ILLINOIS POLLUTION CONTROL

BOARD

May 10,

1973

ENV IRONMENTAL

PROTECTION

AGENCY

)

#72~-i52

THE

FEINTROTE

COMPANY

YfiuMus

3

IMMEL,

ASSISTANT

ATTORNEY

GENERAL,

APPEARED

ON

BEHALF

iv

ENVIRONMENTAL

PROTECTION

AGENCY

EDWARD

BEWECIKI

APPEARED

ON

BEHALF

OF

RESPONDENT

OPINION

AND

ORDER

OF

THE

BOARD

(BY

SAMUEL

T.

LAWTON,

JR~)

Complaint

was

filed

by

the

Agency

against

The

Flintkote

Company

Lags

ur

the

hesTJCnaerLL

i

toe

oera

~1op

of

~s

Mnunt

CarTnel

felt

i~~i

DL

oa

~eE

oxygen~eerrd ia~aa

ai

J~ and

other

L

ont~m~nants

Lnto

~

Aiv~

~ci

two

snamEb

L

hives

~r1luEd2~T

ho

the

Wacash

River,

so

as

to

cause

water

pollution,

En

violation

of

Section

12

(a)

of

the

Li

0050_fl4

a

0

~OC

C

00

Ic

t

iin_

r

o

—t

o~

C ~

~pec

~

d

nrov~s~ons

iv

Sbl3iv

and

SYiLB-~14

of

the

Sanitary

Water

Board

Regulations,

with

c

is

C

r~

ski

5~

40

it

~

~

)dUCO_Ofl

of

col:or~

odc.~r and

other

nuisance

•conAitions,

failure

to

meet

specified

1

~

i

C

t

u

ro

to

side

-scarm~iv

s

as

regLiled

sa.id

Reciulations

The

entry

of

a

cease

ana

desist

order

and

penalties

in.

the

maxirlium

statutory

amount

are

sought

A

stspula

tiOLl

and

roposed

settlement

have

been

submitted

to

the

Board

pursu.ant

to

which

the

coausany

and.

the

Agency

oroposes

a

two—stace

ii

u.

p~c

~

wh_c~

,

-

na

~on~nivd,

4rOflLd

jOsOJ

The

eompan~

opec-

I

S

P

( 0~ 1

~Jfl~C

r~

~uJ ~t

on

~nd

:aa Os

tory

provc

ions

The

stLL.pulation

re.c ite:s

that

the

Company

operates

a

felt

mill

a I

Moont

~I

~rffle

IL..

at.

which

vaper,

wood

and.

waste

water

are

proces set.

into

feiLt

for

uiti:na

he

use

in

~tne

~nanu

actor

ng

of

roofing

materials,

which

I

~I

4

nfl

er

t

CO

C

0

t~

d

L

0_i

CC

0

hi

tmihasb

1

tes

iv

wan

aOl

an

wnamed

ditch

The

Comoans

s

discharce

into

the

river

has

beerì

between

Os,

DO

an.~ /00

03(1

qalions

daily

average

:0 low

containing

an

averaqc:

at

I:i.U(i

tOurids

01:

p.fli)~

ettluent

at:

between

500.

and

1

000

~

I

c

1T0_

~h

n_

r~

i00_L

Lia~ rapc1~

~o~o

led

t

~~5ti

:n. vu.rous grab

samples

Allowable

discharges

into

the

Wabash

~

have

been

governed

by

SWB~

9

dur:L:eq

all

periods

pertinent.

to

the

ppoceeding

A

pots ution.

abatement

.study

has

been

clevelopea

v

the

Bust.

Engineering

~

cOlic

~

r

—

DO

gI0_eti.o

.1 soc

;.~

para tad

tne.re in

tape t1aer

vi EL

I eEtc

ainch

..:

I .i..ontin

n

dated

Novam—

bc r

llt (I

~L9.

1

2

IL

a a

5

~5

:LpuSuit ii..o

~e t.

:1:

:J:~

tL~

th a

I let

oi..o

~

c ohm

---

program generated by Rust Engineering Company is designed in two

phases to ultimately achieve

a complete closed loop and eliminate all

discharges of process water into

the

waters of the State.

Phase

I of the Rust program,

as described in the study,

is

designed to partially close the “loop” and achieve

a 75

reduction in

daily flow to the Wabash River,

upon completion of which phase, the

discharge of suspended solids would range between 50 and 250 pounds

and the BOD discharge would be reduced to 2,800 pounds per day.

Phase

I would be operational

in thirteen months from the date of the

permit application submission to the Agency, which would occur within

10 days from the entry of an Order approving the proposed settlement.

Phase II of the program provides for recapture and recycle of

the final 25

of the average daily flow to the Wabash River.

Upon

completion of Phase II,

no processed water would be discharged to the

waters of the State.

Suspended solids previously uncaptured by Phase

I

would either be incorporated into Flintkote’s product or removed from

the process and disposed of in a manner approved by the Agency.

The

Stipulation recites that additional research is required to determine

if the final 25

of suspended solids can be incorporated into the

product.

It is anticipated that approximately 16 months will be

needed for research,design, obtaining of permits and construction of

Phase

11, which would be completed within 27 months from the date

that permits are issued for construction of Phase

I.

The Board would

retain continuing jurisdiction for the granting of variances, which

would be necessary to enable completion within the Board’s contemplated

plan.

If Flintkote shows satisfactory progress to the Agency, the

Agency shall recommend that the petition for variance be granted.

“Satisfactory progress” shall mean substantial compliance with all

time tables set by the Board for completion of Phase

I and submittal

of a sound engineering program for implement~ionofPhase II.

Flintkote shall post a corporate bond in the amount of $150,000

to assure compliance of all Board orders entered and that upon comple-

tion of all conditions of said Bond,

the Agency will execute and

deliver

a bond release to Flintkote.

During construction of Phase

I,

Flintkote will supply the Agency and the Board with periodic progress

reports at 30-day intervals,

which report shall include the status of

all design and construction progress on Phase I and Phase

II.

A fine in the amount of $8,000 for past violations of the Environ-

mental Protection Act and the Rules and Regulations of the Sanitary

Water Board is stipulated.

In the event a fine in excess of this amount

is

specified,

the Company would have the right to appeal.

The details of Phase

I and Phase

II are set forth in the Rust

Engineering Company pollution abatement study, which is incorporated in

its entirety by reference in this Opinion and Order.

Phase

I

is desig-

nated as in-plant changes specified on flow sheets 22-l039-FS1 and FS2..

The program contemplates the installation of new side bill screens,

white water storage tank,

filter, shower water tank, centrifugal separa-

tors,

seal tank and four pumps.

The purpose of the new equipment is

to

collect the white water now being discharged into the river,

to screen

—2—

7

—

740

---

and filter it, and then return

i~

co the process for reuse.

Existing

sump pumps will

pump

the white water effluent to the new

side hill screens which will flow by gravity to the existing shower

water chest, which will be converted to a surge chest.

A new pump

will be installed on the existing shower water chest which will be

converted

to

a surge chest.

Clarified white water will be returned

to the process and excess white water from the cylinder vat will be

pumped to the stock preparation white water chest by an existing pump.

The demand for white water at the hydrapulper will be met from the scre

white water tank by

a new pump

(P-3)

as determined by the level

in the

stock preparation white water chest.

Existing wash-down pumps will be

re-piped to use white water from new pump P—3 for wash—down.

The existing No.

4 shower water pump will be relocated to supply

clarified white water from the North filter to the machine showers.

The new North

filter will remove suspended solids that might adversely

affect the operation of the machine showers.

These showers will be

replaceIwith white water type showers

to assure minimum disruption of

machine operation.

Centrifugal separators will be installed on the suction sides of

three vacuum pumps to remove the water pulled from the sheet and felt

in the machine press section.

This water will be collected in a new

seal tank and be pumped to the effluent ditch.

Since this water has

been screened by the felts, the suspended solids content should meet

the initial requirements of the state.

A Parshall flume will be installed

in the existing effluent

ditch to measure the effluent flowing to the river.

Under Phase

I,

all cooling water will be picked up in the white

water system.

cboling waters would be collected and discharged directly to the

river.

The Phase II operation

is described in the report as follows,

reference being made to flow sheets FS1, FS2 and FS3:

The mill presently discharges from 500,000 to 700,000 gallons

per day to an effluent ditch that eventually flows to the Wabash

River.

Prior to discharge, the mill effluent is collected and pumped

to

a flat screen.

This screen removes large solids and some fiber

prior to discharging to the effluent ditch.

This ditch has an effluent

weir to furnish manual flow measurements.

The intent of the proposed system as shown on FS2 and FS3 is

water and reusing this water in the process of producing roofing felt.

The system recommended for Phase

I is shown on Flowsheets 22—

l059A-FS2 and FS3-—”Recornmended Water Refuse Flowsheet”.

The system

—3—

7

—

741

---

includes the following equipment to reduce the effluent to the river

to 125,000 gallons per day and to reduce suspended solids to 1,000

pounds per day:

The mill effluent will be pumped by the existing sump pumps

to two side-hill gravity screens sized to handle 500 gpm each.

These

screens will be located in the beater room.

They will discharge

through the floor into the existing shower water chest located in the

basement below.

Screened white water from the side hill screens will be pumped

to a 30

ft. diameter by

14

ft. high straight side, clarifier tank.

The clarifier rake mechanism and mixing zone are not included but can

be installed at a later date if required.

The screened white water storage tank will be used to store the

screened white water, thus providing surge capacity for the high water

demand for the hydrapulper operation.

It will also provide sufficient

retention time for gravity separation of much of the suspended solids

in the white water.

Flocculating aids may be added to improve the set-

tleability of the suspended solids.

The tank bottom will be conical in shape to receive the possible

future rake mechanism.

The suction piping of the new white water trans-

fer pump

(P-3)

will be connected to the center of the conical bottom,

thus providing a means for removing settled solids.

The settled solids

will be returned to the process with white water.

It

is anticipated

that pumping the white water containing the solids from the cone will

prevent excessive build—up of solids in the storage tank.

Since the white water from the press section of the paper machine

will be collected and discharged to the effluent ditch,

it is antici-

pated that there will be no overflow from the storage tank.

The table below shows the design conditions and process efficiency

predicted:

DESIGN CRITERIA

FLOW RATE

Average

Maximum

Flow

(gpm)

465

1000

Suspended solids to side-hill screens

(lb/l000 gal)

6 lb

126 lb

Percent remOval for screens

0-10

90

Suspended solids to screened water storage

tank

(lb/l000

gal)

6 lb

13 lb

Predicted suspended solids

in press water to

effluent ditch

(lb/l000 gal)

.5 lb

3 lb

—4—

7

—

742

---

New pump

(P—2) will supply white water from the screened white

water storage tank

to a new North-type gravity filter that will be

installed to remove suspended solids from the paper machine shower

water,

The rotating drum of the North filter will be equipped with

a fine mesh stainless steel filter screen to filter out the suspended

solids contained in the shower water.

Three white water type shower pipes will be installed on the

paper machine.

These shower pipes will be equipped with nozzles

especially designed for white water.

A chemical feed package as shown on FS3, consisting of a 300-

gallon tank,

a metering pump,

and an agitator would be capable of

adding coagulant aids or other clarification aids if necessary.

It

also can add chemical slimicides

to control the growths that will

tend to develop in the white water system.

A chlorination system as shown on FS3, will be provided.

The

effluent during Phase I

(125,000 gpd) will require chlorination to

insure disinfection of this discharge.

The control of microorganisms

will depend on the ability of the chlorination system to feed sufficient

quantities of chlorine and to maintain a chlorine residual throughout

the white water system.

For design purposes,

a feed rate of

6 parts

per million

(ppm)

is anticipated to maintain a residual of

2 to

3 ppm.

The chlorinator is sized

to be capable of providing shock doses of

chlorine

(10

to 20 ppm)

to each chlorination point.

This shock dosing

would last for 10 to 15 minutes, probably not more frequently than once

a shift.

Four chlorine meters have been provided.

Three of these are

proposed to eject chlorine into the new supply pumps, P-i and P-3 as

well as new effluent pump P-4.

One additional chlorine meter has been

included for ejection at a slime problem location after start-up.

If

extremely tenacious slimes develop, slimicides would have to be used

to penetrate the slime envelope that protects the organisms.

However,

if chlorine is used properly and dosed frequently enough, slimic~des

will not be required.

We believe the stipulation and proposed settlement to be

a good

solution to a difficult problem and, accordingly, approve it.

We

grant a variance for one—year, subject to extension upon satisfactory

showing of progress for completion of Phase

I and Phase II.

Penalty in the amount of $8,000

is assessed for violation of

Section 12(a)

of the Environmental Protection Act and SWB-9,

as

alleged in the complaint, which we find appropriate in the circumstances.

This opinion constitutes the findings of fact and conclusions of

law of the Board.

—5—

7

—

743

---

IT IS THE ORDER of the Pollution Control Board:

1.

Stipulation entered into between The Flintkote Company and

the Environmental Protection Agency, incorporating therein

document captioned “Pollution Abatement Study for The

Flintkote Company” by Rust Engineering Company

is approved

and incorporated therein.

2.

Variance is granted to the Flintkote Company until May

io,

1974 from the provisions

of SWB—9 and the Water Regulations

of the Illinois Pollution Control Board,

as applicable,

to enable implementation of Phase I and Phase II of the

compliance program herein provided.

Permits for construc-

tion of the abatement system shall be applied for within

ten days from the date of

this order.

Phase

I shall be

completed within 13 months and 10 days from the date of this

Order and Phase II shall be completed within 27 months from

the date the permits are issued for construction of Phase

I.

Variance herein granted may be extended upon application

submitted to the Board no less than 90 days before the

expiration of any variance herein allowed, which shall be

extended only upon a demonstration that Flintkote

is

making satisfactory progress toward the completion of its

abatement program as defined herein, requiring substantial

compliance with all time tables for completion of Phase

I

and the submission of

a sound engineering program for im-

plementation of Phase

II.

3.

Corporate bond in the amount of $150,000 in form satisfacthry

to the Agency shall be posted within 35 days of the date

of this Order,

to guarantee compliance with all of the pro-

visions of this Order and the Stipulation entered into be-

tween the parties.

Upon completion of all conditions of

the bond, the Agency will execute and deliver

a bond

release to Flintkote.

4.

Flintkote,

during

construction

of

Phase

I,

shall

submit

to the Agency and the Board, periodic progress reports at

30—day intervals which shall indicate the status of all de-

sign and construction progress with respect to Phases

I and

II.

—6—

7

—

744

---

5.

Penalty in the amount of $8,000

is assessed against

the Flintkote Company for violation of Section 12(a)

of

the Environmental Protection Act and

SWB-9,

as alleged

in the complaint.

Penalty payment, by certified check

or money order payable to the State of Illinois,

shall

be made within

35 days and sent to:

Fiscal Services

Division, Illinois Environmental Protection Agency,

2200 Churchill Drive, Springfield,

Illinois 62706.

I, Christan Moffett, Clerk of the Illinois Pollution Control Board,

certify that the above Opinion and Order was adopted on the

/&“7

day of May,

1973, by a vote of

4’

to

o

—7—

7

—

745

---