEM
30 3.6 450 220 155 2q J
415 94 - 4500 MMEMIMI
2600 1.3 <20 ® 20 12
155.08
no sam- -le
500 353
800 547
no sample
no sample
no sem le
no sample
(m
CPI
./14
Nitrate-
Nitrite
(m8/i4 _
Ammonia
(mg/L)
Ammonia
Prism
Results
(mg/L1
COD
(mall_)
CBOD
(meld'(mggL)
Total
Phosphorus
14
30.11)
-
19
5
27.0
<0.2
_
95
3.2
3.0
.
4.2
23,7
<0.2
2.8
160
<0.2
2.2 9.9 <0.2
22
no sample
2.3 6.4 <0.2
38
<2
102.26
4362 65.21
1.
<0.2
Elloo
mom
110.11.11.
33®.11111
no sari) le

Influent
Table B-2. Clariant Onb. Pilot Unit Daily Operational Measurements
Anoxic Aerobic
r Recycle
Date -Throe pH Flowrate pH DO Temp. Flowrate pH
(mL/min) 1 WJL) (C) (mg/L) -
6/24/2000 2:30 2.8 7.8y 2.5 17.6 35.0 7.7
6/25/2000 8:00 7.3 1.9 , 7.6 4.0 17.2 8.2
6/26/2000 8:23 2.5 7.5 4.3 16.7 50.0 7.8
6/27/2000 6:38 7.2 2.6 7.4 0.6 14.4 30.0 7.7
6/28/2000 9:15 7.1 2.5 7.4 14.4 33.0 7.7
6/29/2000 8:30 7.1 22 7.5 8.0 14.4 30.0 7.7
6/30/2000 7:55 7.1 2.0 7.4 2.3 14.2 18.0 7.6
7/1/20009:00 7.6 2.4 7.4 0.4 14.4 18.0 7.6
7/2/2000 8:20 7.4 2.5 7.4 1.0 13.6 21.0 7.6
7/3/2000 9:10 7.0 2.8 7.4 1.4 13.9 22.0 7.6
7/4/2000 8:50 7.4 2.5 7.4 0.2 14.4 26.0 7.4
7/5/2000 9:45 6.8 3.2 7.2 0.4 14.4 29.0 7.5
7/6/2000 7:55 7.2 3.0 7.2 0.7 14.4 27.0 7.3
7/7/2000 10:15 7.1 2.8 71 0.2 13.9 28.0 7.3
DO Temp.
melt (C)
8.8
8.5 17.2
8.6 16.7
8.1 14.4
14.4
1.5 13.3
Effluent Comments
OUR OUR off Volume
*min�mg/L*hr)
(f.)
8.0 63.0
2.3
8.0 2.8
0.1 3.0 6.9 3.8
7.3 2.1
8.7 11.9
8.3 12.2
0.1 3.0 8.0 2.5
7.8 3.7
8.4 12.2
8.5 12.2
8.2 12.2
7.7 12.2
7.8 3.5
7.7 3.6
7.6 3.4
0.1 3.0 7.6 3.2
7/8/2000 9:00 8.0 2.6 7.3 0.8 15.5 26.0 7.4
7/9/2000 B:50 8.0 2.8 7.2 0.4 16.0 25.0 7.5
7/10/2000 8:00 7.0 2.8 7.1 0.8 14.0 30.0 7.1
7/11/20001:00 7.1 _ 3.0 6.9 2.3 14.0 32.0 7.1
3.6 12.2
7.3 12.2
101 15.0
9.6 14.0
7.1 2.4 Moved Long Creek sampler to pump station site.
7.7 3.8 Took a gab sample of Long Creek wastewater to meet aliquot volume requirements.
7.4 3.0
7.4 3.2
7/12/2000 8:00 3.0 6.9 1.0 14.0 10.0 6.9
7/13/2000 12:00 7.4 2.9 8.0 0.4 17.2 30.0 7.6
7/14/2000 8:15 7.8 3.0 7.4 0.5 15.0 35.0 7.1
8.2 13.0
9.8 13.0
8.5 14.0
0.1 3.0 6.9 3.8
6.9 3.7
6.8 3.1
Took a grab sample of Long Creek wastewater to meet aliquot volume requirements.
7.7 15.6
7.1 3.7
7/15/2000 8:00 8.0 2.6 8.0 0.7 13.0 18.0 7.8
7/16/2000 8:05 7.6 23 7.9 0.8 14.0 15.4 7.6
7/17/2000 7:30 7.7 3.0 7.6 0.4 14.0 22.0 7.4
7/18/200012:00 7.9 3.6 7.8 0.5 14.0 23.0 7.6
7/19/20008:10 7.5 3.0 7.9 0.3 14.0 9.0 7.4
7/20/2000 12:45 7.9 3.2 8.3 0.7 14.0 11.0 8.1
7/21/2000 8:45 2.6 8.3 0.5 13.0 10.0 8.0
7/22/2000 9:00
7/23/2000 9:00
7/24/2000 8:00
7.5 13.0
7.9 12.0
8.5 12.0
8.3 12.0
7.8 13.0
0.1 3.0 6.9 3.5 Groundwater unit offline. Used DI water in place of sample volume.
7.7 3.3 Began adding polymertoClariant Only unit
7.5 2.9
7.3 3.6
7.2 4.0
Acid sampler back in service.
8.5 13.0
9.9 12.5
8.0 11.0
0.1 6.0 7.3 3.3
7.6 2.0
7.6 2.6
Reduced recycle flow to 3:1 ratio
7/25/2000 8:15 8.1
7/26/2000 7:30 7.7
7/27/2000 8:50 7.8
7/28/2000 9:20
7/29/2000 2:00 7.6
7/30/20008:35 7.8
3.0 8.4 0.5 13.0 8.5 8.0
2.2 8.5 0.6 14.0 8.8 8.1
2.3 8.5 0.2 14.0
8.2 14.0
6.5 13.0
7.5 4.5
7.8 1.7
Chuiant staff had not replaced influent buckets over the weekend. Began tciwig soi du*bk nitrogen series samples.
8.1
2.7 85 0.6 17.2 15.6 81
2.9 8.4 0 2 12.0 10.0 8.3
3.0 8.1 0.7 13.9 8.6 8.0
2.5 8.5 0.5 14.0 7.3 7.9
7.6 13.0
7.7 3.0
8.8 13.3
7.8 3.5
8.6 13.0
8.8 13.3
0.2 _ 9.0 75 3.5
7.5 1.8
Took a grab sample of Long Creek wastewater to meet aliquot volume requirements.
3.1 12.0
7.4 3.5
7/31/2000 1:00 7.5
8/1/2000 1:15 7.1
8/2/2000 9:00 6.5
8/3/2000 9:00
2.8 8.1 0.2 14.0 10.0 8.0
3.0 7.7 0.3 15.0 14.0 8.1
9.9 12.0
7.7 11.0
O.l 6.0 7.4 3.6
7.8 2.5
Took a grab sample of Long Creek wastewater and alkaline stream to meet aliquot volume requirements. Acid sewer much darker than ussual with
strong odor.
2.9 8.1 0.5 17.0 10.0 8.1
8.6 15.0
0.1 6.0 7.7 2.9
Took grab sample of acid and alkaline waste stream.
8/4/2000 11:00
8/5/2000 10:45
8/6/2000 9:00
8/7/2000 9:20
2.8 _ 8.2 1.0 13.0 9.0 8.1
7.6 2.7 8.4 1.3 14.0 4.2 8.1
7.9 i. 2.2 8.4 0.9 14.0 7.5 8.0
2.8 8.3 0.3 15.0 9.0 8.1
8.6 14.0
10.0 12.0
9.9 12.5
8.7 12.5
0.1
Took a grab sample of Long Creek wastewater to meet aliquot volume requirements. Very large storm the night before (2 m. ofrain). The long Creek
3.0 7.4 3.7 rumple was much darker than ussual.
7.6 3.01
0.1 6.0
7.7 3.0
73
33
8/8/200011:00 7.4 2.9 8.1 0.5 8.2 8.0
8/9/2000 9:00
8/10/2000 11:30 6.8 2.6 8.5 0.3 9.0 8.1
8/11/2000 9:15
9.0 15.0
7.1 3.5
Added 450 mL of nitrifiers to each unit Removed and settled 450 mL before addition Returned solids to reactors. Began adding new polymer to
reactors.
8/12/20008:05 6.9 2.2 8.3 0.5 32.0 8.4
8/13/2000 8:30 7.0 2.2 8.6 0.6 30.4 8.7
8/14/20009:00 6.8 2.6 0.B 7.9 14.0 30.0 8.8
8/15/2000 9:30
8/16/2000 9:00
3.6 15.0
7.5 12.0
8.2 13.0
8.2
8.3 3.2
8.5 2.8
Groundwater unit off line. Used DI water in place of sample volume. Boosted recycle rate to 9:1 ratio.
Added 450 mL of nit ifiers to each unit. Removed and settled 450 mL before addition Returned solids to reactors. Began adding new polymer to -
reactors.
6.3 2.7 8.5 0.6 14.0 32.0 8.5
8/17/2000 9:00 6.9 2.8 B.6 0.6 14.5 33.0 8.5
8/18/2000 9:00
2.8 7.7 0.8 13.0 30.0 8.0
8/19/2000 10:00 7.5 2.5 8.6 0.7 20.0 8.3
8/20/200013:35 8.1 2.6 8.6 0.8 22.0 8.5
8/21/2000 9:00
2.6 8.8 0.6 14.0 23.0 8.9
8/22/2000 7:45 6.6 2.7 0.4 1.0 27.2 8.5
8/23/2000 8:00
2.8 7.0 0.3 13.0 26.0 7.4
8/24/2000 11:30 8.1 3.0 8.1 1.0 30.1 8.3
8/25/2000 8:30 7.8 2.9 8.1 0.6 26.0 7.6
0.3 13.0
6.9 13.0
6.0 13.0
3.9 12.0
7.4 12.8
8.6 3.0
8.3 3.0
8.2 2.8
0.1 6.0 7.4 3.8
7.8 1.4
Groundwater unit ofTline. Used D1 water in place of sample volume.
Groundwater unit offline. Used DI water in place of sample volume.
Stopped running ing pilot study with acid samples. Used DI water to make up for volrmte.
Took a grab sample of Long Creek wastewater to meet aliquot volume requirements.
7.0 12.3
8.4 13.0
8.2 12.0
8.2 12.0
7.8 3.0
7.8 2.5
8.0 2.4
7.0 3.5
Took a grab sample of Long Creek wastewater to meet aliquot volume requiremen�
8/26/2000 11:40 7.0 2.8 7.4 0.5 26.0 7.4
8.4 14.4
7.0 15.0
8.8 14.4
7.7 3.3
0.1 3.0 7.1 3.2
8/27/2000 8:30 7.1 2.4 7.8 0.5 28.0 7.6
8/28/2000 9:30 7.8 2.8 7.1 6.0 28.0 7.1
8/29/2000 10:10 7.5 _ 2.6 7.0 6.8 30.0 7.1
8/30/2000 7:30
8.7 15.0
6.8 1.7
Added 450 mL of nitrifiers to each unit Removed and settled 450 mL before addition Returned solids to reactors. Plant upset by over dose of
polymer.
2.6 6.7 0.8 12.0 26.0 7.0
8/31/2000 13:15 9.0 5.0
7.7
9.2 14.4
8.2 11.7
9.0 11.0
7.6
6.9 3.2Took a grab sample of Long Creek wastewater to meet aliquot volume requirements.
7.0 2.9
0.1 _ 3.0 6.9 3.0 Took a grab sample of Long Creek wastewater and alkaline waste stream to meet aliquot volume requirements
9/1/2000 8:20 6.9 4.8
9/2/2000 9:20 6.8 2.2
7.4
7.6 16.2
0.1 3.0 6.9 5.0
9/3/2000 9:45 7.1 1.8
9/4/2000 11:00 5.5
9/5/2000 10:00 7.8 5.3
9/6/2000 10:00 7.1 4
7.5
7.6
7.5
7.5
9.9 9.0
9.8 8
8.7 13
9.6 13
7.0 2.8
7.1 2.0
7.3 7.0
7.1 4.0
7.1
9.8 10
7.1 3.9
G:\19047\Gen\Lab Reports \Clariant Only -- Daily Log Record

Lai Report
PIUSM
LABORAvb %1as, Die.
Pal
Pail
9/11/00
Brown&Caldwell
Attn: Jay Fulmer
200 Providence Rd.
Suite 204
Charlotte, NC 28207
Customer Project ID:
Customer Sample ID:
Prism Sample ID:
Login Group:
Sample Collection Date/Time:
Lab Submittal Date/me:
Full Service Analytical & Environmental Solutions
Page 1 of 4
Clariant Treatability Study
CLARIANT ONLY
AB79773
2820G1
8/29/00 08:00
8/29/00 10:00
1"+ The following analytical results have been obtained for the indicated sample which was submitted to this laboratory
Fool
TEST
PARAMETER
TEST
RESULT
REPORTING METHOD
UNITS LIMIT REFERENCE
DATE/TIME
STARTED ANALYST
ACENAPHTHENE
ACENAPHTHYLENE
ANTHRACENE
BENZO(A)ANTHRACENE
BENZO(B)FLUORANTHENE
BENZO(K)FLUORANTHENE
BENZO(A)PYRENE
BENZO(GHI)PERYLENE
BIS(2-CHLOROETHOXY)METHANE
BIS(2-CHLOROETHYL)ETHER
BIS(2-CHLOROISOPROPYL)ETHER
BIS(2-ETHYLHEXYL)PHTHALATE
4-BROMOPHENYL PHENYL ETHER
BUTYL BENZYL PHTHALATE
4-CILORO-3-METHYLPHENOL
2-CHLORONAPHTHALENE
2-CHLOROPHENOL
4-CHLOROPHENYL PHENYL ETHER
CHRYSENE
D I BENZO(A, H)ANTH RACE NE
DI-N-BUTYLPHTHALATE
1,2-DICHLOROBENZENE
1,3-DICHLOROBENZENE
1,4-DICHLOROBENZENE
2,4-DICHLOROPHENOL
DIETHYL PHTHALATE
2,4-DIMETHYLPHENOL
DIMETHYL PHTHALATE
2,4-DINITROPHENOL
2,4-DINITROTOLUENE
Not detected ug/L 10 625 9/6/00 16:42 HWC
Not detected ug/L 10 625 9/6/00 16:42 HWC
Not detected ug/L 10 625 9/6/0016:42 HWC
Not detected ug/L 10 625 9/6/00 16:42 HWC
Not detected ug/L 10 625 9/6/00 16:42 HWC
Not detected ug/L 10 625 9/6/00 16:42 HWC
Not detected ug/L 10 625 9/6/00 16:42 HWC
Not detected ug/L 10 625 9/6/00 16:42 HWC
Not detected ug/L 10 625 9/6/00 16:42 HWC
Not detected ug/L 10 625 9/6/00 16:42 HWC
Not detected ug/L 10 625 9/6/00 16:42 HWC
Not detected ug/L 10 625 9/6/00 16:42 HWC
Not detected ug/L 10 625 9/6/00 16:42 HWC
Not detected ug/L 10 625 9/6/0016:42 HWC
Not detected ug/L 10 625 9/6/00 16:42 HWC
Not detected ug/L 10 625 9/6/00 16:42 HWC
Not detected ug/L 10 625 9/6/00 16:42 HWC
Not detected ug/L 10 625 9/6/00 16:42 HWC
Not detected ug/L 10 625 9/6100 16:42 HWC
Not detected ug/L 10 625 9/6/00 16:42 HWC
Not detected ug/L 10 625 916100 16:42 HWC
Not detected ug/L 10 625 9/6/00 16:42 HWC
Not detected ug/L 10 625 9/6/00 16:42 HWC
Not detected ug/L 10 625 9/6/00 16:42 HWC
Not detected ug/L 10 625 9/6/00 16:42 HWC
Not detected ug/L 10 625 9/6/00 16:42 HWC
Not detected ug/L 10 625 9/6/00 16:42 HWC
Not detected ug/L 10 625 9/6/00 16:42 HWC
Not detected ug/L 50 625 9/6/00 16:42 HWC
Not detected ug/L 10 625 9/6/00 16:42 HWC
NC Certification No. 402 - SC Certification No. 99012 - NC Drinking Water Cert. No. 37735 - FL Certification No. E87519
449 Springbrnok Road P.O. Box 240543 .... Charlotte, NC 28224-0543
Phone: [phone] ..Toll Free Number: 1-800/529-6364 .. Fax: [phone]

Lab Report
G
t.AeoRATORiESM, INC.
rmr1
Poi
run
rat
9/11/00
Brawn&Caldwell
Attn: Jay Fulmer
200 Providence Rd.
Stile 204
Charlotte. NC 28207
Thefollowing analytical results
Customer Project ID:
Customer Sample ID:
Prism Sample ID:
Login Group:
Sample Collection Date/Time:
Lab Submittal Date/Time:
have been obtained
Full Service Analytical & Environmental Solutions
Page 2 of 4
Clariant Treatability Study
CLARIANT ONLY
AB79773
2820G1
8/29/00 08:00
8/29/00 10:00
for the indicated sample which was submitted to this laboratory
TEST
PARAMETER
2.6-01NITROTOLUENE
DI-NOCTYLPHTHALATE
FLUORANTHENE
FLUOREME
HE)(ACHLOROBENZENE
HE)WCHLOROBUTADIENE
H E)(ACHLOROCYCLOPENTADI ENE
HEXACHLOROETHANE
INDENO(1,2,3-CD)PYRENE
1SOPHORONE
2-METHY L.4.6-D I N ITRO P HE N O L
NAPHTHALENE
NITROBENZENE
2-NITROPH ENOL
4-NITROPH ENOL
N-NITROSODIPHENYLAMINE
N-WITRO SODI-N-P RO PY LAM I N E
PENTACHLOROPHENOL
PHENANTHRENE
PHENOL
PYRENE
1,2,4-TRICHLOROBENZENE
2,4,6-TR I CHLO RO PH E N O L
BENZIDINE
1,2-DIPHENYLHYDRAZINE
PREP. METHOD 625
METALS DIGESTION
SILVER, TOTAL
ARSENIC, TOTAL
TEST
RESULT UNITS
Not detected ug/L
Not detected ug/L
Not detected ug/L
Not detected ug/L
Not detected ug/L
Not detected ug/L
Not detected ug/L
Not detected ug/L
Not detected ug/L
Not detected ug/L
Not detected ug/L
Not detected ug/L •
Not detected ug/L
Not detected ug/L
Not detected ug/L
Not detected ug/L
Not detected ug/L
Not detected ug/L
Not detected ug/L
Not detected ug/L
Not detected uglL
Not detected ug/L
Not detected ug/L
Not detected uglL
Not detected ug/L
Completed
Completed
Less than mglL
Less than mg/L
REPORTING METHOD DATE/TIME
LIMIT REFERENCE
10
10
10
10
10
10
10
10
10
10
50
10
10
10
50
10
10
50
10
10
10
10
10
100
100
0.005
0.010
625
625
625
625
625
625
625
625
625
625
625
625
625
625
625
625
625
625
625
625
625
625
625
625
625
625
EPA 200.7
EPA 200.7
EPA 200.7
STARTED ANALYST
9/6/00 16:42 HWC
9/6/00 16:42 HWC
9/6/00 16:42 HWC
9/6/00 16:42 HWC
9/6/00 16:42 HWC
9/6/00 16:42 HWC
9/6/00 16:42 HWC
9/6/00 16:42 HWC
9/6100 16:42 HWC
9/6/00 16:42 HWC
9/6/00 16:42 HWC
9/6/00 16:42 HWC
9/6/00 16:42 HWC
9/6/00 16:42 HWC
9/6/00 16:42 HWC
9/6/00 16:42 HWC
9/6/00 16:42 HWC
9/6/00 16:42 HWC
9/6/00 16:42 HWC
9/6/00 16:42 HWC
9/6/00 16:42 HWC
9/6/00 16:42 HWC
9/6/00 16:42 HWC
9/6/00 16:42 HWC
9/6100 16:42 HWC
9/5/00 07:30 GRR
8/31/0011:00 PRF
8/31/00 18:27 MSP
8/31/0018:27 MSP
NC Certification No. 402 - SC Certification No. 99012 - NC Drinking Water Cert. No. 37735 - FL Certification No. E87519
449 Springbrook Road ... P.O. Box 240543 .•Charlotte, NC 28224-0543
Phone: [phone] ...To11 Free Number: 1-800/529-6364 Fax: [phone]

Lab Report
PRISM
LABORATORIES, INC.
f�l
fon
9/11/00
„ n Brown&Caldwell
Attn: Jay Fulmer
200 Providence Rd.
Suite 204
Charlotte, NC 28207
Customer Project ID:
Customer Sample ID:
Prism Sample ID:
Login Group:
Sample Collection Date/Time:
Lab Submittal Date/Time:
fm1 The following analytical results have been obtained for the indicated sample whi
a*l
fmi
PEI
rot
TEST
PARAMETER
TEST
RESULT UNITS
Full Service Analytical & Environmental Solutions
Page 3 of 4
Clariant Treatability Study
CLARIANT ONLY
AB79773
2820G1
8/29/00 08:00
8/29/00 10:00
ch was submitted to this laboratory
REPORTING METHOD DATE/TIME
UMIT REFERENCE
STARTED ANALYST
CADMIUM. TOTAL
CHROMIUM. TOTAL
LEAD. TOTAL
BARIUM, TOTAL
SELENIUM. TOTAL
IRON, TOTAL
MANGANESE. TOTAL
MERCURY. TOTAL
MERCURY DIGESTION
SULFATE
CHLORIDE
PHENOL
PHENOL DISTILLATION
MBAS, SURFACTANTS
BENZENE
BROMODICHLOROMETHANE
BROMOFORM
BROMOMETHANE
CARBON TETRACHLORIDE
CHLOROBENZENE
CHLOROETHANE
2-CHLOROETHYLVINYL ETHER
CHLOROFORM
CHLOROMETHANE
DIBROMOCHLOROMETHANE
1,2-DICHLOROBENZENE
1,3-DICHLOROBENZENE
1,4-DICHLOROBENZENE
1,1-DICHLOROETHANE
1,2-DICHLOROETHANE
Less than
0.006
Less than
Less than
Less than
Less than
5.5
Less than
Completed
1400
500
0.11
Completed
0.4
Not detected
Not detected
Not detected
Not detected
Not detected
Not detected
Not detected
Not detected
Not detected
Not detected
Not detected
Not detected
Not detected
Not detected
Not detected
Not detected
mg/L 0.005
mg/L 0.005
mg/L 0.005
mg/L 0.1
mg/L 0.010
mg/L 0.10
mg/L 0.10
mg/L 0.0002
mg/L 50
mg/L 50
mg/L 0.06
mg/L 0.2
ug/L 5
ug/L 5
ug/L 5
ug/L 10
ug/L 5
ug/L 5
ug/L 10
ug/L 10
ug/L 5
ug/L 10
ug/L 5
ug/L 5
ug/L 5
ugfL 5
ug/L 5
ug/L 5
EPA 200.7
EPA 200.7
EPA 200.7
EPA 200.7
EPA 200.7
EPA 200.7
EPA 200.7
EPA 245.1
EPA 245.1
EPA 300
EPA 300.0
EPA 420.1
EPA 420.1
EPA 425.1
EPA 624
EPA 624
EPA 624
EPA 624
EPA 624
EPA 624
EPA 624
EPA 624
EPA 624
EPA 624
EPA 624
EPA 624
EPA 624
EPA 624
EPA 624
EPA 624
8/31/00 18:27 MSP
8/31/00 18:27 MSP
8/31/00 18:27 MSP
8/31/00 18:27 MSP
8/31/00 18:27 MSP
8/31/0018:27 MSP
8/31/00 18:27 MSP
8/30/0016:02 PRF
8/30/00 11:00 PRF
9/6/00 21:49 PBF
9!6/00 21:49 PBF
8/30/00 22:55 KAP
8/30/0016:00 KAP
8/29/00 17:00 EHT
8/30/00 23:08 MP
8/30/00 23:08 MP
8/30/00 23:05 MP
8/30/00 23:08 MP
8/30/00 23:08 MP
8/30/00 23:08 MP
8/30/00 23:08 MP
8/30/00 23:08 MP
8/30/00 23:08 MP
8/30/00 23:08 MP
8/30/00 23:08 MP
8/30/00 23:08 MP
8/30/00 23:08 MP
8/30/00 23:08 MP
8/30/00 23:08 MP
8/30/00 23:08 MP
NC Certification No. 402 SC Certification No. 99012 - NC Drinking Water Cert. No. 37735 FL Certification No. E87519
449 Springbrook Road ... P.U. Box 240543 .. Charlotte, NC 28224-0543
Phone: [phone] ...Toll Free Number: 1-800/529-6364 .. Fax: [phone]

Lake Report
PRISM
LABORIATORIES, (NC.
4\.
Mgt
9/11100
F„1 Brown&Caldwell
Attn: Jay Fulmer
200 Providence Rd.
fon Suite 204
Charlotte, NC 28207
The fallowing analytical results h
Customer Project ID:
Customer Sample ID:
Prism Sample ID:
Login Group:
Sample Collection Date/Time:
Lab Submittal Date/Time:
Full Service Analytical & Environmental Solutions
Page 4 of 4
Clariant Treatabiiity Study
CLARIANT ONLY
AB79773
2820G1
8/29/00 08:00
8/29/00 10:00
ave been obtained for the indicated sample which was submitted to this laboratory
TEST
PARAMETER
TEST
RESULT
UNITS
REPORTING METHOD DATE/TIME
LIMIT REFERENCE
STARTED ANALYST
1.1-DICHLOROETHENE
TRANS-I.2-DICHLOROETHENE
1,2 0ICHLOROPROPANE
CIS-1,3-DICHLOROPROPENE
TRANS-1.3-DICHLOROPROPEN E
ETHYLBENZENE
METHYLENE CHLORIDE
1,1,2.2 TETRACHLOROETHANE
TETRACHLOROETHENE
TOLUENE
1.1,1-TRICHLOROETHANE
1.1,2-TRI CH LO RO ETHAN E
TRICHLOROETHENE
TRICHLOROFLUORO METHAN E
VINYL CHLORIDE
ACROLEIN
ACRYLONITRILE
Not detected ug/L
Not detected ug/L
Not detected ug/L
Not detected uglL
Not detected ug/L
Not detected ug/L
Not detected ug/L
Not detected ug/L
Not detected ug/L
Not detected ug/L
Not detected uglL
Not detected ug/L
Not detected uglL
Not detected ug/L
Not detected ug/L
Not detected uglL
Not detected ug/L
5 EPA 624
5 EPA 624
5 EPA 624
5 EPA 624
5 EPA 624
5 EPA 624
5 EPA 624
5 EPA 624
5 EPA 624
5 EPA 624
5 EPA 624
5 EPA 624
5 EPA 624
5 EPA 624
10 EPA 624
100 EPA 624
100 EPA 624
8130/00 23:08 MP
8130100 23:08 MP
8/30/00 23:08 MP
8/30/00 23:08 MP
8/30/00 23:08 MP
8/30/00 23:08 MP
8/30/00 23:08 MP
8/30/00 23:08 MP
8/30/00 23:08 MP
8/30/00 23:08 MP
8/30100 23:08 MP
8/30/00 23:08 MP
8/30/00 23:08 MP
8/30/00 23:08 MP
8/30/00 23:08 MP
8/30/00 23:08 MP
8/30/00 23:08 MP
Sample Comments:
Analysis note for 625: Surrogates for this sample fell below acceptance criteria for this test due to thick
emulsions encountered during extraction. Internal standard area response also low, matrix interference
suspected. No sampl®.duplicate a ailable for confirmation.
.//)
Angela D. Overcash, V.P. Laboratory Services
NC Certification No. 402 - SC Certification No. 99012 - NC Drinking Water Cert. No. 37735 - FL Certification No. E87519
449 Springbrook Road .. P.O. Box 240543 ...Charlotte, NC 28224-0543
Phone: [phone] ...Toll Free Number: 1-800/529-6364 .. Fax: [phone]

lot
r-n
MEMORANDUM
Date: March 3, 2000
To: Meeting Attendees
From: Rick Carrier, Brown and Caldwell
18362-01/05
18362-01/09
Subject: February 11, 2000, Meeting Regarding Charlotte Mecklenburg Utilities (CMU)
r•, Wastewater Treatment at Clariant NPDES Facility
NPDES permit: NC0004375
CMU PN: 622-97-682
fon
A meeting was held on February 11, 2000, at North Carolina Department of Environment and
Natural Resources, Division of Water Quality (DWQ) offices in Raleigh to discuss the
ramifications of treating domestic wastewater from the CMU Long Creek sewer collection
system at the Clariant Corporation (Clariant) wastewater treatment plant (WWTP). The
following persons were in attendance:
Rick Carrier, Brown and Caldwell
Jackie Nowell, DWQ
Dave Goodrich, DWQ
Gary Sanderson, Clariant Corporation
Mark McIntire, DWQ
Barry Shearin, CMU
I. Project Overview and Status
A brief overview of the proposed project was presented by Mr. Carrier. Brown and Caldwell is
designing a new pumping system including flow equalization to replace the existing Long Creek
pumping station and force main. The new system is being designed for an average dry weather
flow of approximately 2 mgd and a peak wet weather flow in excess of 14 mgd. Both Clariant
and CMU wish to consider the use of the wastewater treatment facility (WWTF) to treat flows
from the Lon
The existing Clariant WWTF is adjacent to the pumping station site and is presently permitted to
discharge at flow rates up to 3.9 mgd. The WWTF is designed for a hydraulic flow of
approximately 5 mgd. Recent process changes have resulted in significantly lower flow rates
through the WWTF and Clariant expects further flow reductions in the near future to possibly as
low as 0.5 mgd. The proposed project will eliminate the need for CMU to pump the wastewater
several times in route to the CMU McAlpine Creek WWTF. It will also allow discharge directly
to the Catawba River instead of to the relatively small McAlpine Creek tributary. Clariant's
llkJN m CtIRLL
P�7 G:\18362 - Long Creek 2\WP\Mceting Minutes and Agendas\MM 00-02-11 - NCDWQ&Clariant.doc

raq
Meeting Attendees
March 3, 2000
Page 2
A treatability study is planned to verify that the proposed concept is technically sound and to
develop treatment plant concepts. DWQ will want to review the treatability information. DWQ
would like the study to address the effect of reducing the percentage mix of domestic wastewater
and will be looking for flexibility on the part of Clariant and CMU.
CMU is working with DWQ to reduce sanitary sewer overflows (SSO's) associated with the
existing Long Creek pumping and force main system. CMU intends to place an advertisement in
the Charlotte Observer detailing their plans for the system and would like to include information
`_' on the proposed project as part of their overall strategy. CMU has significant money set aside
for sewer rehabilitation. A manhole rehabilitation project has been designed and additional
infiltration and inflow reduction methods are being considered for the basin. CMU is purchasing
a set of portable diesel driven pumps to improve the reliability of the pumping station.
Ultimately, growth in the Long Creek basin will exceed the capacity of the Clariant WWTF and
CMU would like to have a regional plant in place at that time. CMU is proceeding with the
construction of a parallel sewer for the Long Creek basin and has performed flow monitoring
which shows the need for increased sewerage capacity on the west side of Mecklenburg County.
CMU is presently exploring several regional treatment solutions but have not completed their
planning efforts. Based upon experience with the Water and Sewer Authority of Cabarrus
County and Union County, it appears that it will take approximately 8 years from concept
through construction for a new plant.
In general, DWQ approves of the proposed concept. Mr. Goodrich noted that the following
similar projects have already been in operation in North Carolina:
• JPS elastomerics (formerly Cramerton Automotive) in Cramerton had an underutilized
WWTF (i.e., 4 mgd permitted capacity with less than 0.25 mgd process flow) and was
approved to accept Cramerton's domestic sewage flow. Cramerton took over ownership and
operation of the facility.
• Monsanto in Fayetteville accepts and treats flows from several other nearby Organic
Chemical, Petroleum, and Synthetic Fiber (OCPSF) industries.
Mr. Goodrich noted that their main concern over the proposal is eutrophication water quality
problems in Lake Wylie related to elevated nitrogen and phosphorous levels. Although there
currently are no known algae problems in the lake, DWQ is concerned about possible future
problems. DWQ feels that the Best Available Technology (BAT) levels for domestic dischargers
is well defined; however, BAT levels for industrial dischargers are less defined. DWQ
anticipates that Clariant will be required to meet BAT -based limits in the future.
DWQ anticipates that a concentration -based summer nitrogen limit of 6 mg/1 and year-round
phosphorous limit of 1 mg/1 will be imposed on all domestic discharges in the Lake Wylie basin
1I
fsml
BROWN AND CtUJL
taq G:\18362 - Long Creek 2\WP\Meeting Minutes and Agendas\MM 00-02-11 - NCDWQ&Clariant.doc

fag
Meeting Attendees
March 3, 2000
Page 3
with any requested POTW expansion. DWQ is more concerned about nitrogen loadings to Lake
Wylie than phosphorous. A total maximum daily load (TMDL) is being developed for nutrient
Fm1 loadings to Lake Wateree, South Carolina. Recent work by the South Carolina Department of
Environment, Health and Conservation (SCDHEC) did not include fate and transport of
nutrients.
Clariant believes that the use of an anoxic zone at the front of their aeration basins as
recommended in their recent BAT study will significantly reduce the total nitrogen loading from
ma' both CMU and Clariant. Clariant's influent organics include a relatively high nitrogen
component and a 6 mg/1 total nitrogen limit would be excessively restrictive. Clariant currently
adds phosphoric acid as a nutrient to support their activated sludge biomass. Clariant also adds
lime for alkalinity which tends to tie up the phosphorous.
DWQ is encouraging industries to undertake pollution prevention programs. Clariant has
already implemented a pollution prevention program in accordance with a recent study.
DWQ will review the proposed project following the treatability study based upon cost and other
factors. In general, DWQ would look favorably upon a program that will not increase overall
run
phosphorous loads and that will reduce the nitrogen loading to the Catawba River. Clariant
noted that the only way that the project will be feasible from their perspective is if the cost is
relatively low in comparison to other projects competing for their limited capital funds.
DWQ has not recently modelled the Catawba River/Lake Wylie system. The Receive2 model
was based upon the Mountain Island Lake discharge and was updated last in 1980. A WASP
model would be required now to ascertain the impact of a proposed discharge and would require
full calibration information including instream monitoring. DWQ's 1995 model of the main
channel of the Catawba River demonstrated that the combined influence of Clariant, Mount
Holly, and Belmont at nitrogen and phosphorous discharge limits in excess of 6 and 1 mg/1
respectively did not degrade water quality in Lake Wylie. This effort was performed by Steve
Bevington. DWQ does not believe that modeling will be required for the proposed project
because the total flow discharged will not exceed the present permitted capacity of 3.9 mgd. The
,E, present limits are based upon OCPSF effluent guidelines. DWQ did perform a Walker Bathtub
analysis of Lake Wylie as part of their ongoing discussions with SCDHEC.
,at The NPDES permit modification process was discussed:
• The treatability study results should be submitted to DWQ with a 30-day period for them to
review. DWQ would like the study to develop several options for treatment based upon
differing discharge limits.
rim • Following review, DWQ, Clariant and CMU will meet to discuss and negotiate new
discharge limits.
BROWN AND CLtL
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Mot
cm Meeting Attendees
March 3, 2000
Page 4
MR
• Upon completion of negotiations, Clariant will submit a request to modify their NPDES
permit.
• The overall permit processing time may be reduced by approximately 2 months by directly
requesting a public hearing with the request for a permit modification. The Catawba River
m.; Foundation (CRF) will likely be interested in the project and CMU/Clariant plan to involve
them in the process. Michael Jones is the technical advisor to the CRF and works closely
with Donna Lisenby.
• A draft permit will then be issued for final negotiation four to six months following the
request. Clariant will have 30 days to provide a written response to the draft permit.
• Following final negotiations, a modified permit will be issued and Clariant may operate
under the new permit following a 15-day waiting period.
DWQ believes that the OCPSF issues raised in Clariant's response to their October 1996 draft
NPDES have now been resolved and should not be an issue for the proposed project. Clariant
mii should expect to receive their new permit prior to completion of the negotiation process for this
project. A "reopener" clause may be included regarding nitrogen in Clariant's permit.
MI A compliance schedule may be required by DWQ as part of the revised permit.
Wasteload allocations and permit limits are typically set in Dave Goodrich's group. The
WM Mooresville regional office will comment on any permit modification request and the modelling
unit will also have influence on the proposed limits. Any request for a permit with limits greater
than 6 mg/I nitrogen and 1 mg/1 phosphorous will ultimately require approval by Colleen
WI Sullens. The Catawba Basin Plan allows for reduced total pollutant loadings rather than
restrictive concentration based permit levels. Dave Goodrich will discuss the project with
Dennis Ramsey regarding any compliance concerns.
A finding of no significant impact (FONSI) will be required from NCDENR. The
Environmental Assessment (EA) for the Long Creek pumping station project should include a
discussion of the proposed project and possible impacts on rare and endangered species,
archaeological sites, wetlands, etc. A copy of the EA should be sent to Dave Goodrich. Rick
Carrier will discuss the project with Gloria Putnam prior to submitting the EA.
PM
flml
MA
WI
Pal
Fml
RAC:dm
fmal
Enclosure
PM cc: Mr. Houston Flippin, Brown and Caldwell
Mr. Thomas Howard, CMU
am
BROWN AND C11flELL
Poi G:118362 - Long Creek 21WP11vleeting Minutes and Agendas\MM 00.02-11 - NCDWQ&ClarianLdoc