E2805 v1 ENVIRONMENTAL STUDY ON NCZ (NITROGEN CHEMICALS OF ZAMBIA) KAFOE FACTORY March 1987 WRITTEN BY DR. ING. L PERES ENICHEM 20097 S. DONATO MI. SE ITALY Sincere thanks to MR J MALOWA, Works Chemist of NCZ Kafue Factory and the whole Laboratory staff without whose collaboration this study would not have been carried out. I ENVIRONMENTAL STUDY ON NCZ KAFUE FACTORY lliQE!.1i 0.00 EXECUTIVE SUMMARY ---------------------- 1 .00 INTRODUCTION --------------------------- 4 2.00 SCOPE OF THE WORK ---------------------- 6 2.01 KEY OF ABBREVIATIONS ------------ 6 3.00 SURVEY ON POLLUTION PRODUCTION FROM THE PLANTS (INTERVIEWS AND VISITS ON SITE) ---------------------------------- 7 WASTE WATER STREAMS GASEOUS STREAMS SOLID WASTES 3.01 Coal Gasification --------------- 7 3.02 Old Ammonia Plant --------------- 11 3.03 New Ammonia Plant --------------- 12 3.04 Methanol Plant ------------------ 14 3.05 Old Nitric Acid Plant 14 3.06 New Nitric Acid Plant 15 3.07 Old Ammonium Nitrate Plant------- 17 3.08 New Ammonium Nitrate Plant------- 19 3.09 Ammonium Sulphate Plant --------- 20 3.10 NPK Plant ----------------------- 21 3.11 Sulphuric Acid Plant (SAP) ------ 23 3.12 Air Separation plant ------------ 25 3.13 Water Treatment Plant ----------- 26 3.14 Boilers ------------------------- 27 3.15 Fuel Oil Storage ---------------- 27 4.00 LIQUID EFFLUENTS ----------------------- 29 II 5.00 PRESENT QUAL!TY AND QUANTITY OF THE L!QUID EFFLUENTS DISCHARGED FROM THE FACTORY (OVERALL AND PLANT BY PLANT ANALYSIS) --------------- 30 5.01 Quality ------------------------- 30 5.02 Quantity ------------------------ 30 5.03 Overall pollution --------------- 34 5.04 Reference to local/international regulations --------------------- 38 6.00 GENERAL COMMENTS ON THE RESULTS OF THE ANALYTICAL CAMPAIGN --- ------------- 40 6.01 Comparison with other Factories -------------7--------- 44 6.02 Possible effects on the environment and health ---------- 49 7.00 PRESENT EFFLUENT TREATMENTS ------------ 52 7.01 Factory Effluent Treatment ------ 52 7.02 Sulphuric Acid Plant (SAP) Effluent Treatment Facility ----- 55 7.03 Slurry Lagoons ------------------ 57 8.00 PRESENT SITUATION OF THE SEWERAGE SYSTEM --------------------------------- 59 8.01 Mixings ------------------------- 60 8.02 Blockings and Breakings --------- 61 8.03 Improper convey1ngs ------------- 62 8.04 sulphuric Acid Plant Effluents ----------------------- 63 B.05 Latest mixing ------------------- 63 9.00 LIQUID EFFLUENT CONTROL PLAN ----------- 64 9.01 Sewerage system rearrangement---- 64 9.02 Study for the completion of sewerage rearrangement ---------- 67 III 9.03 First rainy water treatment facility ------------------------ 69 9.04 Storm water draining system ------ 72 9.05 Water Intake improving interventions ------------------- 72 9.06 Purchasing of mobile oil skimmers ------------------------ 73 9.07 In-Plant treatment and interventions ------------ 73 9.08 Review of liquid effluent disposal system --------~--------- 77 9.09 Review of "B" effluent washwater system ----------------- 78 9.10 The problem of ammonia and nitrates: proposal of a ion exchange unit for Ammonia removal and Ammonium Nitrate recovery ------------------------- 78 9 • 11 Review of Sulphuric Acid Plant effluent treatment facilities ---- 84 9.12 Liquid effluents monitoring ------ 87 9.13 Organization and training needs --------------------------- 89 9.14 Lay-out ------------------------- 90 10.00 SUMMARY OF RECOMMENDATIONS WITH COST AND TIME ESTIMATES FOR THE LIQUID CONTROL PLAN --------------------------- 92 11 ~ 00 AIR POLLUTION -------------------------- 98 11.01 Necessity of dispersion maps ----- 98 11.02 The problem of air intake location ------------------------- 98 11.03 Possible effects on the environment and health 99 12.00 OUTLINES ON INDUSTRIAL HYGIENE 100 13 .00 SOLID WASTES ------------------ 101 13.01 Other Solid Wastes -------- 102 IV 14.00 PRESENT QUALITY AND QU~~TITY OF THE WASTES CONVEYED TO THE LAGOONS ---------- 103 14.01 Calcine Lagoon -------------------. 103 14.02 Slurry lagoon and coal ash deposit -------------------------- 104 14.03 Possible effects on the environment ---------------------- 104 14.04 Adequacy of disposal ponds ------- 105 14.05 Leachate tests ------------------- 106 14.06 Seepages pollution risks' of the water table ------------------ 108 14.07 Possible utilization of solid wastes --------------------- 111 14.08 Solid wastes control plan -------- 111 15.00 SUMMARY OF RECOMMENDATIONS WITH COST ~~D TIME ESTIMATES FOR THE SOLID WASTES CONTROL PLAN -------------------- 113 BIBLIOGRAPHY ---------------------------- 115 0.0 EXECUTIVE SUMMARY The execution on the field of the environmental study relevant to NCZ Kafue Factory revealed a situation really heavier than what was expected. The most remarkable aspects, as regards the liguid effluents, are: 1 High contents of ammonium, free ammonia, nitrates and suspended solids as major pollutants in the waste waters for a total amount of about 10 tons/day ammonia in the sewers (almost 10% of the production at the time of analytical campaign) and 8 tons/day of nitrates (about 7% of ammonium nitrate production) and 56 tons/day of suspended solids (mainly coal ash and dust and calcine by-product from pyrite roasting not conveyed to the lagoon). 2 A very chaotic situation of'sewers system, with many abusive connections between industrial and storm water trenches. 3 A remarkable dispersion of the physical points of discharge practically distributing polluted streams along all the perimeter of the factory. 4 The beginning of visible pollution even in Kafue River (whose northern bank by the confluence with Kasenje River is full of coal deposits, while a chemical analysis on the coastal waters reveals high ammonia and nitrates); considerable presence of algae was noticed even in the middle of the river. 5 Operation of the two lagoons (for calcine by-product of pyrite roasting from Sulphuric Acid Plant (SAP) and for coal ash) not as closed systems of ultimate disposal for solid materials, but as open basins continuously discharging liquid overflows into the open land. All these aspects determine a situation highly not complying with national laws (Statutory Instrument No 161/8th November 1985 of Government of Zambia as regards Trade Liquid Effluents) and with every international rules. 2 To face this situation a control plan on liquid wastes has been elaborated. However the environmental control must begin with proper maintenance and operation of each single part of the plants. Sensitiveness towards the environmental problems must be awakened in all the personnel, starting from the management, by means of tailored training courses and written communications. Moreover a responsible person for environmental protection must be urgently appointed, following the model of developed countries factories, who acts as landmark both as regards the technical aspects of the desirable realization of the proposed control plan and the legal aspects relevant to the inevitable needs of dealing with public authorities about environmental matter. The rough investment cost estimates (chapter 10.00) amount to US $3,008,000 of which only 496,000 liable to local supply (civil works, labour, electrical cable and some steel work fabrication), while the remainin'g 2,512,000 are machineries and materials to be imported. The main objectives obtainable by means of this interventions are: - To fully comply with the tables of standards indicated in the above mentioned Zambian law, so discharging less than 354.3mg/1 of nitrates (as N03), less than 60.7mg/l of Ammonia and Ammonium (as NH3) to the public sewer and less than 221.4mg/l of nitrates, less than 12.1mg/l of total ammonium and less than 50mg/1 of total suspended solids as regards any other effluent. - To recover most of the above mentioned conspicuous losses of production so allowing expected savings of about 12 equivalent tons of ammonia per day for a value of US $900,000 per year (under the hypotheses of a value of 2500 Kwacha/ton NH3, an exchange rate of 10 Kwacha/US $ and 300 days of operation per year) versus an increase of operating costs only relevant to electriCity, chemicals produced in the factory (such as nitric acid) or already present (such as slaked lime), small quantities of polyelectrolite and some periodic make-up and substitution of ion exchange resins. Of courSe the proposed control plan cannot be a profitable plant, but, as it happens allover the world for 3 any ecological intervention, it must be regarded as an additional cost to the business of making fertilizers (just the same as utilities, depreciation, or other associated process costs) in order to get the priceless benefit that even in Zambia is the Environment Protection. As regards pollution caused by solid wastes, possible seepages and pollution risks of the water table have been investigated by means of some wells dug nearby the calcine lagoon site; samples from the ground water were collected at differenct depths, none of them showing contamination by the toxic metals disposed of in the lagoon. Some leachate tests (EP toxicity suggested by Environmental Protection Agency) were carried out as well on samples of the solidified materials abandoned in the lagoons: these latter indicate some reasons of worrying about the possibility of toxic substances (Selenium, Lead and Cadmium) release from these heaps. Consequently cautions on the operation of the lagoons (not to overfill above upper limit) and fencing of the whole area are suggested as recommendations. As regards the future needs of the factory for the next fifteen years two new lagoons are required (260,OOOm2 for calcine and 215,OOOm2 for slurry and coal ash to be constructed after five years, unless a possible utilization of solid wastes is found. As to this latter point a feasibility study and marketing research are recommended to exploit the iron contents of pyrite cinders (about 50% for a total of 3MT/hr) in producing sponge iron to be sold abroad to some steel industry. As regards slurry and coal ash the heat value looks too poor to be exploited. Moreover a fencing for the overall lagoons areas and a guard post are recommended to avoid vandalism and dangers to people who may come into contact with toxic materials due to ignorance. The amount for the new lagoons and fencing intervention is about US $250,000. 4 1.00 INTRODUCTION The present study was carried out from July 1986 to March 1987 in order to comply with EA obligations involved in the contract. Therefore the terms of reference for the study are the same as in the contract, while the inner meaning according to which it was carried out was in accordance with the guidelines of the World Bank (staff appraisal report of June 19, 1985) and following direct discussions with the World Bank specialist from 9th to 11th September 1986. For convenience sake herewith are the guidelines of the World Bank reported integrally: 1.01 ABSTRACT FROM THE WORLD BANK REPORT ~ 5658 ZA G. Envionment and Safety Aspect.s 5.32 Presently, the NCZ FertiJ.izer complex has a severe pollution problem caused by nitrogen oxides (NOX) gaseous emissions from the NCZ I and NCZ II nitric acid plants. The current level (up to 2,200 ppm) of such emissions 1s 6-10 times the maximum levels presently permitted in most industrialized countries. Such high levels are partly due to the higher levels permitted when these plants were designed and partly due to the deterioration of the facilities. This high level of emissions affects adversely the environment and the rains generated fron NOX gases corrode the plant facilities. Under the Project, both NCZ I and NCZ II plants would be equipped with NOX abatement units to reduce contaminant in stack gases to a maximum of 500ppm, the present international standard (paras 5.18 and 5.19). 5.33 Solid waste and part of the liqUid effluents from the plant are sent to two disposal ponds. The remaining liquid effluents are neutralized in a water treatment plant before discharging into the Kafue Township sewage system. Under the Project, NCZ will rehabilitate the water treatment plant, install a closed loop system at the AN unit of NCZ II plant, and take other necessary measures to prevent pollution. After Project implementation, the liquid effluents will meet international standards. Under the environmental study to be carried out by 5 OMP, by September 1986, all aspects related to solid waste and liquid effluent disposal will be reviewed in detail and recommended measures will be implemented. In addition, the proposed safety study will recommend steps to be taken to deal with any potential safety hazards at NCZ (para 5.20). Assurances will be sought at negotiations that NCZ will rehabilitate and operate its facilities under environmental and safety standards satisfactory to IDA. 2.00 SCOPE OF WORK According to the terms of reference the scope of the study was mainly restricted to liquid effluents and solid wastes production. Air pollution and industrial hygiene probles were only outlined. However, some attention was paid to the overall ecological problem of the whole area Kafue-Lusaka, stated that the drinking water intakes for these towns are situation on the Kafue River downstream NCZ factory. 2.01 KEY OF ABBREVIATIONS SAP = Sulphuric Acid Plant tId = MT/DAY = Metric Tons per day t/y = MT/Y = Metric TOns per Year m3 = M3 = Cubic Meter Cubic Meter per Hour m3/hr = M3/hr = M3!DAY = Cubic Metres per Day 7 3.00 SURVEY ON POLLUTION PRODUCTION FROM THE PLANTS In order to understand better the way of pollution generation from the single plants some interviews with the plant chiefs were carried out, on the basis of the questions contained in the information questionnaire, whose text is reported in Annex 1. The contents of questionnaires are resumed in the present chapter. The plants for which the investigations were carried out are listed in Table 1. The main purpose of this part of the study was to clarify from which apparatus or from which operations the liquid effluents, gaseous streams and solid wastes were originating from. The data were mainly drawn by the chiefs of the plants from the process books and material balance sheets. As a general consideration it appears evident the contrast between the collected statements from the interviews and the analytical results from the proper campaign (see chapter 5.00). From the declared discharges it would result an extremely clean and dry factory, with very few systematic process streams, some leakages and almost clean waters to the sewer system. On the contrary from the analytical campaign it results a conspicuous mass of liquid discharges, moreover distributed in many points, especially of the storm water sewer, with large pollutant contents, particularly suspended solids, ammonia and nitrates (for an amount up to almost 10% ammonia production). 3.01 Coal Gasification (including coal handling and preparation) The plant consists of 4 units (1 stand-by) of about 7000kg/h coal capacity each and produces raw gas and steam as by-product. The employed raw materials, apart from coal, are unslaked lime (supplied by Ndola Lime Company), for the purpose of reducing the melting point of the ash and oxygen from the air separation unit of the factory. The employed utilities are demineralized water as feed for the numerous waste heat boilers, cooling water, kerosene and diesel Oil, nitrogen for sealing and purging coal dust transportation. As regards chemicals, sodium phosphate and sodium sulphite are employed for the boilers. As regards pollution the following was declared during the interviews. TABLr, 1 LIST Of' PLANT_S AT PRES!,:I'l'1' UNDER OPERATION REI!AllIL 1 PROCESS I DESIGN ACTUAL COMMISSIONING TAT ION PRO DOC T ION KNOW-BOW CONSTRUCTOR CAPACI'l'Y CAPACITY YEAR YEAR Coal Gasification Krupp-Koppers Kobe Steel 320MT/d) 1970 1986 (Line 0) of Coal) NeZ Line A , 306 ) Coal Gasification Expansion Ammonia Plant (309) Krupp-Koppers UBE-Japan Klockner (Line B.C, Kobe Steel 320~lT/d) ofCcal) 95MT/d 84MT/d , 1981 1970 1986 H2S removal: Stadford Process Ammonia Plant Casale (Nil] Klockner 217MT/d 128MT/d 1981 1988 Exp •• (11309, Krupp-Koppers (CO Conversion) I,j nde (Rectisol CD Methanol) Ni tric Acid (401) Montecatlni Kobe Steel 172MT/d 172MT/d 1970 1986 Nitric Acid Exp. Grande Klockner 212MT/d 1 95MT/ d 1981 1988 Paroisse Ammonium Nitrate Sumitomo Kobe Steel 226M'r/d 205MT/d 1970 1986 (501 ) Ammonium Nitrate Kestener Klockner 242MT/d 242MT/d 1981 1988 Exp. (A501) Ammonium Sulphate Kestener Klockner 151M'r/d 1 51 WI'IeI 1 9 El1 1988 (AS03) NPK Plant (A5041 Cdf Chemie Klockner 142000Mt/y 100000MT/y 1981 1988 Sulphuric Acid Plant Nissan Chemi Kobe Steel 60000MT/y 22000MT/y 198] cals (Shanki Japan for roasting section) 9 3.01.1 Waste-water streams 20M3/hr slurry from the wet scrubbers of the old coal handling plant (301) continuously flowing to an ash pit and then to storm water, containing coal dust) 2 Continuous leakages from pumps and pipes both to storm water sewer and to industrial water sewer) no identifiable as to quantity) 3 Washings of electrostatic precipitators at shutdowns (supposed once a year) to storm wateri 4 Effluents from wash towers for cleaning the gas, continuous 120M3/h per unit flow to 4 settling ponds A321 in which sedimentation occurs. Clear Water comes ba'ck to gasification and slurry is pumped out to dedicated lagoon (for further details of this facility see the proper chapter 7.00 on the present effluent treatment plants). 3.01.2 Gaseous streams Raw gas flare; height from the ground about 40 mtrs, it occurs at start-ups for about 45 minutes without burning, contains raw gas. 2 Nitrogen from 301 B/C electro-static precipitators chimney (height about 45m), apart from N2 that is the gas carrier, contains C02 and coal dust; 3.01.3 Solid Wastes 1 Ash plus slag from gasifier chambers; continuous production of 0.5 MT/hr per unit is collected by trailers and moved to the lagoon (or some dumping areas around Kafue at the request of the Township Council). This contains unburnt carbon, Silica, calcium, aluminium and as ppm, copper, selenium, zinc, lead and arsenicj 2 When pumps break down the slurry from A321 is taken by means of crane buckets and dumped nearby; water evaporates and the area remains full of coal dust. 10 3.01.4 Visit on Site During the visit on site it was noticed that the water consumption was much more than expected (one reasons was the water leakage from the shafts of ash extractor G1206 which necessitated the use of a lot of external water, taken from firewater, as seal water of the shaft). Besides, most of the waste water which was supposed to go to settling ponds was flowing to storm water due to choking and breakdowns of the industrial sewer. Even the "e" effluent from the other plants, which was only supposed to cross the area of the plant, was diverted to storm water. Recently the original path was re-established. For this purpose see the proper chapter 8.00 on the situation of the sewerage systems. Of course, the water flowing in all the open trenches loads coal dust and coal ash, while passing through the coal prepara.tion and coal gasification units. : i 3.02 QlQ Ammonia Plant (303) This plant produces an average of 84 t/day of Anhydrous Ammonia (versus a design capacity of 95 t/daY)1 raw materials are raw gas from gasification and nitrogen from air separation plant. Many chemicals are involved: phosphate for the boiler, potassium carbonate, MEA and caustic soda for C02 removal, antraquinone disulphonic acid, sodium carbonate and sodium vanadate for H2S removal: as utilities demineralized and cooling water, steam and diesel fuel are employed. 3.02.1 Waste-water streams 1 2M3/hr of demineralized water utilized for sealing of carbonate and caustic pumps continuously flow to the industrial sewer at room temperature without loss of solution; 2 Once a day for cleaning of H~S removal filter press 1m3 of water containing sulphur and other chemicals goes for one hours to the industrial sewer; 3 3M3/day of water at 45 Deg.C containing traces of K2C03 flow to the industrial sewer during the backwashing of K2C03 side stream filters which occur once per shift for 45 minutes; 4 0,2M3 of caustic tower spent liquor go to industrial sewer once a shift for 30 minutes, temperature is 40 Deg.C and composition 8 : 10% Na2C03 and 0,5% NaOH; 5 150 It/hr of raw gas compressors condensate drainings continuously to industrial sewer containing only water (because there are installed oil separators). As a general consideration the plant has no emergency discharges into the sewers due to the presence of storage facilities to handle. 3.02.2 Gaseous Streams 1 Continuous flowing to atmosphere of H2S traces at 20 mtrs height from slurry tank V206. ; 2 8000NM3/hr from K2C03 regenerator vent containing C02; 3 The same from MEA regenerator; 4 600NM3/hr of purging gas from NH3 synthesis containing 1,5% NH3, at present recovered as burning gas in the coal fired boiler. 3.02.3 Solid waste production 1 Sulphur cake from H2S removal section sent to sulphuric acid plant; 2 Exhaust catalyst for NH3 synthesis, consisting of iron oxide once in 3 years is spread in the plant; 3 Exhaust CO conversion catalyst consisting of porous iron oxide is forwarded every three years to lagoon; 4 Old rashig rings are cracked and spread in the not paved areas of the plant or in fields for roads. 3.02.4 Visit QE site The storage facilities are in common with new ammonia plant and located in old nitric acid area. They consist of two spheres, one 800m3 volume and the other 1715m3 (respectively SOOt and 1000t ammonia capacity). The operating refrigeration system is one for both the spheres and if one of the two compressors is out of order is not enough to maintain the low required storage temperatures, so that some NH3 is vented to atmosphere and, occasionally, even to the sewer; this amount can be up to 500 kg/hr. 3.03 New Ammonia Plant (A309) The plant produces on average 128MT/day of anhydrous ammonia (versus a design capacity of 217MT/day: this is because of some bottlenecks and lack of apparatuses in the plant), moreover the plant produces 6MT/day of aqueous ammonia (25% concentration). The plant requires 5M3/day of demineralized water for start up and making NH3 solution, cooling water and chemicals for its conditioning, steam and sodium or potassium chromate for the start up of A303 plant (H2S, C02 removal). 3.03.1 Waste-water streams 1 Process condensate from CO conversion consisting in continuously about 6MT/hr at 45 Deg.C at maximum capacity (so supposed 2,5M3/hr at actual capacity) flowing to industrial "c" effluent; it presents alkaline pH (about 2500ppm total ammonia) and 250 free ammonia. 2 20M3/hr cyanide rich washwater going to wash water cooling tower and then recycled to gasification together with clear water from settling ponds; 3 Cooling water from raw gas compressors continuously flowing through 1" pressure pipe (say about 2,5M3/hr) to the industrial sewer, contains CO, C02, S, CN; 4 Seal water for raw gas holder continuously flowing through 2.5" pipe (say about 20M3/hr) to the industrial "c" effluent sewer; the type of water employed is cooling water. 5 Cleaning of condensers which occurs once in three months and contains ammonia and scalings. 3.03.2 Gaseous Streams 1 1900 Nm3/hr H2S fraction from C1202 separator of A303 plant containing 3% of H2S and COS. 2 380Nm3/hr of flash gas from C02 wash containing 62% C02 and 37% H2, N2, co; 3 Ammonia synthesis off-gas, consisting in 2 KMOLS/hr at 37 Deg.C containing-CO, C02, H2, CH4, N2; 4 Ammonia synthesis off-gas, about 20 KMOLS/hr 70% H2 and 30% N2; 5 2770Nm3/hr of tail gas from T1201 liquid nitrogen wash (A308) containing CO, N2, H2, CH4 and other gases go to a dedicated holder; if this latter is full flow to atmosphere) 6 18400Nm3/hr C02 vent to atmosphere. 3.03.3 Solid Waste Production 1 Exhaust catalyst spread on the floor once in two years; 2 Packing materials for saturators: the same as above. '4 3.03.4 Visit En site This plant presents one of the few process effluents of the factory: the process condensate from CO conversion containing 2500ppm of ammonia (which is added for corrosion reasons) is responsible, together with the leakages from mechanical seals of refrigerating pumps, for one of the main industrial hygiene problems of the factory (NH3 concentration measured by means of Draeger pumps along the main road up to 150ppmJ. Some intervention is necessary for this point. 3.04 Methanol Plant It produces methanol at 91% (design capacity 5 t/day) from synthesis gas. It utilizes cooling water and stearn as utilities. Practically daily production is 2,5t but only when the storage tank is not full. 3.04.1 Waste-water streams Nothing (some discharges containing methanol can be found from Rectisol, which is the plant utilizing methanol, especially from the cleaning of pump filtersl. 3.04.2 Gaseous Streams 46Nm3/hr off-gas from methanol receiver at 37 Deg.C containing H2, CO, CH4, N2, C02 (from Rectisol there is a loss of 1,2MT/day of CH30H from T1206 tower tail gases to atmosphere. 3.04.3 Solid Waste Production Exhaust catalyst once a year. 3.05 Old Nitric Acid Plant (Low pressure) (401) This plant produces a maximum quantity of 172,5MT/day (as 100%) of nitric acid at 55.5% concentration starting from 48,3MT/day ammonia; it employs 945M3/hr cooling water, small quantities of sodium sulphite, sodium phosphate and caustic soda as chemicals. The waste heat boiler utilizes about 11MT/hr of boiler water feed producing about 10MT/hr steam at 14Kg/cm2. The process utilizes about 3MT/hr of demineralized water for the absorption of nitrogen dioxide to produce nitric acid. 3.05.1 Waste-water streams 1 0.5M3 weak nitric acid during start ups to the industrial sewer; 2 Boiler blow-down containing sodium sulphite and phosphate and caustic soda; about O,5M3! hr; 3 Sporadic discharge into the sewer of some 5 Its of pure ammonia when the ammonia pumps from the storage spheres (which are located at Nitric acid area) lose priming; 4 Discharges from sampling lines; 5 Eventual leakages from mechanical seals of the three acid pumps or some we1dings. 3.05.2 Gaseous streams 1 NOX tail gas: average 500 : 950ppm, maximum 2200ppm; 2 Ammonia during each start up of unit: average twice a month, duration one hour. 3.05.3 Solid waste production Nil 3.06 New Nitric Acid Plant (medium pressure) A401 It produces 212Mt!day nitric acid as 100% (310MT!day as 55% concentration). It employs about 15MT!hr demineralized water (llMT!hr for boiler feed water and 4 for the process), 1800 M3/hr cooling water, 4 bar steam for ammonia evaporation and 14 bar steam for start up; besides the plant utilizes the usual chemicals (sodium sulphite and phosphate, caustic soda) for the feed water treatment to the waste heat boiler. 3.06.1 Waste-water streams 1 O,5M3 draining of weak nitric acid (40%) during start up for fifteen minutes to industrial water; 2 Leakages from some weldings, especially at elbows, of the piping; 3 Discharges from sampling lines: the above streams flow to a pit where sometimes lime is thrown for neutralization and then the effluent is pumped to industrial sewer; 16 4 Continuous boiler blowdown; 5 Emptying of ammonia evaporators for two hours to industrial sewer for maintenance of major shutdowns; 6 Continuous 2Mt/hr steam condensate from evaporators and heaters to industrial sewer; 7 6MT/hr steam condensate from superheaters to storm water; 8 oil spillage from compressors oil seals, oil filters and coolers cleaning; about 440 ltrs/ month to storm water, 9 Emptying of some heat exchangers at shutdowns, containing weak acid. 3.06.2 Gaseous streams 1 36000Kg/hr NOX tail gas continuously flow to atmosphere, containing 95% nitrogen and 7500 average of NO + N02 (maximum 9800) at 72 Deg.C; 2 Ammonia preheater venting only during start up total 0,2 ton for 15 minutes at 92 Deg.C containing 100% NH3; 3 Leakages from burner flanges containing mainly NH3 and air. 3.06.3 Solid waste production Nil, because the catalyst is sent to UK for processing. 3.06.4 Visit on Site The pump located in the above mentioned pit is not working even if the pit level is always the same. May be because of evaporation and seepages. ~l 7 3.07 Old Ammonium Nitrate Plant (501) This plant produces 20SMT/day of ammonium nitrate (porous and dense explosive and dense fertilizer) employing 45MT!day NH3 and 16SMT/ day nitric acid (as 100% conc.). It utilizes 2400M3/day of cooling water for surface condensers of ammonium nitrate vapours, of which about Sm3/hr for pumps sealing do not recycle to the cooling tower but go to industrial effluent; moreover, it employs 216MT!day steam for concentration solution and as chemicals a coating agent called Nuflo, based on Mg, CO, and Si02. 3.07.1 waste-water streams 1 Continuous Sm3!hr cooling water for sealing pumps containing high concentration of ammonium nitrate and free ammonia to industrial sewer; 2 0,5m3 washing of blower casings for five minutes five times a day at 85 Deg.C containing ammonium nitrate dust to industrial sewer; 3 1,4m3/hr of first concentration condensate from the seal pot of the surface condenser V06 at 40 Deg.C containing 1,5 - 2% ammonium nitrate plus free ammonia to industrial sewer; 4 10m3/hr of steam condensate from various services, polluted in the case of leakages from jacketed pipes, to industrial sewer; 5 Salt section washings for cleaning the plant twice in a month containing some hundreds of ammonium nitrate kgs and Nuflo to industrial sewer; 6 Bucket elevators washings once in two weeks containing weak ammonium nitrate solution to industrial sewer; 7 Oil spillage from pumps oil seals and grease washings from various apparatus (drier, coolers, conveyors and bucket elevators); once in a month to industrial sewer; 8 Draining of NH3 evaporator a-t main shutdowns (average three in a year); about 200Kg NH3 to industrial sewer. 18 3.07.2 Gaseous Streams 1 60Kg/hr reactor off-gas continuously flowing to atmosphere containing 74% ammonium nitrate vapours at 60 Deg.C that sublime and fall down as dust; 2 13Kg/hr ammonium nitrate dust from the (porous) prilling tower at 45 Deg.C, 3 41Kg/hr of ammonium nitrate dust from the (dense) prilling tower at 75 Deg.C; 4 Continuous emission of NH3 and ammonium nitrate vapours at 76 Deg.C from top hole of the final concentrated solution tank V32 (receiving from falling film evaporator El0) • 3.07.3 Solid Waste Production 1 Ammonium nitrate scalings and depositions removed from the floors and the platforms once in a month; 2 Ammonium nitrate dust removed from the floors by washing once in a month. 3.07.4 Visit on site The plant 'is provided with a recovery system consisting of the tank V25 where the sampling catches from the reactor and the washings from prilling towers are connected, and of the pump Pl1 for recovery to the reactor. Even for emergency reasons all the necessary drainings are collected in the recovery tank V2S. However, the losses of ammonium nitrate dust from the various handling apparatus and from the prilling tower look fairly remarkable (it is so fine as to permeate the concrete of pavements and roads) to account for the considerable contents of ammonia and nitrates in the sewer (both industrial and storm water), Some sampling points (V04 ammonium nitrate 80% solution and nitric acid line to the reactor) are not connected to the recovery system and it is recommended to realize the connection. ,Q 3.08 ~ Ammonium Nitrate Plant (A501) The plant is able to produce 242MT/day of ammonium nitrate of which 165MT/day is granulated fertilizer and 77MT/day of 95% aqueous solution supplied to NPK plant. The employed utilities are 9600m3/day of cooling water and 67MT/day of steam. As regards the chemicals Nuflo-10 1s utilized as coating agent. 3.08.1 waste-water streams 5,2m3/hr condensates from V1206 collection tank of multiple effect concentrator at 66 Deg.C containing small NH3 and A.N; 2 O,4m3/hr of weak ammonium nitrate (concentration 5%) solution with cooling water from tank V120S to industrial sewer; 3 0,lm3/hr of cooling water from V1217 seal pot. 4 2,5MT/hr of steam condensate at 76 Deg.C from jackets of pumps and other apparatus and from steam-traced lines to storm water trench; S O,2MT/hr of steam condensate from heating coils of V1220 and V1202 to industrial sewer; 6 SMT/hr of clean cooling water from N1201 seal pot to industrial sewer; 72m3 of 99% ammonium nitrate solution to industrial sewer from V1210, V1211 in case of shutdown of the plant (average once a month); 8 Ammonia gas to atmosphere and liquid ammonia to the industrial sewer in Case of depressurising the ammonia system for maintenance jobs; 9 Washing of prllling tower (T1201) grill: 1MT/day of ammonium nitrate going to industrial sewer once a day due to lack of recovery tank. 3.08.2 Gaseous Streams 1 K120S blower off-gas at 3S Deg.C containing ammonium nitrate dusts, consisting of continuous 9,26m3/sec (at 60 Deg.C and 445mm H20); 20 2 Exhaust gas from K1203 A/B ventilators of the prilling tower at 75 Deg.C containing ammonium nitrate dusts; consisting of continuous 16 : 21m3/sec (at 50 Oeg.C and 50 : 28mm H20); 3 K1201 off gas at 45 Oeg.C consisting of 0.5m3/hr (at 80 Deg.C and 150mm H20) containing ammonium nitrate dusts) 4 K1202 off gas at 36 Oeg.C consisting of continuous 0,5m3/hr (at 80 Oeg.C and 150mm H20) containing ammonium nitrate dusts. 3.08.3 Solid Wastes Oversize material blocking Y1203 outlet chutes in dehydration section. It may happen once a day and consists of about lMT/day of ammonium nitrate sometimes recovered in bags and reclaimed to V25 or sent to NPK. 3.08.4 Visit £ll site The visit on site has pOinted out the absence, contrary to the old plant, of any recovery system in the plant. However, a new recovery system, based on technical department design, is at present under fabrication. The discharges that are intended to be collected in an under ground tank of 47m3/AISI lined, and pumped back to the system (V1202 feed tank for the falling film evaporators) are the grill washings, spillages from dehydration section, solutions from V1210 and V1211 and V1205 weak solution. 3.09 Ammonium Sulphate Plant (A503) The plant is able to produce a maximum quantity of 6,5MT/hr of crystalized ammonium sulphate, using 96% sulphuric acid, gaseous ammonia, which arrives in liquid form and is evaporated in the plant, small quantities of 25% ammonium hydroxide and 75% phosphoric acid solution (this latter for crystal growth). The employed utilities are: demineralized water (for initially filling up the reactor to get H2S04 concentration down to 5gr/lt and also for make ups), 200m3/hr cooling water for condensing process vapours from the reactor and 2MT/hr steam for the heaters (the condensate is recovered). Waste-water streams 1 Process condensate overflow from the reservoir tank V1204 at 90 Deg.C for few minutes everyday, especially at start ups, containing ammonia and ammonium sUlphate pumped to industrial sewer (but flowing to storm water sewer if the pump is broken). 2 Centrifuges and floors washings for few minutes every shift by means of 3/4" hose pipe, containing ammonium sulphate at room temperature flowing to industrial sewer. 3 Sometimes acid leakages from reactor and pipes. 4 Mother liquor tank (V1202) overflow (very rare) • Gaseous streams 1 Continuous emission of reactor va pours to the a~mosphere at 94 Deg.C (containing ammonia). Solid wastes 1 Losses from the conveyor belt to the ground are mostly collected in bags and go to NPK plant; after washing the floors these losses may go both to industrial and storm water sewer. 3.10 ~ Plant (A504) The plant is designed to produce 142,000MT/year of six compound fertilizers, namely A, C, V, X, D, R. At present the only fertilizers requested by the farmers are X, D and R. Actual capacity is 100,OOOMT/year. The employed raw materials are mainly liquid ammonium and solid ammonium sulphate; besides liquid sulphuric acid and small quantity (up to 300Kg/hr) of liquid anhydrous ammonia, which is evaporated in the plant itself by means of joulethomson effect; all these latters produced by NCZ itself. Moreover di-ammonium phosphate, triple super phosphate, potassium sulphate and potassium chloride imported from various countries. 22 As utilities about 7SMT/hr of fire water (new raw water network is under study) are employed for the scrubbers N1201 and N1202 A/B positioned down stream of the drier and granulator; moreover 2,2 MT/hr maximum of low pressure steam and 6MT/hr medium pressure, with condensates recovery in area 1. As fuels 4S0MT/hr of synthesis gas are burnt and mixed with air in order to dry the product in 01201. 3.10.1 Waste-water streams 1 OVerflow from V1211 (resevoir tank for venting scrubbers) when the pumps are under maintenance containing S% total solids at 30 Oeg.C going to industrial sewer. 2 Washings of floors by means of hose pipes for annual shutdown: Containing NPK salts going to the industrial sewer for three days without interruption. 3 Seal water for the pumps: distributed by means of 6" pipe and going to industrial sewer. 4 Emergency emptying and cleaning of scrubbing section: at least once a month for mechanical problems. 3.10.2 Gaseous Streams 1 Dusts from the venturi scrubbers N1202 A/B. 2 Continuous dusts from the stack C1210 for the scrubbing N1201 and blower K1205. 3 Continuous dusts from the stack C1211 in service to screens, bucket elevators, conveyor belts and coating drum. 4 Dusts from stack C1212 for the cooler J1201 about ten times a month, if some problem arises in ammonia or gasification plant. S From C1247 stack when the plant stops the combustible gases go to the atmosphere automatically. 6 Dusts of coating agent, conSisting of clay and ammines, from V1207 (while transferring). 23 3.10.3 Solid wastes Materials swept everyday and for the annual shutdown are recovered in off specification hopper V1205 and recycled. 2 Spillages of raw materials from conveyor belts: are reclaimed into the bags. 3.11 Sulphuric Acid Plant (S.A.P) The plant is designed to produce 60,000MT/year of H2S04 at 98.5% concentration, but practically the actual production is 22,000MT/year due to lack of ammonia to be used in the production of Ammonium Sulphate. The raw materials are 176MT/ day (design quantity) of pyrite mineral from Nampundwe Mine and sulphur cake from area 2 (gasification). As regards utilities S.A.P. is provided with its own pumping station (capacity 160m3/h) of raw water from Kafue River and its own water treatment plant and cooling water tower; practically the necessary quantities are less than 100m3/hr of raw water and 20m3/hr of cooling water but in order to avoid choking of the pumps due to the growth of sea weed the pumping station is operated at maximum rate and a continuous overflow of water is flowing to new Kasenje River through the point of discharge SW3. As chemicals for water treatment there are employed 400Kg/week of alum, 400Kg/week of caustic soda, 2Kg/week of aid coagulant and 5MT/day lime for the neutralization in the waste water treatment (100 bags per shift). As fuels 20,000 Itrs of diesel oil are utilized every start up of roaster and converter. 3.11.1 Waste-water streams Most of the discharges go to the autonomous S.A.P. waste-water treatment plant, which is briefly described below and in the proper paragraph 7.02. Back washing of F401 A/B/C/D sand filters for cooling water: 55m3 for 3 minutes every shift at room temperature to the anti-acid painted basin V1001. 24 2 Spillages from sampling points and leakages from piping connected to pumps P201, P202, P203, and 400 section (acidic) to Vl001. 3 Washings of V201 settler, T201 cooling tower, T202 washing tower (for which design figure is 8,7m3/hr) even to Vl001. 4 Washings of the "mist cottrell" electrostatic precipitators; very small for 2 minutes each day to V1001. 5 Continuous sludge from V201; about 8m3/hr at 80 Deg.C containing diluted sulphuric acid to the basin V901 (feeding for the neutrali2ation tanks V902, V903). 6 6m3/hr of continuous spillage from packed tower T202 at 65 Deg.C containing diluted sulphuric acid conveyed to V901. 7 Continuous calcine mixer IV108) effluent. It is surely the most important effluent of the plant (and perhaps of the factory), consisting of 76 : 90m3/hr (capacity of pumps Pl03 A/B) of sludge at 40 Deg.C containing mainly iron oxide Fe203 going now to the ageing tank V904 (V907 as design) and from there pumped by means of P902 to the dedicated lagoon. 8 Overflow of pyrite heap pit in case of rain: directly to new Kasenje River, in consideration of lack of the pump Pl003 which has been moved to Vl001. 9 Overflow of raw water in case of water treatment shutdown: to storm water (point SW3). 10 Drainings from T203, T204, V201 in case of bad operations; the full contents of vessels to V1001 without pumping out. 11 Drainings from compressors, containing oil spillages, to storm water. 3.11.2 Gaseous streams Continuous about 20,OOONm3/hr of SOX stack emissions at 80 Deg.C containing less than 550ppm of S02 plus S03 (1,7ppm). 25 3.11.3 Solid wastes The calcine by-product of pyrite roasting is pumped out of the plant in liquid form but in the lagoon water is progressively evaporating and there remains solid waste perfectly able to be trampled on. 3.11.4 Visit 2n site The areas around waste water treatment facility are full of calcine losses, so that it is hard to walk around. Most of raw water drawn goes overflooding, due to the fact that the pumps must work always at maximum capacity, otherwise choking occurs of too much living plants in the water. 3.12 Air Separation Plant It consists of two units; the old one employs 22,OOONm3/hr of air to produce 2,800Nm3/hr of nitrogen and 3,850Nm3/hr of oxygen (the rest being impure nitrogen), the new one utilizes 52,OOONm3/hr of air to produce 9,OOONm3/hr of nitrogen, 7,800Nm3/hr of oxygen and the remainder, most part, is impure nitrogen. For the coolers and air scrubbing the old plant requires 1000m3/hr of cooling water while the new 3000m3/hr, all recirculated on own cooling tower. 3.12.1 Waste-water Streams Only 30m3/day of cooling water for sealing oxygen, raw gas and impure nitrogen holders: coming from the not conditioned cooling tower located near the water treatment and flowing to storm water sewer. 3.12.2 Gaseous Streams Impure nitrogen vented to the atmosphere when coal handling or gasification are shutdown (air separation plant is not stopped because start up is a big problem). 3.12.3 Solid wastes None 26 3.13 Water Treatment Plant The water treatment plant for all the areas except SAP has a practical capacity of 400m3/hr. It consists of two precipitators 501 and A501 (the new one is called npretreator n ) followed by the settling basin S601-1 from where water is pumped by means of 601 P03 A/B to the valveless filters. The chemicals employed in the precipitator are alum, lime and an aid coagulant called Himoloc. As demineralization plant there are an old NCZ unit consisting of one cationic and one anionic exchanger at present not working; therefore another unit, built up by Kobe Steel, consisting of cationic, degasifier and anionic sections for a capacity of 38m3/hr is running together with the newer Klockner unit, also consisting of cationic, degasifier and anionic sections for a capacity of 48m3/hr. Downstream of the treatment there are two reservoirs for demineralized water of capacity 140m3 and 210m3. 3.13.1 Waste-water Streams 1 Sludge from precipitator: it is intermittent, consisting of about 2m3 every 8 hours for half a minute containing 2% suspended solids and flowing to the same neutralization tank of the following point. 2 Eluates from resins regeneration flow to a pit of about 100m3 volume where partly auto neutralize themselves; then the effluent (an average of Sm3/hr) is pumped to the waste-water treatment (nOn effluent pond 605 Cl0 A/B). 3 Backwashings of sand valveless filters (No 1 Kobe and No 2 built up by NCZ): overall 10m3 once per day, duration 4 minutes, containing suspended solids. 3.13.2 Gaseous Streams None 3.13.3 Solid Wastes Old resins (changed about every 2-5 years). 27 3.14 Boilers At present in the factory four boilers are working (a new boiler is under erection): one coal operated and three fuel oil operated (even if two of them, called "twins" were designed for coal but were modified by NCZ to fuel oil). The new boiler will have a capacity of 30MT/hr steam and will be coal operated. The capacities are: 11t/hr of steam for the "carbon" boiler (which works with coal dust mixture with little fuel oil), 9t/hr for the for the "twins" and 6t/hr for the last "diesel boiler" (which is operated with light fuel oil and was degraded in the past from the initial design capacity of 10t/hr steam at 29 bar due to four explosion accidents. 3.14.1 Waste-water Streams Sharp blow down twice per shift for each boiler: about 5m3/each flowing to industrial sewer ("C" effluent). 2 Effluent from sedimentation basin for the ashes of coal boiler: consisting of fire water containing suspended solids going to industrial sewer ("C" effluent). 3.14.2 Gaseous Streams Coal fired boiler is provided with a 30 mtrs high chimney. The other boilers are provided with only 6 mtrs high chimneys. The new boiler will be provided with a 35 mtrs high chimney. Sometimes, due to difficulties of pulverisers operation, light fuel oil is being used in the coal fired boiler, resulting in a dark smoke to the atmosphere for short time. A dark smoke is also coming out from the "twins" boilers during soot blowing operation every shift and at start-ups. 3.14.3 Solid Wastes None 3.15 Fuel Oil Storage Fuel oil is supplied by Ndola Refinery; it travels by means of tankers on the roads. 28 Daily consumption is about 35MT/day. The storage consists of the two 70m3 tanks VOG A/B (of which one has no heater) one 100m3 tank (V06/C) for light fuel oil and of the new 300m3 tank for "diesel" fuel oil (this latter to supply gasifiers, coal handling furnaces, ammonia plants, and in emergency, the boilers) Fuel oil is transferred to the storage tanks by means of a centrifugal pump (capacity 10m3/hr)1 if this latter is broken a mohno portable pump is employed. 3.15.1 Waste-water Streams 1 Leakages from the coupling with the flexible pipe. 2 In order to drain about the last 100 ltrs remaining at the bottom of the tankers after pump transferring to the tanks the workers drain this oil in some drums and then pump the contents of the drum to storage. During this operation some losses of fuel oil in the surrounding areas occur, spreading mainly to the storm water sewer. Sometimes these losses are covered with lime. 3.15.2 Visit 2n site Fuel storage is located just close to the open trench effluent from the waste water treatment plant. There are restraining walls, but an eventual leak from the tasks risk to pollute the treated water. 29 4.00 LIQUID EFFLUENTS This aspect covers most of the efforts employed in the study. A considerable analytical campaign was carried out by the laboratory from 23/07/86 to 19/09/86 and some supplementary analyses and tests were accomplished in October and November. Checking analyses were carried out in December 1986 and February 1987 to verify eventual changes after the turnaround of the factory. For this purpose some points of sampling, practically coincident with the main points of discharge of the factory sewerage systems, were located and the analysis schedule reported in Annex 2 was drawn up. Eight points of the storm water (SW) sewer were specified and eleven of the industrial sewer (namely IW1 : IW11), moreover three points for the sulphuric acid plant were specified and some intensification of the NOX and S02 controls were required as regards air pollutiorl. The location of these points can be found on the enclosed "map of sewers and points of sampling" (Drawing A201-0064). The data collected, together with the flow rate measurements and considerations on the actual situation of the sewerage systems of the factory were utilized to outline the necessary recommendations to be adopted for the pollution control of the factory. The analytical data collected during the campaign are contained in the Tables of Annex 3 (pages 1 - 17). These data must be read in connection with the production situation of the plants of the factory during the time of samples collection, which is summarized in Annex 4 (pages 1 - 2). The results of the flow measurements (carried out by means of several methods, in comparison with them when possible: propeller hydrometer, chronometer calculations of the paths of some floating materials and gauging weires) are reported in Tables 2 and 3. Some difficulties were met during the measurement, due to considerable amounts of sediments along the trenches and outward fouling in some of them. The location of points of sampling and the summary tables of the analytical campaign are even shown on the "simplified diagram of sewers system with points of sampling and analytical results" (Drawing No A60S-0010). 30 5.00 PRESENT QUALITY AND QUANTITY OF THE LIQUID EFFLUENTS DISCHARGED FROM THE FACTORY (OVERALL AND PLANT BY~T ANALYSIS) 5.01 QUALITY (POINTS OF SAMPLING SWl :11 AND IW1:11 ON THE DRAWINGS A201-0064 AND A60S 0010) The analytical campaign was driven as much as possible into the details of the single plants effluents; however, due to objective difficulties in catching representative samples, as usual in these kinds of studies, it was not possible to investigate every small branch of sewer inside the plants, but only the main collectors from the plants. The analytical results in the above mentioned sampling points are summarized in the following Table 2, for industrial waste water, and Table 3, for storm water, elaborated from the single analysis by means of simple statistical methods and rejecting not representative data (samples taken during days of shutdown of some plants or figures visibly out of standard. During the execution of the analytical campaign two more points of sampling from the storm water sewer as to the previous schedule, namely SW9 and SW10, were considered worthy of investigation. As regards the parameters investigated in the Table 2 and 3 chromium, nickel and cadmium are neglected since they were always found equal to nil in all the analyses. As to the sulphuric acid plant investigations and A321 slurry the analytical results are shown in Table 4. 5.02 QUANTITY The series of flow measurements were driven as much as possible into the single plants effluents; however, due to objective difficulties in introducing measurement instruments, it was not possible to investigate every small branch of sewer, but only the main collectors. Whenever the flow was so low as not to affect the sensitivity of the employed methods, it is assumed the flow be equal to lm3!hr or less. The results are shown as "Hourly Rate" parameter in the same above mentioned Tables 2 and 3. SUMMARY OF INDUSTRIAL SEWERS ANALYTICAL CAMPAIGN IAMBII IWI 100ES RE,ULAliOI lW 6 IW 2 IW) IW 4 IW5 II[V/ LA lW 7 lW8 IW9 IIW10 IIW11 BAllKtE RELEVANI lI~IIS 1110 lANK T . O· .a' 010 I A MEW AI lEW Ai A104 AIIUl A5. MP ! HFlum 10 IW 1 PUBLIC SEWE. EfflUENI EFflum [fflum UfIUE!1 ElflU~1 IfFlU!iT HfIUEHI [fFlUm EfflUENT EfflUEN] EXPRISSEO REf PARAMETER AS UHIl ·c 10 MIN 115 HI 111 I HMPERATUR MAX 11 60 11 151 15 6 15 6 114 115 M 111 f'~ --- -" -------- - - - - _ " -"--- MIN L L 1; 1 pH 79 MIX 96 6 ; 10 83 64 11 151 9 15.. 9 79 Ii L-l """"---.-- ./~-,.-- 3 TOTAL NH4 NH~ ''Jr l 18L MAX l!ll 60 I 150 m III il 7651 3791 L04 m 11000 .. L16 0 _--- ------------ MIlS! lIMES --- ---------- I' , 'r-'" J"" , L FREE NH) NH) " 41 Nil """ 56 III 36 I MIl II4L 11,0 13 III 115 III r' .. - - ---------- -,' s CYANlOit" CN - " MOS! liMES 05 o Ii 51 Nil 5 o 98 - 02 o 005 "l E HIOCYANATES SCN .. o 0, ill HOIMIME! NIL ill 1 06 ill III . .. .. r" c, .. ,-- .. " r" , 7 SUlPHATES rI SO = ",L I'"'' 361 I~:~ IIIL " 500 3LL m 191 190 II 35 15 10 130 ODD LUlO PHOSPHATES PO,' .. 01 Mil N~L Ill! IIAUi o II o Ii 014 DO. 015 - - - ~ 2111 Cd s NITRATES " NG3~ .. m MIN II MAX 1)" JlL 160 IlL III 501 1495 Hl6 1&1 81 141 I' 1151 Iii SUlPHlliES S= .. II MOIl ilKS 1 016 19 L1 Mil o 06 - - - . " II SH£MIUM Se .... 1Il IllilY 111(£ "' ,"""" ----- , oIll! III <l - " " - - " " " ~ '''il ARSEiiiC As .. Olin SlIMEHM£S III I " - - " , -, - .. .. [J COPPER Cu DOLI Mil MAX 102 n 3 , , , 0011 ~OLL 011 ------ DO' o 01 001 005 0·0, a 12 001 " ZINC Zn .. 011 MIN 0113 II o 01 DIS o 01~ 011\ 011 03 001 0·01 OJ 016 ri5 IRoli Fe .. 011 MAX 0 J£ MIN O! II 046 1 II JLl III OLL OU au OIL Ii 16 'l6 HAD. Pb .. 001 MAX 211 MAX 096 15 o 015 0011 011 006 --------- DOllS 011 00, 001 801 o 01 -- 11 - Oil .. u MAX IL I 100 511 1&4 3 101 1I I - 1 11 --- .. - lOrAl SGLlGS .. 1160 Miii'llo IM!LillL 7500 , ILl! llli 1111 5111 11m 1515L " LO! 315 1\ milia 113111 J mlt '"'''' 15 . SUSPENOED Mil 11 moo 1SO MAX 1170 1100 L1L 1061 m 1741 150li .1 \l 10m 1111 SQlmL~. --- - -. _ '"'' .~ .. HOURLY RATE Ml Mil 160 MAX mBE iii liD MAX III PRESCRIBED SHOO!,ll 55.. III " 10 - 10 LO - - " --- .. ". , " " " " " " ' " " " " - .. -""--" lABLE 2 SUMMARV Ot STORM WAHR SEWERS ANAIVJI(AI. [AMPAILN I :A~/j1~ SW2 SW) SW4 SWs I SW £ SW 7 SW B SW91SW101_ I Hili i!1<: ~II(~ r I" R'ME1£R t\ [ , 11 M" RAT URE I~.'J 2" 20, 'I ?C 'I 20" 7' 24· I 2~ ] f ~ lO ,h I. c. 7 4- I £', c.,~ 7 n 1 ,-9 1 1 pH 7,7 2,4 o~ <pc. ///. .7.< 8 ' l '/." /:-;, -I ,IDIAI I iH" - HR,' 7, I~ !~ I"' .. ,",,0 " II }~z/!. ,- :J -I 'L' I \ f " fREl I H1 H" J N'''' N lL. ~Il «.1'> 12 NIL '>~ i I /"./ ..''?> . 0.1 !!. ~ (IAm!s [I 07 t?~2 ;;' 2 i we f: ~IL Nil 11HIWU.1EI It, ,_,II fJlL;u >J1l- 1°,04 02 0.1'" lUll: 10, },/l 17~ Iq-:~~ I" n':> .DOO 11 j'llIPHAltS ZO 7",,0' 4 .:;:;-, 7(" I? 07' Ill>?> rI 'HO"H'IES 10, -'_~II 0,0' ,I D 17 "2 Zz I 0 I 74~4-"'M;1 ! 0,,,.;/'/ ~-/"r~ 1 1. -1-,/1 ~6 ' / / /120 ' -. /,T/ I 'f! Ki1"HS HC) _ "''''' 1 eg, e.8 ./ 'l; .7:~ !>4a.;' lOt; 142"" //7/'~ I?:>"i 111, , 1!6 "'.t- I Z 41 0.r-}./,d ,"I:;" - - ,10 IUIPHID£I 1"\11< 0 M ;!. ~I ~ ""j I ':> j' 0 _I'" I a. I? <:1 c, " 0 '~l t:>_~? =-'---=- - 1 ,11 !5£IOIUM 0.01 '0) I. ". ??1 -~ -j/' i1 [17 AR![ HI( k. -,It , "OD I -;r-- r// • + / ... ,.,../~ 4: (P" /hI7/:/177>',--- ,- ---1 - - -- ,- 1 0.\ [Tl t:;,tj ;.,,~ WIER t. '"JI~ I, 7 ~. ~11; 11M /, "//~1 ~/;) )/«l~/~; 14 ~ 2~~~~~- 7//~~=-' 0 10 2"'4 - ~48' 1(;"'4 s~ 1 8 < 1 IRQ! I. , 'Ill.] 1 ~ o.~:tl 72 1·1 "< l [An I.J~I~ oo~~' 0 4; 0,;-'\ :;~: ~-I-Jo 006 ~'~I ... ·I- t I, I ,:: I au II ' ,~- - J /:;r,:; 7/~ 7~! -/-0-"/ ~~~---- 7,.)""h. 1.--:,,// I",lt ~il:. __ ZJ t.»;// ~e. ~ ?? ~ ~~P ~'f ~t ~.~~! 9> _"1 j l I -Jill .. '1& liD,"') """3:y' "'''''', G.~"'~ ~?~.!!1 7"'8 I IOe...4.. I' P-?'..... -~---- 0 11 I IOlAl 1DC 0 II OS ~Q /~>/ //~ :j "':'I':~' f';:~:1:~ ::oi::L~:1::r~, -.. -.,.. ////'1 rQ/. //,.-;.. / / " / ........//;:.:t· 7""'-..'lj 1Z?7 . IUIHHOEO ['" 101lDS I 10 1 '* OUR"G ORY Wf'IRIR *' ~~tf I - 3J TABLE 4 SAP I SAP 2 SAP 3 A 321 Vl00l V901 V 904 SLURRY EFFL. EFFL. EFFL. TO L.I\GOON -------- REF. PARJlMETER EXPRESSED UNIT AS Temperature °c 33.5 30 32 31.5 2 pH 8.93 O. 12 0.57 11.9 3 Total NH4+ NH4+ ppm 26.6 4 Free NH3 NH3 " NIL 5 CyanIdes CN " 6 Tr, i ocyanates SCN- " 11.5 7 Sulphates S04 = " 270 975 4980 8 Phosphctes P04= " NIL 9 ~Iltrates N03 61 10 Sulphides S= 8.7 II SelenIum Se " 0,045 6 2.3 12 ArsenIc As " 4 47 5 13 Co;;per Cu " 2,2 158 1539 449 14 Zinc Zn " 0,34 1,5 363 52 15 I ror, Fe " 29.3 0,047 2 12300 16 Lead Pb " 0,4 0,29 9.7 2,5 17 Oi 1 " NIL NIL NIL NIL 18 Total so 1ids " 59102 19 SusDended so 11 ds " 58555 1500 58000 44600 SULPHUR IN S SOLIDS 6,6 34 As regards point IW2 "D" effluent the flow rate is nil because at the time of the analyses the flow of this sewer was deviated into others and no effluent was flowing to the double "D" effluent pump. Where a dash is indicated instead of a figure the flow rate measurement was impossible because of too much sediment in the sewer or of the lack of the discharge pump in the pit of investigation (thus resulting in standing water in the pit and overflooding of polluted water into some storm water sewers. See the chapter 8.00 for this). 5.03 OVERALL POLLUTION By combining average flow rates with average analysis relevant to the most meaningful parameters as regards the complying with the law (see next paragraph 5.04 for the reference to discharge regulations) it results that Kafue NCZ factory is discharging towards the surrounding environment (mainly new Kasenje River or open drainages conveying into the Kasenje River), the quantities of pollutants exceeding the limits from the final points of discharge indicated in Table 5. Of course these computations are based on the hypothesis that 24 hours a day both the hourly rate and the discharge of pollutants are constant and equal to the average. The considerable amount of suspended solids has been directly confirmed during a boat trip taken along the Kafue River by the compiler of this study together with NCZ Works Chemist as far as the confluence of Kasenje River with Kafue River. Here the distressing and impressive sight of some hundred square meters of Kafue northern side covered with black sediment could be observed. The height of the sediment layer was so big that the sampling bottle could not be immersed in the river water, even many meters from the bank. Samples of the sediment and of the supernatant water were taken. The analytical results, shown in Annex 5 and 6 indicate that some alteration has started in the Kafue River natural geochemical concentration, at least on that portion of northern bank in proximity of the Kasenje confluence. Infact, ammonia, nitrates, salinity and solids are rather high, (see analysis of sample 2 in Annex 5) while at the center of the river ammonia and nitrates are nil. The position of sampling points on Kafue River are shown in Table 6 BIS. SUMMARY TABLE FOR OVERALL PRESENT LIQUID POLLUTION FROM NC.Z FACTORY KAFUE IflNAI POINIS OF DISCHARGEINTU'I.IlUC SEWER OR WAHRCOURSESI nONlY PARAMETER fiGURES ABOVE ZAMBIAN SIANOAROS ARE REPORlfO lW 1 SW10 *I SW2 SW 3 SW 4 SW5 *1 SW6 *1 SW7 SW 8 SW9 OURlY DAILY HOURtY IlAlty mum DAILI IlliIJlLV DAILI HOURLV OAlli IIIlJ11l! DAILV ~~l~LV IlIIlY Houm D~LY 1111118Ll OAIlV IIIURIV '.VAII i RAT! AMIl1IHl RAT£ AHlUHl lilt AHlUIl HAlE IMOlMl tAl[ IMlIUH1+..!.!!£ _ AHlIIi1 RAIE AMOIllH RATE AMOOHl W£ "!lMOUHI lOlA~ .f. 351",W~ 3S'%, 93.6% 1 9.~,. 456%; lUV9~~ 263.5~68h, ~!~'I a.s" CYANIDES 07~ 17~ O]2~ 77D/. ID5I~ 2S I!. 20 9 , ().51}. t· .. ..-. _.. ...... . ..-. . "- . ..-...- ...-. ..._. .......- ..hf.. .''''L ....'. ..d"1 ....•, day /t<. ...d", 1_--1 ce SUlPHAJES 51~ 120~ 14441~ 06,),: 1741~ 42~, _---j-.i<r do . I 1.:1" dc, ; ,or dQ. !....-t--+-..... 1---+-.-+--. PHOSPHATES 4}1.\", 113 t I .. ···t-I- I NI1RAIES ~5Itr5~151%, f61\ --+__ I I 911~ 461' h, da, 2.1 1i t< 504!i rill sUlPHm£S_nI036~192;~Ir"b,'163~,vlu_l192i1'~'61~{ ... H_~I_J39/h' In0-a;.y 195'%, U ----"---+ 15° -"h, 036'%.~ l \;, I 'J v' , SElENIUM Hi/. 86 9/ --<----- ru .. n... h' .d''tYI_-+ 1- .. +. AR s~~~. _-!-Wn I 320\", 7Jitl1849{, H%'I -+--+---+--11 -1--+---1 1__.I----J-_~r·63't. "Slt Mil 4.3l103~ u COPPER 1 i '"h, 26'~ 1 - ._. --t---ll I IRON . 2~491! ~6g,ri,__ ~1'~, ~07\ u.''Yh, mit 16 -,& 384~~ 1 48%,iJsS i" .. . . _ . . _ .. ~IL_ __ u _ 6 1 t 144~+ u_ u m-i n- u •••• ,_u H~, 912!.l;.75'{, 180 3-51~, 84K9~319/hJO.n'l;~77'5~o-66~ 1 , 1101Al snll~s.~. 21 ~., 45't 63 ';;" .__~ ~71 ~ru_ .... __ sWt,W o U'lh, 106'tr 72\ 72!~rI!y 17:\, ,1'dOY 32'~! i1Ji~~4gg'hr 36\ 350%;~1Jri. 2651~1w~4Yda ~95~~I~~YI(}76ItI182:;' ~~~RA1E l u I 350 ~ 8400~" .. I 40 ij 960i-y 80 iR 1 Ml 1 92t10AY~O ~R !liO ~y ~ 1 1 M ... * * 350iR 84~ 10 iii ~40D11 Ml 1 • " RtGAROS ALMOS! SI.GUll mws I alJ!!lHG DRV WEAlHERI IDMPUlA11DIS RAV[ 8ftl MAD£ AS f flDWRA!! WDUID Of 1M¥HR lADLE 5 TABL-E 6 Q,..$ SI<f'l'CHCF'SM1P LlfJ 'i POINTS ON f(I'IFVE R'VFR. (14'H t0oV.1'186) (FOR "'IV"'L"ITICA< Il.{:SUVfS £FE' A,u"''''x 5\ NCe I'VI1PI1005E 0r l ~ KTi'./BI\"1'A!L££ 'FAST k1iS·,,}lJE W 0 U'FlO8IJT5 RrVf'R)f\lCl! ETfL.<JEIJ' ~_ _ _ _ _ _- - " , - _ - - . . ._ _: : - - . - " ' - - - - CNA/J/VFL .~ 2 X I'll leI\': "150,,, ~ C. p:ol.llTH ~ OF R.-f05 • 1 <5::-- 71JOrr-. ',,,,( 5001'\~~-<,-, 1000", ,. ...- -"'!-. k ~------- ~ J lS.lAIJI) .3 " I", 200", I< A FUE------- t\WJ fIllEt 5 G ., , .~ -.,/---.- . J .... 37 THE REPUBLIC OF ZAMBIA TA B LE'" 6 O~· 'IS '16 '11 '18 '19 "20 '21 '11 'n hi' ,mF, ", ~ ~--I"" """~~--- '~'_~;'\C\',900I" ""-, DEANS/' ',h ,1~Nc:H '" ,I '" "'-"'0 I I :\~' ~ 9Q01~·m 1 .' ',' '-, --" -', , ,_ I ,; ~"~_" 1"" ,472a.\ ;1 . ~ _" ~- AR ., """ ... ( ~ nat l< ENG _ ) , . , ) , , " ' '--- , ';CHITE , "F~·--:~ . -' -( • . -T I_",,_,i~ / Us. ,,' ,- , \ , -, i ~~ "~~ ;' II ... --" . ",~:.:) r ~ 1-- _.~ .. ",I " I . -,~:---\ r.>o-.r.-. .JIi. -'" , / 475a • " , '1' . r mo' I :~-" . ,! , ", . ~----- , -:-:J ' "''; \ \ " \' ' l' "o.v ~~ ..",. - .. \, \) ~ •,.' , .~. I r-'l--- ,_} \ ' ~!.:..-F- U-£',_, 4C. -" . ( , '\ il', , 'I' , , "", , \t \ _} - 7 " , t' • '-' J"\,. S t~_:.~- 1,'{ 5,1 ~ 16". f, -. -- ' . 'J(_:' --:-~'iC~P ~ 3)1. '" " , - --- " ',1 '\ . --"1',-- -.,.-'---- OUTH Ic FARI1 ' " " '" ~r:: ,~ --~~ , ~.. ,..-~~r::~ --r ___ I . .. . . . . . , : - - , - - - -'1~--" Uu' , ,-', ",,#' ,\ ~"......r.j"""""--"'" --'--'---',r .-,\:~-. _+_'V" __ :;"..~~f-- r~:-j=:t"Y~- -" -- . " .' '/ ( ~-,:...~ 38 It is necessary to point out that the 20ppm of ammonia and the 32ppm of nitrates found in the water supernatant the above mentioned coal ash layer were relevant to a day, 14th November, during the general shutdown of the factory. The position of NCZ factory as to Kafue River is shown in the small map of Table 6. 5.04 REFERENCE TO LOCAL/INTERNATIONAL REGULATIONS Till last year in Zambia there were in force only some old Local Government Acts regulating the discharge of "Trade Effluents". The ones which we got acquainted with (Kafue Township Council and City of Ndola) were rather lacking as regards contents and indications in the sense that many important parameters (among them the main pollutants of NCZ Kafue factory) were missing and for some of the others the concentration limits were not given. On the contrary on 8th November 1985 the Statutory Instrument No 161 (herein enclosed as Annex 7) was issued with the aim of disciplining in all the Republic of Zambia, the discharge of trade effluents both into a public sewer and into any water courses or lakes. of course, the limit specifications valid for any water course are stricter than those valid for the discharge into a public sewer. This law appears very clear, including even a very detailed formula for calculating the charge for the disposal of trade effluents into a public sewer and the amounts of fines in case of offences to any provision of these regulations. As regards the standard figures some parameter limits appear too high in comparison with European or USA ones, but it looks quite reasonable taking into account the substantially different level of Zambia industrialization. If someone just wants to move some critiques to some points of the Law, it appears unusual the presence of a limit for thallium, which is not taken into account by any international regulation. Moreover, the limit of 25mg/1 for zinc appears too permissible, as in all countries this compound is considered rather tOXic, on the contrary tin limit of 2mg/l looks too low, stated that this metal is generally not considered toxic. Even the limit for oil (1-2mg/l) is quite'low (for Italian Law if 5). Moreover, biological pollutants (coliforms and streptococci) are missing. However, the Statutory Instrument No 161/1985 looks, in this context, the most reliable and complete term of reference for the aim of present Environment Stury and it will be taken into consideration as the national regulation in force which is mentioned in the contract, neglecting any not very clear reference to mysterious "International Standards", 40 6.00 GENERAL COMMENTS Qli THE RESULTS OF THE ANALYTICAL CAMPAING The previous pargaraphs with enclosed Tables 2, 3, 4 and 5 practically reply to the demand of investigating the present quality and quantity, overall and plant by plant, of the liquid effluents. As regards the expected level of pollutants after completion of the technical rehabilitation of both the Kobe and the Klockner line it is likely not to be a large change to be expected; that is why on the one hand the capacity increase will produce higher level of pollutants, but on the other hand the ameliorations to the condition of apparatuses will involve a minor amount of leakages and losses of pollutants at present higher because of poor maintenance. Which of the two effects will be prevailing is rather hard to forecast, but we believe that to consider valid present levels of pollution even for the future will be quite conservative. AS general comments it appears evident that the final effluent from the industrial sewer (IW1), which is discharging, together with the sanitary sewer, into the main council public sewer line is, by itself, out of the Zambian Law as regards ammonia, nitrates and slightly, sulphides. If we consider the combined industrial/sanitary effluent from the factory, as confirmed by some analysiS, this latter remains faulty as to ammonia and nitrates. This is quite reasonable stated that, even if we do not know in detail the township sewage treatment plant project, a municipal waste water treatment plant usually does not present high capacities of nitrification and denitrification, while a fertilizer factory like NCZ typically discharges mainly ammonia and nitrates. However, the major problem for NCZ factory is the large number of storm water drainings polluted at a higher extent than the industrial sewer. The discharges through storm water drains must comply with column 3 regulation 4 of the Statutory Instrument No 161 of 1985, as they do not occur in a public sewer, so that the standards to be observed are stricter. As pointed out by the dashed lines in Table 3, at present storm water discharges not complying with the Law are the following for the mentioned parameters: 41 SW10: Total ammonia, sulphates, phosphates, nitrates, sulphides, iron, oil and suspended solids. SW2: Copper and suspended solids. SW3: pH, sulphates, sulphides, arsenic, copper, iron, salinity and suspended solids. SW4: pH, sulphates, selenium, arsenic, copper, iron, salinity and suspended solids. sws: Total ammonia, cyanides, copper, iron, oil and suspended solids. SW6: Total ammonia, cyanides, sulphides, iron, oil and suspended solids. SW7: (Which represents the biggest effluents from the factory, even in dry weather): Total ammonia, cyanides, nitrates, sulphides, oil, salinity and suspended solids. SW8: Total ammonia, cyanides, sulphides, oil, and suspended solids. SW9: Nitrates, oil and suspended solids. The overall situation is summarized on the simplified diagram (Drawing No A60S-0010). It appears evident that the major responsibility of this heavy and so widely dispersed pollution is the chaotic situation of the sewerage system, with a big mess of mixtures between industrial and storm water trenches, breakages, blockages and, may be, even improper conveyances of polluted discharges to the wrong sewer for design or construction mistakes. As regards the sulphuric acid plant sewer (SW2, SW3, SW4) responsible is the the heavy corrosion and abrasion of piping and pumps, which often are not working, resulting in discharging effluents directly to new Kasenje River instead of conveying them to the waste water treatment plant and then to the lagoon. To the above mentioned pollution frame there must be added the overflow from the lagoon which, as results from the analysis enclosed in Annex 8 (pages 1 - 6), is systematically out for sulphates. 42 For precision's sake Nez factory, apart from other branches of storm water sewers which are surely not dry only in rainy weather, has another discharge into the public sewer from the sanitary sewer collecting buildings located in the western area of the factory, but this latter, as it originates exclusively from hygienic facilities, surely comply with column 2 standards. As further general comment, if we compare the quantities of ammonia and nitrates averagely lost with the polluted discharges with the production amounts in the period of the analytical campaign, we can say that almost 10% of ammonia production and 7% of ammonium nitrate production has been lost with the polluted waste water in this period (though plants were stopped many days). If this percentage persists, once rehabilitated the plants at maximum capacity, the lost amounts will be 31t/day of ammonia and 35t/day of nitric acid for the considerable value of Kwacha/year 43 million. Of course, not the whole pollution is removable with practical and economical methods, as it,occurs invevitably in every factory of the world, but very much can be done at Kafue factory to reduce present big amounts, only by means of simple interventions, good maintenance and some precautions, as we shall strive to indicate with our recommendations. A particular comment is worthwhile for oil parameter: The standard limit of 1-2mg/l (it is odd that for this parameter there is not indicated a clear figure "one" of "two") for "any discharge other than sub-regulation 1" looks quite low, especially in comparison with the 100mg/l for the discharge into public sewer; so that all the storm water drains appear out of law as to oil, even if this parameter can be easily assessed bringing back the discharge to the proper industrial sewer. As regards the visible effect of iridescence that can strike the average man in the streeet it is necessary to bear in mind that it is only a matter of the presence on surface of a molecular layer of oil, but no massive amount of oil is in the bulk of the waste water, as it results from all the analyses. Infact according to an experimental table supplied by A.P.I. (American Petroleum Institute) in its "Manual on disposal of refinery wastes" (see bibliography 1) to the appearance of visible bright bands of colour it corresponds an approximate thickness of 0,0000120 inch film and a quantity of 200 gallons of oil for film 1 square mile in area; it means that about O,73cc of oil everyone meter of iridescent open trench, since the average trenches width is about 40cms. 43 As regards the s~z~ng data for the review of effluent treatment plant for the fertilizers area We can notice that, apart from smaller streams, the major contributors are IW1 and SW7 for a total of about 700m3/hr, that is approximately the same amount drawn from the water intake for the same area. Actually there is another water immission of water into the factory, namely the drinking water coming from the council; this latter flows through a 4" pipe and a meter (supplied by Bosco & Co. Torino which however is not working) and serves all the control rooms, toilets, the canteen and the laboratory. The used tap water is supposed to flow to the sanitary sewer system, so that, even if some losses can be found in other sewers, this contribution to the effluent treatment plant is not remarkable. It is not at all clear as to why the conspicuous figure of 700m3/hr are corning from the practical observation and flow measurement of the main factory effluents, while from the theoretical examination of the waste water streams plant by plant not more than an overall 100m3/hr are arising. The suspicion that may be the balance tank effluent was not really flowing to main council sewer, due to some breakage in the sewer system and was in communication with the storm water sewer discharging through SW7 must be dispelled due to the different elevations of the two sewers. On the contrary direct observation of the very small flow in the branch of sewer directed to main council sewer (by lifting the grating of a man hole located in front of bagging house on the other side of the railway/and the concomitant big flow at swa (usually dry) in the period of the collapse of sanitary/ industrial sewer (see point 12 of Chapter a.OO) convinced that the balance tank effluent contributes, in case, to swa, not to SW7, so that the only likely explanation for this discrepancy is that the number of abnormal operations involving emptying and flushing of apparatuses and various washings of vessels and plant areas are very much more than what even the plant chiefs can realize, due to the frequent shutdowns and leakages of parts of the plants that occur for poor maintenance, lack of spare parts or electric power failures. Generally speaking no plant operating people interviewed on the pollution control matter were conscious of the problem, but their main interest was the production and the operation of the plants without troubles. This can explain the numerous diversions to the wrong sewer and the other anomalies that will be object of the next chapters a.oo and 9.00. Moreover this lack of sensitiveness stresses the hypothesis of urgently designating a responsible person for the environmental control of the factory as proposed in paragraph 9.14 - 44 6.01 COMPARISON WITH OTHER FACTORIES As rough consideration if we compare the pollution generation from NCZ Kafue Factory with know figures from similar European Factories, we can state that NCZ is polluting more than 3 - 4 times bigger factories. This statement is indirectly confirmed by an application of American E.P.A. (Environmental Protection Agency) "Effluent Guidelines and Standards for Fertilizer Manufacturing" (see Bibliography 2), which supply some reference figures for effluent limitations as to well operated plants subdivided in the main fertilizer manufacturing categories. The subcategories of NCZ interest are as shown on the following tables: 7, 8, 9., By applying the figures suggested by EPA to NCZ Plants, it results, as shown in table 10 that NCZ level of pollution is a long, way off the best practical control technology currently available, so that many improvements are still possible inside the Fertilizer Manufacturing Plants in order both to reduce pollution level and to increase valuable products recovery. Subpart 8-Ammoni& Subc_tcgo(')' ... "':' ' ~ 418,20 Applieabi1i1'f~ d"$orrtp1ion of (hI:' ammoni. U.bc.lorr;Or}. The pro\i.slons of thIs f;ubpart ce ap.. phenol/;' to cLs:.:hal'lt~~ re!>u1tmg from the manufacture 01 alTlJnoru5 . ~ '18.:22 Emurnl U0halion, "'Id"lin~~ • 4 18,2'3 Emuornl Hmi... tton:. cu'drHtu::t rrprrK"ntiDt: th.. de,Jnl' or "'fth.... nt NprnC'Jltinf I-ht' dt'1t1"H" of II:fRu(Ont nduction .U,IIIin.bl,t- bv thC' .ppl1~~' ""t Muortion aU.inablt' b~ thr applln; tion of 'he' pndk.abl(' r(fn1t'o. ": It:<hnoloto· c\JTHntly _,,"ail.blt'. lion of t.he b"a, ..",.. nahle u:chnolt V ~ «onomieaU, .c:hh.,\'uJe. The fonOWing lImltallons establL~h the Tht' !ol;owlng ll:cnH.ationl/tiSLabUsh tM Quantity or quahty of pollutants or POl Quantity or Quality of pollut.aDt.5 or pol .. lutant propenJes. controlled by thls &e<:~ lutant propertIes. controlied by thi,s lec" Hon, ,,·h.1ch may be d1.stharied by .. POlnl Uon. lLhich may be d1.schar(ed by. pomt source 5ubje<t to the pro'ti.s.1ons of thu AOllrce &Ubjed to the pro\isions of this subpart e.!ter appHcal1an of the be!t &ubpart Uter application of the best available technology economicallY "pr~bCabje control technology c>JTTently achif'vablt' : "valla'bJe: r~:I~"! .3' ..... n,u, ,)hrtmun:; kw ' f' "Wf ,.,r ..' ""'.....'1"... to, d~ll; ..0,' 1!1..1' Wn~IlUvt dll\" Ib~:t M: nn'~'J- ).!rtr!( unIts ('tIIor.'tV$'-, I,tll; il, (I( prlll<iut(J I~'''':-;)" OM 0(12';' Am.no(!:;U" 1M- K), •• O.U75 .•.••.. 'IIi·lthlr. tnt nf'lllte.\ll(o'/o. l'H...," ''' .. ~ ... _. Ji liN!) \1,~ 1'fIL~f:tOII'l t:Jl,ILJII uI\ILJ q:Xluf'llh '-' 1,(0) .t.. •• A''''''''l,I&{,-~XJ... 0,01'0 01 f)I'Od.utt) O,~ pi:. ..... " __ . l\'lIh.h) ttlf' rw.nc' 1,0t..) 8,0 "'l.II..fti~ (u "-I ••• I) 1117£,,_ I; «t.'! pll" .. ~ ............ lII';UUll <,h( ranrSO'fl) u 140 Fk 26':15, June 2), i 91 51 Subpart O...:'Ammonlum Nitrate :.subcategory (43 FR pell. April 26. J97tt! t U~.'{l Apjilli:('1Ibility~ docripti(lfl or .... 4! I ammonium ftilrat.e eubai1.r:(lT)'. The pro,,'l.sions of this lubpart are applicable to d.1schArQ:es resu!t1nl from the manu!&eture or ammonJum ni· trate, DLschargcs attrlbut.&ble t.o ship.. ping 1055es, preclplta.tlon runofl trom out.slde t.he ba.ttery llmIu of the &m. mONum nitrate manwuturtng opel" atIons, C:Miine tower blo~:down, and dlIchaTies ftom planu whIch tol&lly condense their neutralizer overhe&4a are exclut\ed. 418.'-3 Emu.tlt UmJlal-il:".. &lid ptd.,. linn ftpruerub" tM 4ctT'H or emu ~nt reduction &U&ine.bJ~ by ~ appUca· 141e.,,f;2 Emu~"t "rnllaliQR' tand I'lhf.. llotl or tht kit .....n.bi. _hftolo()' linl!" rt'preeC'ntln, u._ 4_1'1"t't of em..... ..nomicalll ac:~le. enl ftducU(ln &tlalr.ul. by ~ applica tion of t.ht kit 'rvllalbl... eonll'Ol The tolloWlnlr I1mJ....Uons esl.&bum kChnol(l(), currently ."Ill11ablt. the 1l."... tlIy or Quality of poUutants c t pollutant properties. controUed by this ..etlon. ..hleh may bE dlschug.d by a potntaaurce aubject to the prov1· L~ljtn~ llulm'OllXl lor ..."t'''', oJ d.l.i.JJ' ~ Ions of t.his lubpart &Iter a~puca.t1on ._ ~N1.1oe a.tII I .... , n.l1HII1or I(; 1#OI'1LMC1JtP\'<l: ...,. o I the best ..aUablt ""'hnololY 0<0. .:n.tJl &ot homle&lb' t.ehievable: ~~{M fh.____ ;U~(MIf)_ Elfl.uent Jtuimtu!! tor .....rat. of IkIl1 lfon._lhU1e ur.Jw· tliOl"l"'l.l:l/\.OOO kt 01 1>I''Od· '!'iuKurutlC • N\¥ 1 M.f ~ua tor JQ iII::U. bl1/.Ih ur.JW. poun4.!l#)O ill oJ P!"Odl,ld.. [44 FR 9388. February 13.19791 t\nmOn1& tL! /'.·1_____.,._. l\i:lnU luNl.._ ...12 .o. ~, '-ION: -"I~trl:; ur.lt.1O. LllOC'h,,""!lLoot of 11.. prod ~. Dl,t.Llh W)H.l jXlu.no/l,/XIG lb Qf p/'OiSu~. Subpart [~ltriC Acla Subcategory § 418.50 Appli(;.bjlil"~ d~ription of Ih~ nitric "t'id .ube.t~f:Of"'. TAB lE" g 'nit proVi.zlons .of th.!s 6ubpart art .p.. Pueable to ducharrts r-esWU.lli Irom prDducUon o! n1t.rle acId in ooncentra· liom up t£l 68 perCent. D1.Sch~rge.l. from Ihlpping los5es.... re excludtd. (b) The following I11:nttatiOn.!l es1&b.. (lH The foliow1.."lg J1ml:tations atab ll!h the quanUty or quality of pollut~ liah the Qua.ntlly or quality of Pollutants liLts wh1eh maY be dlscna.rcf'd U'. process wh..!ch may be <Uschara:ed. 10 proetS$ ....a.:si..e water from J:)jtrtc Acid P1'OOuc1.lon .......tt ....ter from nitrIc add production in ...·b.kh .ll lohe taT mat.enaJ a.mJDon.i& in WhIch all tnt raw lI"later1al ammon!£! 15 in tbt ablPptd liquh1 form.: 1s in the &hipped Uqutd form: It.lfil"l< tJo!WI. •,lth or V"Qd .....l: EuCJ!sb E,;j,J'~. Ii rw.ll"!t t'roE!. "\:'r iiI rtOOo"l; !nf1ul') t'llIu.11',1.!J"" U((, ,b oJ p'Ood;)nl .1. of pr0\3IX:\\ :1:.1'1':1)''''11 A .......... ' Of dOll" F t:"J~,.1 A... ~.w, of.c.,." dll101'''1W:l.:thl,' Nui...'TII)rt: for • .. h,~ftrr III, . d.'''.'''·''H''· "u f"lUIr' flY IIIr} J (1;!~ ".,..,~, lor. '7H~C1JW'" {hn IL('.)' I d.\ -.:'U1J\l'~d. .. ,. al\ltl no! .Ii,,- nt'l .~~- --~ Amti'lQnl. (.... S) ••• II ()1 .... .iIW:l:\O.rt.J.. {u NI ... 0" .• - ....... . ,."" "!:.n.~ 1&.1 P'I •••••• (1..1<1. '"' 0<," P>1;.n,tt ("" N;".". 1Ui, ..... ,. ,."_ (<2 fR "'40. Mmh 25. 1917) 0.0'.:3 142 rR 16140, March 2!i. 19i';' I 14UUiO Appliubillt); d~c"ipljon .or 11](' .mmoniUDl .urr.l(, proodutlion tubCIII~~orJ' 'Thf pro"~ions of this r;ubpatt applJ' to discharges resultL.." frOm the production 'J! ammonium 5uHatt bY Lhe l)'11thtUC ~riX~S and by coke o\.'en by .. product. recoVfr:,. The provisions or this lubpart do not appJy to' &mmO'nium &ul!att pro -+uced as a by·product. of t'.a~rolacl.a.m pro(hJctJon. § 418.61 Eff1ue"nt limitation. l'uidf'lin_ tf'pf"fi.('ftlinJ Ihe" d~f'~ of <,fRu<,nl ffdu('lion .ttaftub'<, br dl<' appliu l'Gn '01 duo b-.eu .".U.bl~ ter:hnolo#y nonomiaU, .e:hin.ble. The roUowln&: 11.rn1tatio!l$ establWl the The folJO.'U:!.i' 1itn.StaUoD.:$ establls~ the quantity or quality of POllutants OT pol.. Jutant properties. ccntrolled. by ttw lec· ~UAntitY cr quality of poUutants or pol tlon. t.'hich may bt d1.scharred. by a point l\lt.ant proptrt.ies. cont.rolled by t.h1s see" Icu.ret subject to the prO'visions of this t1On. whJch may btt dJ.scl':).art'e~ by .. point lubpart a.lter application or the bc~t. lQW"Ce Abject 10 &be prov1stons of this available teehnoioi')' er:::lomJcal)y achievable: 'There sh:lll be nO' dlSc:harie aubpan a.tttr app4e.a.t1on cf the best 01 proce~s .·ask .'atcr poll';Jtants to pracucablt control teehnoloE)' currently naVijiable .'aten, avallable: 'There Ihall be: no dJscharge of process ti'aste wakr pollutant.s ic. na~'~~ aable "akU, 47 TAB LE :3 SubPirt G--Mi• .-d ,nd Blend rertm:er ~~rr;Jldurtio" $\,lbl;.ltebory § 418.10 App)k..bilitr; d:~.CI'ipllon ot lilt' .,i:.;cd .nd bl«'nd (t'nilil:t'r I'rOo ductton auhrult'for). The provl.sioxa of this aubpart lore ap Ji;lJcabJt' &0 C1I.&¢h..re~ resuJti,lli:' from tht production of m1:ttd ftrUhzn &l'\d blend: terUllZer, § 418,73 Emu..n. limitation!. l'Uide-)in." § 418.72 Emu~nl liMitllion• •uJd~fin~1 I't'prt"f'l'Iling Ihf' dot(l't'f' of I!'ffil.lf'nl HprTU'n',ne th~ d~J'l'~ of "-fh'(,rl:l N'ouclianan.in.blt' b, trtf' ."pllu. r~du<lion .n.itl.. bl~ by Ih~ applia. ·tion of ahe ktt .... iI.bI,. I«hnolugy Hon or the b~1 pn(,lif'.hl~ ~ontl'Ol ('('unomle..U, aehif'ublf'. '~('hnolor.· (':urnnd~ aui:bhl~. The toUo":ing UmiLaUons e$tablish tht The qwtntH.y or quaJity or polJutabt.s or folJovdng limH.allons establish the qUilnw pollutant properties, controlled by this: tHy or Quam}' of pollut.ants or pollutant section, wfUch may be dbchArved by .. properlles. controlled by this section. pomt $ource subject to "he provisiotll ot ,,·hh:h may be dlse::ha..rged: by a polm this subpart a.!t.er appl1catltm of the four-ce subJect to Lhe prOVlMOtlS of thl.s best anilable technolon economJtally bubpart aJter applJ:::at.ion of the Wst acrue\·a.blt: There shall be n:l du.ch.arfe practlca.ble control technolosy currently of pratt'$.!! .. ~tt .. ater polh.lLaflt.6 to avaHable: There 'hall be PO dIscharge nayiga.bte ":ate:'!, of process ••ute water polltlt.. nts to .na..igabie .:at.er:i. TABLE" 10 BES'T P~AC.TI c:.A L c::.ONT~oL B EST AvA/LA 8LE TEcHNOLDG'::I Ac..TUAL I -re.C.HNOLOE,';;;I c:. .. I{a.E.NTL::I ~C.ONOMI <:.ALLY ACI{FEVA8LE Pl_ANT (OR.DeSIG"'~ ./lVAILABLE' (t::PA GUIDeLINeS) (e PA GUIDELINES) ... Ptl.OPUc.T c.. A fA <:./ T::J E FF'LL/ENT L,IYlITfl.TIOI\I c.f..'FLuEN'T LIIY>ITflTFON' AMMONIA I'll Tfl.ATEO pH /ih>tnONIA I' N ITIl-A rEi pH (A:;' N) . (.... S N) (As N) (A, AI) 01., i) ~mmOIVFA, '&4 t. I Ja.,:/ I S·.:!S I('J(d4'1 ;;[.II{,(daY G-"I '" - "I I NEW AIYlMONIA la~ .. ~ . I b - "I 3 01 "":! t b - "I ()L6 AlITR..IC- A<:Ib aos .. \·b!.j. " q. 001. 1i,(J.y I· btj. " <J.. y;:l, IVJI NEw NITII..Ic.. AuO; i>I q. QI . \"4- .. 10.b " 1·"Itt " 5· 59 ., o L 0 Rm MOHfUM NI-rtU.7E l'l~ .. 6"1- .. 63· 6 " b'&'8 " (:>'.0'+" " '" NEw AMmo..,,,,.. III'TilAfE 'il. :. " '1-8·1+" 8· 'f 8 " ILl . 84 " al a.. I' AmmONIUM S<JLPHATfi IS I " o o o o o , i i gLEN/) FE4.TILIZ&I!~I, __,~~O .. I ! 0. I , 0 I' o o o l. l O T A.I", I _~J! ,(,. $. ~ II.-J/da~ ,I (, I . f>;:I, '" lday illf . .!iI't 1{:J/d41 3'1 . ( 'l1CJ rel"y ~7~:~ fi:n~;~T~;~SENT F~~~T '7/-. "1 OF 1117/1>"':1 AmmONIA OF i·8SmT/DA'::J N/TIt~TJi! I CAS N) ( As "'). ~ EXISTING LA~OUT OF sew/::.( NETWOA.K boe.s NOT ALLOw Fott PLANT By PLANT SPLI-r-rIN6 OF 'THE. OVERALL Fflc:.TOII.~ POLlllTION A mOLlNT. 49 6.02 POSSIBLE EFFECTS ON THE ENVIRON~£NT AND HEALTH Water is considered polluted when it is altered in composition or condition so that it becomes less suitable for any or all of the functions and purposes for which it would be suitable in its natural state. This definition includes changes in the physical, chemical and biological properties of water or such discharges of liquid gaseous or solid substances into water as will or are likely to create nuisances or render such waters harmful to public health, safety or welfare, or to domestic, commercial, industrial, agricultural, recreational or other legitimate uses of water, or to livestock, wild animals, fish or other aquatic life. It also includes changes in temperature due to the discharge of hot water (Thermal Pollution). From these principles inspiration was drawn by all the legislation of the world, not excluding the statutory instrument No 161 of Zambia. Human Health may be affected by ingesting water directly or in food, by using it in personal hygiene or for agriculture, industry or recreation, and by living near it. Herein we shall briefly deal with possible hazards from some chemical pollutants, which are present in the discharges of NCZ Factory Wastes, since the hazards from biological agents (Pathogenic Bacteria, Viruses, Parasites and Nuisance Organisms) should be faced and covered by the Kafue Township Council Effluent treatment. If present above a certain level, some chemicals pollutants (eg Nitrates, Arsenic and Lead) may constitute a direct toxic hazard when ingested in water. Other water constituents, such as Fluorides, are benefiCial, and may be essential to health, if present in small concentrations, though toxic if taken in large amounts. Certain other substances or chemical characteristics may affect the acceptability of water for drinking purposes. Ingestion is, however, only one possible pathway to exposure. Man can be exposed to water pollutants through other types 0: direct contact, eg in recreation or the use of water for personal hygiene. The possible health implications of these non-drinking uses of water (including agricultural and industrial uses) are 50 less well understood and no international criteria or guidelines exist for the control of such exposure. In addition to the possible effects of ingestion and other direct water contacts, chemical water pollutants may influence man's health indirectly by disturbing the aquatic ecosystems or by accumulating in aquatic organisms used in human food: for some pollutants these effects may be the most important public health aspects of water pollution. 6.02.1 NITRATES The concentration of Nitrate in surface waters is usually below 5mg/l. Much higher concentration are sometimes found in ground water. The consumption of water (or baby food preparations) with a Nitrate concentration higher than 45mg/1 may result in infant methaemoglobinaemia. Another hazard is the formation of Nitrosammines due to the reaction of Nitrites (coming from Nitrates reduction by means of intestinal bacteria) with secondary and tertiary Ammines present in food. Because of its carcinogenic power, Nitrosammines constitute a risk to man's health. The presence of high nitrate concentrations in the water courses gives rise to the so-called phenomenon of "Eutrophication", that is the abnormal and excessive growth of Algae. 6.02.2 ARSENIC Concentrations of Arsenic in surface water bodies are usually low. Rather high concentrations (0.2 - 0.9mg/l) have been reported in some drinking water supplies and are associated with endemic Arsenic poisoning and the so-called "Blackfoot" disease. Arsenic is also known to accumulate in some marine organisms, such as clams and shrimps. Certain epidemiological studies assign arsenic even a carcinogenic power. 6.02.3 SELENIUM Selenium seems to couteract Arsenic toxicity; however the specific protective action of Selenium seems well established against the toxic effects of cadmium and mercury. Selenium levels in water appear to be subject to natural control by absorption by sediments and precipitation. In trace amounts Selenium is a 51 micronutrient; at higher levels (over 2mg/l) it may have adverse effects on mammals. Some studies have indicated that Selenium increased the susceptibility to dental caries in early life. 6.02.4 TURBIDITY (SUSPENDED SOLIDS) The presence of Turbidity in a water body is mostly noxious for the interception of sun radiations, thus disturbing the regular chlorophyll photosynthesis. In many cases suspended solids may directly damage fishes by means of abrasion or choking action or, indirectly, preventing them from a good sight of the prey, thus interfering with food assumption. 6.02.5 These have toxic effect on human health if present in drinking water above 0.05mg/1 concentration. 6.02.6 METALS Copper concentration above 0.05mg/1 provides the water with astringent flavour, colour and corrosive properties. Lead content (even due to the use of lead pipes or of plastic pipes stabilized with lead compounds) may accumulate in shell-fish. Zinc gives the water an astringent flavour and opalescence. Iron causes unpleasant taste, colour, turbidity and iron bacterial proliferation. Cadmium and Nickel, fortunately not present in NCZ discharges, are very toxic even in small concentrations. 6.02.7 SULPHATES In presence of Magnesium or Sodium, Sulphates, if ingested cause gastro-intestinal irritation. 52 7.00 PRESENT EFFLUENT TREATMENTS At present NCZ Kafue factory is provided with two effluent treatment facilities, one dedicated to Sulphuric Acid Plant and the other for the remaining areas; within this latter the settling pond and cooling tower system for hot slurries from coal gasification is inserted, at present operated in autonomous way, but before interconnected with the main system. A separate talk must be dedicated to the lagoons system. 7.01 FACTORY EFFLUENT SYSTEM (Refer to the part of the Drawing 605-0049 enclosed by dotted lines and entitled "Existing Neutralization Plant") The effluents treated in the Plant are the following; - The so-called "S"-Effluent (point of sampling IW4) corning from Coal Gasification (the "A" Effluent which was coming from the Carbon Dioxide removal at present does not exist any more due to the change of the removal process). - The "c" Effluent (point of sampling IW2) from Ammonia, Nitric Acid, Ammonium Nitrate, Ammonium Sulphate and NPK Plants. - "0" Effluent (point of sampling IW3) from Compressor House, Air Separation and Water Treatment (Precipitator and Demineralisation Unit) Plants. "B" Effluent orignates mainly from the T1201 Cooling Washer for cleaning the gas corning from Gasifiers; the resulting Hot slurry (about 40Deg.C) is conveyed by a gravity canal to the Four settling ponds A321 in which separation of coal dust from clear water 1s supposed to occur. After sedimentation the clear water recycles to T1201 Wash Water Cooling Tower; the average flowrate with three running Gasifiers is 360m3/hr. If too high water losses occur due to evaporation, windage or other a make-up water from A601-E01 is provided. Two slurry pumps (1211 A/B: 80m3/hr 13.89 Bar) are sending the slurry collected at the bottom of the settling ponds to the dedicated lagoon outside the factory fence, from where overflow water is supposed to corne back to the ponds. 53 The condition of the whole system is poor. The settling ponds are equipped with moving scrapers not working since years and the original slurry pumps, which were not good have been substituted by a submersible pump which is alternately moved from a pond to another by means of a crane. The practical result is to often get an off-specification raw synthesis gas with some problems at Ammonia Plant. Moreover the pumping station for the clarified water from the lagoon is not working since it was stolen years ago, resulting in waste of water for the Factory and awkward overflow out of the lagoon. Sound interventions are required for this section in order to establish an efficiency situation as regards solids separation and clear water recycle from the lagoon, as to the recommendations contained in the chapter 9.00 "Liquid Effluents Control Plant") • However the present way of operating this section of the Effluent Treatment Plant as an autonomous service to the Gasification Units remains an idea to share. The so-called "c" Effluent, most of the time basic, is conveyed by gravity to the proper 605 C09 "c" Effluent Pond of about 160m3 volume ; the contents of the pond is maintained in agitation by means of air flowing through slotted pipes positioned on the bottom. The air is coming from the service network of the factory, while in the past was furnished by proper blowers. The pond material is concrete lined with acid proof asphalt. By means of the 605 POS AlB pumps "C tt Effluent is then pumped to 60S Cll neutralizing tank together with "0" Effluent. Here neutralization begins with the help, if necessary, of lime milk or sulphuric acid addition: this tank is provided with a vertical mixer (Impeller Diameter 500mrn of S.SKw power) and is built up in concrete coated with epoxy paint. DM Unit Effluent, together with sludge intermittently spilt from Precipitator, is collected into a transfer basin of about 100m3 volume located at the site of Water Treatment Plant, from which is pumped through an aerial pipe to the "0" Effluent double pond 605 C10 A/B. No more effluents are going at present by gravity to this pond, due to blocks and improper deviations of the sewerage system. 54 However the forecast figures for effluent flowrates are low in comparison with "c" effluent, so that it looks singular to provide storage volume of 2 x 160m3 for the minor one. The material of construction of "D" effluent double pond is concrete lined with acid-proof mortar. The 605 neutralizing tank has a volume of about 22m3, such as to assure the contact time of five minutes sufficient for a "flash mixer" service. A pH indicator-controller regulates the neutralization. The neutralized effluents flow by gravity to the so-called "Balance Tank" 605 C08 (volume about 480m3) located underground and built up of concrete line with water-proof mortar where the neutralization goes to completion; a pH indicator is inserted into the Balance Tank in order to verify the efficiency of neutralization. The water contents of Balance Tank is maintained under agitation by means of bubbling air. This allows the mixing of the mass to be neutralized but involves the solids to be kept in suspension. The outcoming stream from the Balance Tank then flows by gravity through an open trench (point of sampling IW1) to a pit where it joins the sanitary sewage effluent so as to be conveyed together to the main Kafue Township Council Sewer line. As it results from the analyses the pH of the final effluent from Balance Tank is almost always within the correct limits, but it is sometimes due to dilution with raw water injection into the trench or directly into Balance Tank from the nearby water intake pipe for the factory (which usually is conveying an amount of raw water exceeding the actual need of the factory); this latter operation represents a very poor ecology. Sometimes, if Kafue Township Council waste water treatment Plant suffers some troubles, the effluent is diverted, by opening a slide gate, to the storm water, from where it reaches directly the Kasenje River. To complete the description of this plant, it must be mentioned that there was a section of the plant (consisting in reaction tank, clarifier and decomposition tank by means of Chlorine) operating with a view to treat Cyanide rich wash water; at present this section of the plant is completely abandoned, due to the change of C02 removal process to Methanol, which causes very much less Cyanide contents; the condition of this plant section is a rust mass covered with deep layers of coal dust piled up from year to year. S5 7.02 SULPHURIC ACID PLANT (SAP) EFFLUENT TREATMENT FACILITY (refer to Drawing ZS BOO 12 There is a series of discontinuous acidic back washings, spillages, washings and drainings (as to the list of which refer to SAP Plant waste water stream paragraph 3.11 which are collected into an antiacid painted basin (V100' volume 137m3) where the effluent (point of sampling SAP1) is pumped from by means of Pl001 at present sUbstituted by the pyrite heap pit pump Pl003 to the neutralization tank V907 (diameter 2.4m, volume l2.6m3) at the rate of 10m3/hr (V100l effluent represents point of sampling SAP 1). Other continuous process etfluents from the gas purification section (namely V20l Settler, Radial Flow Thickener type, Diameter 9m, for dilute Sulphuric Acid coming from wet dirty S02 gas cooling Tower and from T 202 Washing Packed Tower for the removal of fine ,dusts and fluorides) are collected in the acid waste water basin V90l (volume 39m3) from where are pumped (point of sampling SAP 2) to the two neutralization tanks v902 and v903 in series. Neutralization occurs by means of lime addition. The effluents both from neutralization tank V907 and from V902-V903 flow by gravity to the so-called ageing tank V904 (volume about 80m, equipped with two 5.5 Kw paddle agitators) where che chemical reactions finish. It is necessary to point out that even the Calcine Slurry from V108 mixer, which constitutes the main waste from SAP, is pumped to the third neutralization tank V907; this Calcine represents the Pyrite roasting by product and is collected from the roaster itself and from the first (most part) and second stage cyclones into an agitated mixer tank (V10S, diameter 2920rnm, height 3l50rnm) where it is dissolved by means of another group of effluents, accumulated into the pit V1002 (volume about 122m3), located in position adjacent to V1001. Main constituent of Calcine is Iron Oxide (about 50% Fe203) but, due to the lack of an iron and steel industry in Zambia, these contents cannot be exploited. Other constituents are metals like copper, Zinc, Lead, Arsenic and Selenium besides Calcium, Magnesium, Silica and some Sulphur; the solids contents of Calcine effluent from Vl08 is average 5-6%. 56 The effluents utilized for dissolving Calcine in the Mixer Tank are coming from the raw water treatment facility, as follows: Blow down from V502 Precipitator, overflow from V503 Intermediate Tank, backwashings of V504 A/B valveless filters, overflow from V509 treated water storage tank and overflow from V601 Cooling Water Pit. All these effluents are collected in the pit V1002 from where the pump Pl002 conveys them to the V108 Calcine Mixer Tank. Since V1002 Pit is often full, large part of these effluents overfloods to the road, going through the storm water sewer to the final point of discharge SW2. From the ageing tank V904 the liquid effluent discharge pumps P902 A/B send the overall neutralized effluent (point of sampling SAP 3) to the Lagoon, located some kilometers outside the Factory fence. The final effluent pH is very high, about 12, in order to avoid sound corrosion of the pumps and line to lagoon; the pumps are even subject to considerable abrasion effect, due to high solids content. The daily lime consumption as 100% is about five tonnesi the lime is fed as 5% suspension. Owing to the pumps heavy duty and poor maintenance sometimes it happens that the final effluent, instead of being pumped to the dedicated lagoon, is spread all around to flow directly to Kasenje River through point SW3 (or even SW4). No water return from the Lagoon is provided: this represents a big ecological fault, as we shall deal with in next paragraph 7.03. This effluent treatment process devised by the SAP supplier appears suffering from lack of a suitable destination for the Calcine byproducti hence the idea to accumulate all, together with liquid effluents, neutralized as well as possible in a site far from the plant. The big corrosion and abrasion problems relevant to the plant together with the poor design of sewerage systems, continuously overflooding from industrial to storm water trenches, complete the frame of the pollution problems from this plant, which represents one of the biggest annoyances of NCZ factory. 57 7.03 SLURRY LAGOONS (refer to Drawing 605 - 0032) The Lagoons system is located about 2Kms outside the southern fence of the factory. The furtherest corner of Calcine Lagoon is some 300m distance from the water intake pump house for the factory and 500m from Kafue River high flood level. There are three small lagoons already full with coal dust and ash, one slurry lagoon (No 8) not yet full and one Calcine lagoon (No 5: dedicated to Sulphuric Acid Plant Effluent from the waste water treatment facility illustrated in the previous paragraph) at present about one third full. The walls of the lagoons are made up of soil with well compacted hard corel the slope of the walls is 45Deg., the height is 2m for slurry lagoons and 3.5m for Calcine lagoon. The feeding of A321 slurry from the factory occurs through two 5 inches pipes (one spare), while coal ash is periodically· transported by means of trucks and spread over the dried slurry layer. Calcine slurry feeding from SAP is through a 6 inches pipe. Since the evaporation capacity of this zone is reported to be about 1780mm per year, while the rainfall is 1020mm per year, the net evaporation is about760mm per year, so that for each 100,000 square meters of area the volume of evaporating water is 76,OOOm3 per year, that is 8.6m3/hr. It appears evident that the provided areas, about 192,OOOm2 for lagoon No 5 and 320,OOOm2 for lagoon No 4 are not enough to evaporate all the water contents in the two supposed aOm3/hr streams from SAP and A321 Settling Ponds (which contain an average of 5-6% of solids) and that recycle of the surnatant water or overflow is necessary. As a matter of fact the provided pumping station for recycling exceeding water from slurry lagoon is not working as the pump was stolen in the past, while as regards calcine SAP lagoon no water recycling system was provided since the start-up of the plant. Moreover during the construction of the calcine lagoon a mistake was committed to realizing properly a side wall which resulted in a lower sector allowing the passage of water. 58 A remedy worse than the damage was found for this defect, by installing a large overflow pipe crossing the wall of lagoon which is discharging towards the surrounding country. Furthermore the slurry feeding line is broken along the path and at present i t is discharging into the same calcine lagoon so that the actual overflow is relevant to an overall stream of about 160m3/hr; the overflow analysis (Annex 7) shows that this steam is systematically out of the Zambian law for sulphates. Moreover, even if not pointed out by the few analyses carried out, it still visibly contains coal dusts coming from the dissolving coal ash layer (due to the action of the leakage from a point on the incoming pipe). In the course of the study analyses of the surrounding soil and water ponds were carried out in order to find out suspended. seepages and some wells were dug with the purpose of investigating eventual pollution of water table. The results relevant to this part of the study are illustrated in the chapter 14.00 deciated to "Solid wastes·. It remains to notice that some people from the surrounding villages are used to fishing from the liquid fraction of the disposal ponds, despite the protection fences that in the past were cut down (probably fish eggs were introduced into the lagoons through the emissions of raw water which occur at the factory). Obviously nobody can guarantee about the quality of fish taken out from a pond where an industry is discharging water containing Lead, Arsenic and other chemical compounds. SQ 8.00 PRESENT SITUATION QE THE SEWERAGE SYSTEMS There are three different sewerage systems, at least in theory, in the factory: for industrial effluents (supposed polluted from the production plants), storm water drainages (supposed to collect only rainy water) and sanitary sewage (for offices lavatories discharges and the canteen). The up to date layout of these systems is shown by means of different pen marks in the enclosed drawing A201 - 0064, according to the legend there included. Even the line pieces running over head or underground are there indicated. Most drainage systems are of the open trench type; this is responsible, as Nez factory main raw material is coal dust, for the invevitable loading into the water flowing through the sewers of large amounts of powder.s, especially in proximity to coal storage yard, of several kinds (coal, soil, ammonium nitrate, NPK) and other outward material (sacks, wood and metal scraps, grass, stones and so on). This state of things involves higher levels of pollution from suspended solids and frequent blockages of the sewer parts with subsequent deviation to another sewer system. One of the outstanding environmental problems at Kafue factory is the flowing of very polluted streams into sewer systems provided only for rainy water, thus not conveying to any waste water facility (neither in-plant nor centralized one), with the aggravating circumstance that the final points of discharge are spread along all the four sides of the factory perimeter. Responsible for this state of affairs is, besides initial design or construction defects, poor maintenance and cleaning practice of the open trenches. In the course of the study some major anomalies were individuated, as herein after reported, but a warm recommendation is addressed to every Process Engineer to investigate inside one's plant for every small anomaly, improper deviation to the wrong sewer, as built modification, construction defect which may give rise to pollution. The location of main anomalies are marked with special sign and figure in the same drawing A 201 - 0064 (see the legend). 60 B.01 MIXINGS 1 At the coal handling site the branch of industrial sewer conveying the ..c .. effluent to 60S-COg pond is an open trench badly covered with concrete plates rather in bad condition. Apart from this fact, that by itself involves the loading of considerable amounts of coal dust, as the crossed area is very dusty, there is practised a junction with the storm water by means of the abatement of some meters of floor (not considered in the design) that allows part of the polluted "c" effluent to flow towards final point of discharge SW7 instead of being conveyed to the waste water treatment facility (see area portion marked with 1 in the Annexed Drawing A201-0064). 2 At the coal gasification site, by the corner of E72 road with N257, the effluent coming from compressor house and air separation plant through the industrial sewer, and supposed to go to the treatment, is, on the contrary totally deviated to the storm water by means of an underground pipe crossing the N257 road that connects the collection pit from the plants with the open storm water trench located on the same abovementioned drawing). That is owing to the blocking of industrial sewer in a down stream pOSition by cooling spray pond. 3 Another direct connection of the industrial sewer with the storm water draining can be found just by the sampling point IW9, at the corner of N182 and E72 roads, where a piece of pipe puts in connection the two kinds of sewers (Area 3 of the same Drawing). 4 At NPK Plant the pump installed in the pit receiving polluted discharges is normally not working; it was supposed to convey waste water through an overhead line on the pipe rack to the effluent treatment facility but, owing to the abovementioned permanent shutdown of the only pump, the effluents are discharged into the storm water draining by means of a channel dug on the floor; final point of discharge is SW10. 5 At Ammonium Sulphate Plant site too the pump, supposed to send to the same effluent facility as above, is not working; thus the effluents flow towards other directions through the storm water drainages to arrive to SWl and SW10 final point. Moreover, it is necessary to note for this plant that a direct derivation flowing into Kasenje River was realised by somebody from the discharge pipe of the pump. 8.02 BLOCKING AND BREAKINGS 6 At Coal Gasification site one of the trenches conveying water washings to the A321 settling ponds is often blocked because of too much coal ashes that pile up in this area, thus deviating the washings charged with the coal dust to the storm water (and finally to SW7). 7 Again at Coal Gasification the internal industrial sewer must be broken somewhere; infact water charged with coal dust is flowing through the electrical trench parallel to road E72. At a certain point from the electrical trench it was realized a small channel, digging the floor, through which the polluted water joins the storm water drainage along road E72. 8 At water treatment plant the resins regeneration eluates are conveyed to the storage pit through an open channel which has even direct connection with the industrial sewer located at the other side of the N257 road (the same blocked, already mentioned at point 2). Since often the water level in the pit is too high. the water treatment effluent overflows from this channel and mixes with water flowing through the storm water drainage crossing the open channel. 9 Then the same storm water draining along the N257 road mentioned above is blocked in the area opposite the cooling spray pond, so a small channel scrapped up from the floor provides an immission to the trench flowing to A321 Settling Ponds. In this way at least a polluted stream which was flowing through the storm water drainage system to the usual wrong point of discharge SW7 is conveyed to a treatment (but if the eluates pit is overflowing acidic water can go to the settling ponds). 02 10 For long ti~e during the analytical campaign the underground pipe crossing N182 road to connect the two branches of industrial sewer was corroded and broken, so that a plate was put in the sewer in order to let the effluent overflood into the storm water trench (so going to SW7). More than one month passed before repairing. 11 Storm water trench is choked on the southern side of N182 road, so the streams pass to the other side of the trench crossing the road through the existing connection. They reach the same pit located at W57.302 to flow to SW7. The pipe connected with the pit got broken long time just near the connection. 12 At present the 450mm sewer, conveying the mixture of industrial effluent/sanitary sewage from the factory to the main council sewer line is broken in proximity of the new Boiler under erection, so pouring the waste water into the open storm wa~er trench below and supplying a big flow (about 90m3/hr) to SW8 that was almost standing during the analytical campaign. 13 The concrete surrounding the "D" effluent sewer is broken in proximity of the crossing N182 road, thus allowing the connection with the near storm water sewer which is even by itself polluted since it is crossing the very dusty coal gasification area. 8.03 IMPROPER CONVEYINGS 14 Surely an improper conveying is an Ammonium Nitrate site where a stream coming from the plant flows to the storm water drainage and may be it is responsible, together with road washings, for high nitrate and ammonia concentrations found in SW9. It is very likely that by examining into details all the designs and constructions of the existing sewerage systems, as built, many more improper conveyings can be found. 15 Some "reverse" improper conveyings are present with almost all the gas holders. Infact considerable amounts of water utilized for sealing are unexplanably conveyed to industrial sewer, while they are clean, thus contributing to useless 03 hydraulic load for the waste water treatment facility. Only the sealing water for the 311-V10 nitrogen holder located at the N322 road near the factory fence is properly conveyed to storm water sewer. 8.04 SULPHURIC ACID PLANT EFFLUENTS 16 The liquid effluent discharge pumps P902 A/B are often out of order because of the heavy duty to suffer in terms of abrasion and corrosion, notwithstanding the particular material (high Chromium Cast Iron) adopted so that the final effluent containing calcine and neutralized streams ends directly to Kasenje River through the storm water sewer instead of going to decantate in the Lagoon. 17 There is a crossing of open trenches conveying industrial effluents and rainy water with the consequence of passage of polluted streams to the storm water drainage and from which it flows to SW3, in case of frequent effluent overflooding. 8.05 LATEST MIXING 18 At gas purification site along the northern side of N182 road there has recently been .realized a direct connection between the industrial effluent IW6 (running at higher level but broken and blocked) and the storm water sewer below, by means of a small channel dug in the concrete. 64 9.00 LIQUID EFFLUENT CONTROL PLAN In this chapter we shall indicate the recommendations that we feel like putting forward in order to solve the heavy pollution problems relevant to Nez Kafue factory liquid effluents. The reasons for such proposals and the advantages that can be got with the adoption of these proposals will be explained. Precautions to be taken for a proper and reliable realization of the proposed interventions will be herein indicated as far as possible in this preliminary study stage. The cost estimates relevant to each intervention are shown in the chapter 10.00. 9.01 SEWERAGE SYSTEM REARRANGEMENT Any attempts to restore the pollution situation originating from NCZ Kafue factory cannot leave sewer rearrangement out of conSideration, otherwise too much money would be wasted in vain as investment and operating costs in order to realize the too big and numerous treatment facilities that should necessitate in the actual present sewers situation. For this purpose we suggest to cancel the above mentioned 18 main anomalies as below indicated. Moreover we suggest to transform from open trenches to closed pipes (of diameter such as to ensure the same flowratel all the branches of industrial sewers crossing coal gasification and coal preparation areas. As regards industrial sewers to waste water facility this would produce the benefit of not overloading uselessly the already polluted streams with coal dust. The necessary inspection wells must stretch themselves well above ground and must be covered by dust-tight plates, though easily removable for inspection. Every inspection well must be realized with regular form and calibrated. A graduated scale in centimeters must be provided on one side from the bottom of the well in order to easily carry out flowrate measurements by means of Chronometer and observing level differences obtainable by closing the discharge pipes with plates. 65 As material of construction, by realizing the sewer pipes of high density polyethilene, a very low roughness Index will be ensured, thus allowing a larger flow, even with small slopes. The pipes can be positioned exploiting as part of excavation of the same existing open channels. Attention will be paid to provide suitable rigid diaphragms above the pipes in case of road crossings. As regards the main anomalies already pointed out and mentioned in the previous chapter we suggest to settle as priority interventions as follows: 1 COAL GASIFICATION Destroy the abnormal direct connection between industrial and storm water sewers, by building up again a concrete wall of separation and transforming the open trench of the industrial sewer to closed pipe. 2 COAL HANDLING Remove all the blocking of the "0" effluent industrial sewer, realizing with closed pipes the crucial crossings of dusty areas, and destroy the abnormal connection with storm water draining. 3 ~ (Pit by impure N2 Holder) Destroy the direct connection with storm water sewer re-establishing the underground pipe connection to .. c.. effluent sewer. 4 NPK PLANT Install a new couple of pumps more reliable than present ones. 5 AMMONIUM SULPHATE PLANT Install a new couple of pumps. Destroy the pipe branch directly pouring into Kasenje River. 6· COAL GASIFICATION Remove materials blocking the sewer and transform it to closed pipe. 66 7 COAL GASIFICATION Repair point of breakage and remove the abusive small channel dug from the cable trench. 8 WATER TREATMENT Provide start-up of transfer pumps at lower levels of water in the pit in order to avoid overflows as much as possible. Transform the open channel for the eventual overflow from the pit in closed pipe just for ten metres tract crossing the storm water sewer in order to avoid not wished mixings. 9 uB" EFFLUENT ~ STORM WATER SEWERS CROSSINGS Re-establish the wall of separation between the two kinds of sewers and remove the cause of blockage by transforming a tract of open trench flowing to A321 settling ponds to closed pipe. 10 N182 ROAD CROSSING QK IW6 EFFLUENT Review very carefully the recent repairing, remove the cause of blockages changing into material more resistant to corrosion. 11 STORM WATER SEWER Remove cause of blockage and repair broken pipe. 12 SANITARY/EFFLUENT SEWER Substitute the broken 450mm pipe branch. 13 "D" EFFLUENT CROSSING OF N182 ROAD Repair the broken piece of concrete which allows the mixing. 14 AMMONIUM NITRATE Deviate the effluent path from storm water to the nearest industrial sewer. 15 ~ HOLDERS Deviate the clean sealing water from the gas holders to the nearest storm water sewer. 67 16 SAP DISCHARGE PUMPS The suggested intervention to solve this problem is illustrated in the ambit of the review of SAP liquid effluent disposal system. 17 SAP SEWERS CROSSING AND MIXING Even here the possible mixing must be avoided realizing some ten meters of closed pipes instead of open trenches at the place of crossing. 18 IW6 EFFLUENT MIXING WITH STORM WATER SEWER Remove the materials blocking the industrial sewer and fill up the abusive channel dug for direct connection with concrete. 9.02 STUDY FOR THE COMPLETION OF SEWERAGE REARRANGEMENT The above interventions surely will eliminate the major anomalies relevant to the present situation or sewer systems, so allowing that as most as possible of suspended solids, nitrates, ammonia, sUlphates and metals will be conveyed through the suitable sewer to a treatment facility to undergo a purification process and not directly to natural water course. However some further sound ameliorations in this direction can surely be obtained by pushing forward the detailed analysis of the whole sewerage system in all the factory, including even a critical examination of the initial design, a punctual verifying of all the construction particulars and the elaboration of remedial modifications. We believe that such work can be carried out in two months' time by three people, a Process Engineer and a Geometer coordinated by the Environmental Control Superintendent (to be appointed as soon as possible: see paragraph 9.14) under the responsibility of the Technical Manager. These people can be chosen from the factory personnel, if available, or otherwise the task can be assigned to an external firm. The scope of the work will be to examine all the sewer detailed drawings section by section of the factory, to check with elevation measurements on site the correspondence with the as-built reality and to suggest deviations and other modifications, keeping in mind the following principles: (a) Storm water drainages must receive only rainy water from surely not contaminated areas and clean streams (such as steam condensates, if not polluted and not recovered, gas holders sealing water, eventually not recycled cooling water, overflows from treated water basins and so on). (b) Industrial waste water sewe"rs must receive process discharges (continuous of batch) from the plants, rainy water originating from contaminated areas (eventually local drainage channels connected with storm water sewerage system must be provided in case of exceptional rains), washing of the floors and of the contaminated roads. (c) Sanitary sewer must receive only discharges from latrines and the canteen. (d) Every improper conveying of a kind of water into the wrong sewer must be eliminated. (e) Every mixing, even potential, between the various types of waters must absolutely be avoided. (f) Open trenches for industrial sewers in dusty areas must be avoided. The suggested modifications subsequent to this study will be carried out as maintenance works. One of the objectives of this study must be the complete elimination of pollution from the storm water final points of discharge SW9 SW8 SW6 SW5. That is why it would be too expensive to collect small streams along all the sides of the Nez complex by means of collection pits, pumps and long pipes of discharge to the centralized waste water facility. As regards storm water sewerage system only SW7 can be allowed to carry massive suspended 69 solids pollution, since the relevant branches of sewer serve the Coal Storage Yard. As regards this point SW7 we recommend the realization of the interventions suggested in the next two paragraphs 9.03 and 9.04. 9.02.1 CONTROL QK WATER CONSUMPTION In parallel with the above study the same task group can carry out a complete survey about overall water consumption in the plants in order to individuate all the abusive withdrawls from the firewater network, the once through streams drawn from the cooling water recirculation system and so on. The main purpose of this study is to explain the excessive discrepancy between the about 700m3/hr resulting from the two major discharge streams, namely IW1 and SW7, and the scarce 100m3/hr resulting as approximate overall total from the figures declared during the interviews object of the survey on pollution production from the plants in chapter 3.00, as regards the plants apart from SAP. Once individuated the abnormal withdrawals, these must be prohibited by means of suitable interventions or procedures. For instance excessive waste of water, that surely at present occurs at an extent many times larger than declared from the same plant chiefs, must be avoided, especially in the areas involving dusts of fertilizers, by increasing the practice of sweeping the lost materials as solids and recover them as a valuable product instead of dispersing them into the sewers with sensible increase of water amount and pollutants contents (Ammonia, Nitrates, Sulphates, Phosphates and suspended solids as coal dust or ash). The experience teaches that water savings up to 50% are possible in this way, with all the subsequent benefits on pollution level decrease. 9.03 FIRST RAINY WATER TREATMENT FACILITY As a matter of fact all the areas, covered or uncovered, of an industrial complex are potentially polluted, so that when rainfalls occur we can be sure that storm water flowing in the sewers is not clean, but heavily polluted, due to entrainment of both dusty materials deposited on the areas and of emissions from the stacks (802 and others). 70 Even more so it is valid for a complex like NeZ factory where raw materials is coal dust and final products are Ammonium Nitrate and Sulphate and NPK fertilizers. So that it is very reasonable to propose even for NeZ what is the common practice in every factory of providing a proper facility for the collection of the waters of first rainfall and their delivery to the waste water treatment plant, which will be the present neutralization unit completed with a new clariflocculator (see the proper paragraph 9.08). This intervention, after realizing the sewers system rearrangement mentioned in the previous paragraphs, and in plant treatments and interventions (paragraph 9.07) can be limited to the main storm water sewer skirting the coal yard and conveying to the final point of discharge SW7', the most polluted one in the whole factory as to the results of the analytical campaign. This would prevent large amounts of suspended solids from contaminating the open drainage into which the sewer is discharging from the point SW7, and from this the new Kasenje River and from this the Kafue River. We would like to stress here that Kafue River is already contaminated from big deposits of coal dusts and ashes coming from Nez factory, as pointed out during the boat trip mentioned in paragraph 5.03. The first rainy water treatment facility will simply consist of an intercepting device installed along the 675mm (27") storm water sewer, designed to divert all dry weather flow and first rainy weather flow to a collection tank, realized underground in concrete and of a pumping station positioned into the collection tank in order to pump out the collected waters to the effluent treatment plant. The intercepting device may be a diversion weir of the overflow type or a leaping weir (an opening in the invert of the sewer of such dimensions as to permit the flow that is to be intercepted to fall through) and must be hydraulically well designed in order to allow eventual following rainfalls surely consisting of water cleaner than the previous) to pass over and continue along the sewer to the storm water outlet into the open drainage (point SW7) • As for some patterns of intercepting devices, see bibliography 3. The design criterion for the collection tank can be to retain 2 days amount of maximum rainfall. Since the most rainy days in Zambia present 30mm of rainfall and the area involved in SW7 sewer (Area II plus Coal Yard) is about 20,000 square meters, it means a volume of: 2 x 30.10-3.20,000 ~ 1,200m3 That we suggest to raise up to 2,500m3 (depth 4m rectangular plan of 625m2) in order to provide a certain holding basin even for the day weather wastewaters that surely will persist also after the sewer system rearrangement. As we estimate this latter amount about 200m3/hr the relevant pumping station, consisting of centrifugal vertical pumps installed in a corner of the basin, will be sized for facing this flowrate plus a rate of first rainy weather water capable of draining all the stored quantity in one day, eg 1200 : 50m3/hr 24 for a total of 250m3/hr. The collection basin must be operated practically empty in dry weather, with the pumping station always running at 200m3/hr, while after rainfalls this latter will run at 250m3/hr, delivering the waste waters to the effluent treatment plant (liD" Effluent Pond) • When the basin is full or the. storm intensity is around the maximum levels the following rainfalls will pass over the intercepting device to directly discharge into the open drainage. 72 9.04 STORM WATER DRAINAGE SYSTEM The above interventions, once realised, will surely mitigate the hydraulic and pollutant load to the storm water drainages which, in theory, will result in clean and full only during the rainy season. However, due to the poor condition of the storm water draining branch discharging into the open drainage through the final point SW7 (about 25cm of sediment layer) and subsequent risk of over flooding during the rainy season we recommend an overall treatment for the final discharge channel (similar to the one suggested by Brian Colquhoun and Partners Consulting Engineers to the new Kasenje River) as follows: (a) Removal of the silt deposits from the sewer pipe by means of mechanical devices. (b) Totally clear the channel of all reed growth, shrubs, excessive grass, rubbish etc for a distance extending 200m. (c) Cut and shape to a regular trapezoidal section with side slopes at a gradient of 1:2 the above mentioned, providing this open drainage with a concrete lining to achieve a constant value for the roughness coefficient of about 0.015. 9.05 WATER INTAKE IMPROVING INTERVENTIONS As reported in other part of the study, the Water Intake pumping stations both for Sulphuric Acid Plant and the remaining of the factory are usually operated at maximum capacity, even if the needs are much lower. That is why, choking the pump discharge, the water velocity is lower and too much sea weed can grow, so causing blockage of the discharge pipe. We suggest to install at the Water Intake Station a proper surface water intake screen of the self-cleansing type in order to stop the inflow of the Algae and other foreign bodies. Moreover from time to time it would be better to proceed with some shock injection of chlorine and specific algae-killing products for avoiding excessive accumulation (of course the installation of fixed devices for this purpose is not advisable owing to the long distance of the non-garrisoned Water Intake from the factory). 73 This intervention will get the benefits of reducing power waste and avoiding clean water overflows in the factory, which turns into useless hydraulic overloads for the sewers or water facilities (here even involving waste of chemicals) with possible overflooding and mixing between different drainage systems. 9.06 Pw~CHASING OF MOBILE OIL SKIMMERS In order to avoid excessive oil accumulation in some pits along the industrial sewers it is recommendable to provide the factory with at least two mobile oil skimmers and recovery system, in order to move these devices periodically from one point to another. Infact the pollution from oil is not so high to justify a fixed separation unit but accumulation in some pits, especially in proximity of compressor houses becomes considerable after many months of not cleaning practice. 9.07 IN-PLANT TREATMENTS AND INTERVENTIONS The nature of the origin sources of most discharges from Kafue factory plants, as resulted from the interviews mentioned in chapter 3.00, is such as to hardly suggest in-plant pretreatments for some streams. Infact only few particular process waste waters can be met and the major problems are arising for reasons of cleaning the plants or accidental leakages due to poor maintenance or washing the apparatus owing to too frequent shutdowns. So just some in-plant interventions will be suggested and for the rest recall to good maintenance, availability of spares for prompt substitution of the broken parts and some cleaning suggestions must be done. 9.07.1 ~ PREPARATION !tlQ GASIFICATION The factory must be provided expressly for these sections with one mobile industrial vacuum cleaning device of the mobile type trailed by means of lift truck. By regularly and periodically operating this device, capable of producing a SSOOmm H20 vacuum and of aspirating a quantity of at least 4t/hr, it will prevent the area surrounding the mills, the fuller pumps and everywhere the coal is dry to be excessively covered of fine coal dust with the consequence of polluting the 74 storm water sewer (as regards industrial sewer crossing this area the pollution will be prevented realizing a closed pipe as already suggested in paragraph 9.01) and dispersing, by means of the winds, allover the factory. The vacuum cleaner will be equipped with discharge device of the screw type, in order to avoid a big cloud of dust when discharging the collected materials into the coal yard back. It will be possible to use the same equipment for cleaning the coal gasification area from the piles of coal ashes with the caution of cleaning the vacuum cleaner properly, after the discharge of the coal ashes into the lagoon, before using for coal dust, in order to avoid contamination of this latter. A rich series of spare parts will be purchased together with the main machinery,' in order to avoid long times of shutdown in case of maintenance needs. A sound relief even for industrial hygiene problems will arise from the adoption of this equipment. 9.07.2 AMMONIA STORAGE We recommend a sound and complete review of the refrigeration system relevant to this area, since it is clearly absurd that, even if sometimes, a certain amount of the valuable final product stored in the spheres must be vented to atmosphere or even discharged into the sewers just due to defiCiency of the refrigeration system. After having suffered all the production costs it is not admissable that even small quantities of Ammonia are utilized for creating air pollution, water pollution and industrial hygiene problems. 9.07.3 OLD NITRIC ACID PLANT (601) The plant must be equipped with a stainless steel (AISI 304) recovery tank of about 2m3 in order to recover acid from sampling lines and other drainages. From the collection tank a high prevalence pump will recycle to the system (bleaching tower). Moreover as regards the discharge of the Chloride contaminated acid from T04 trays a draining system must be installed able to send the contaminated acid to the product stock tank (similar to the one installed in A401 Plant). 75 9.07.4 NEW NITRIC ACID PLANT (A601) The present pit v-1201 is collecting even rainy water. It must be substituted by a closed tank and the recycle pump, often not working, must be reviewed or substituted by a more reliable one. 9.07.5 OLD AMMONIUM NITRATE PLANT (501) This plant together with the expansion one are highly pollutant. So a good deal of attention must be paid to every possible recovery of recycle intervention in these plants in order to reduce nitrates and Ammonia contents in the industrial effluent within the law standards. The following interventions are possible: 1 Recovery of continuous 1.3m3/hr condensate from first concentration (containing 1.5 2% Ammonium Nitrate plus free Ammonia) as process water in the nitrous gases absorber of the associated NItric Acid plant. The study about this recovery is in progress with the relevant plant Process Engineers. 2 Connect to the existing recovery tank V25 the sampling points at present missIng (80% Ammonium Nitrate solution from V04 and Nitric Acid Tank line to the reactor) and, if possible, all the drainages due to shut downs of apparatus. 3 Improve the maintenance of all the solid material handling equipments in order to reduce dust losses from chutes and other openings. 4 Submit drums and buckets elevators to the aspiration of a fan connected with the existing wet cyclone separator scrubber system in order to recover Ammonium Nitrate solution in the V25 underground recovery tank. For this latter intervention, it is advisable to consult a solid handling equipment specialist. 5 Abandon the practice of washing the floors with water by means of hose pipes, but adopt the habit of sweeping the large amounts of Ammonium Nitrate on the floors and roads 76 collect in bags and recover or inside the same plant or in NPK plant. Unfortunately here the adoption of a vacuum cleaner of the type suggested for coal is not advisable due to the property of deliquescence of the particular product. 9.07.6 NEW AMMONIUM NITRATE PLANT (A5al I 1 Like the Old Plant provide recycle of multiple effect concentration condensates (about 5.2m3/hr at 66 Deg.C from V1206 collection tank) as process water to the absorber of the associated Nitric Acid Plant. This intervention too is in progress. 2 Speed up the realization of the provided closed loop system (an underground recovery tank lined with stainless steel material) trying to collect as much as possible of sampling lines, possible overflows and shutdown drainages. 3 Like the Old Plant improve the maintenance of solids handling equipment and adopt the cleaning practice of sweeping instead of washing the floors. 9.07.7 AMMONIUM SULPHATE AND NPK PLANTS 1 Improve the maintenance of solids handling equipment, trying to reduce the losses. 2 Recollect from the floors and recycle as much as possible of solids materials without washing the sewers. For this purpose it is advisable to purchase an Industrial Vacuum Cleaner dedicated to NPK plant since often in this plant many tons of materials are piled up due to various troubles. For this plant it is better to forecast, instead of a mobile unit, a fixed installation with a pipe network distributed at the various floors. 3 Install a new couple of pumps in the pits collecting the discharges (as already mentioned in paragraph 9.011. 77 9.08 REVIEW OF LIQUID EFFLUENT DISPOSAL SYSTEM (see drawing No 605 - 0049) The adoption of the previous recommendation about sewerage system rearrangements, water intake and implant interventions will surely achieve a sensible reduction of the polluting load in industrial effluents and moreover, will concentrate pollutants on only one stream, the waste water facility feeding. At present this facility suffers from the absence of any suspended solids removal equipment (it is appropriate to be reminded of the surprising condition of the Kafue River portion by the confluence of Kasenje which was found during the already mentioned boat trip): so that we suggest to review this plant by realizing above ground a new unit of clariflocculation in the area now occupied by the old not utilized cyanide removal unit so that the neutralization plant will remain the same, while the new clarification unit will be able to treat 500m3/hr of polluted water (since we estimate that a 200m3/hr reduction in waste water flow is possible due to the above mentioned interventions as regards to internal recoveries in the production plants, no over flows of raw water after installations of screen at Water Intake, no floors washing and control of abusive water consumptions) with about 2000mg/1 of suspended solids. The clariflocculator can be either of the forced internal sludge recirculation (by means of a turbine) type or of the simple crossflow type equipped with mechanical flocculator drive assemblies. The difference between the two alternatives are the higher cost for the recirculation unit together with minor dimensions: 18 mts diameter for a recirculation unit versus 30 mts for a mechanical flocculator clarifier, which is simpler to operate. Both can run with or without flocculant addition. We suggest to experimentally study in operation the advantages of adding a poleylectrolite as coagulant. It is better to provide facilities for scum removal (a rotating scum blade attached to the bridge) • The sludge collected by the proper valves can be stored in a pit from where it will be transferred by means of pumps to the same settling ponds operating for "B" effluent. 78 The clarified water outlet can be delivered to the main Council sewer. 9.09 REVIEW OF "a" EFFLUENT WASH WATER SYSTEM As regards the autonomous treatment for the so called "a" effluent from gasifiers it is recommendable to arrqnge the repairing of the machinery installed into the existing settling ponds. Each pond must be provided with its own efficient scraper and slurry extraction pump. For this purpose we suggest to purchase from a specialised firm the new machinery to install in the existing ponds (so that 4 scraper bridges and 4 slurry pumps), sending the drawings of the settling ponds to allow a proper design. Such an intervention will improve the separation efficiency of the entire wash-water cooling tower system; thus resulting in a cleaner raw synthesis gas with less troubles to Ammonia plant. 9.10 THE PROaLEM OF AMMONIA AND NITRATES: PROpOSAL OF ION EXCHANGE UNIT FOR AMMONIA REMOVAL AND ii.MMONfUM NITRATERECOVERY - Till now the recommendations suggested will involve the benefits of ending the spreading or pollution without control in numerous points of discharge in the factory and to depurate the main waste water streams (IW1 and SW7) from the particular pollutant "suspended solids" (mainly coal dust). The major problem of Ammonia and Nitrate pollutants remains to be solved. If we pay attention both to the single analyses relevant to the campaing (Annex 3 pages 1 - 17) and to the average summary Tables 2 and 3, we realize that the Iron Ammonium contents in the waste waters is a lot beyond the amount tied to the Anion Nitrate in the molecule of Ammonium Nitrate; it means that Ammonium is bound even to other Anions, such as sulphates (so very probably coming from Ammonium Sulphate Plant), carbonates and some phosphates; moreover often a considerable amount of free Ammonia can be found in practically all the points of discharge and mainly in the major streams IWl and SW7. By means of the in-plant interventions suggested for the Ammonia, Nitric Acid, Ammonium Nitrate, Ammonium Sulphate and NPK 79 Plants, it will be possible to reduce considerably the quantities of Ammonium and Nitrate, Sulphate and Phosphate Ions but sure it will not be possible to reduce Ammonium concentration below the Zambia regulation standard of 12.1mg/1 as NH3 (10mg/l as Nitrogen), since this latter is very low, even if higher than most international standards. Infact if we look at the figures of the tables 2 and 3, apart from SW9 and SW10 that must be led back to the main streams IW1 and SW7 due to sewer rearrangements, we realize that Nitrate contents are in average of 480mg/1 that must be reduced below the standard of 3S4mg/1 as N03 (80mg/1 as Nitrogen). This is quite achievable if we adopt the recommendations already indicated to avoid the arrival into the sewers system of only part of the various tons of solid Ammonium Nitrate particles that usually are present in the two Ammonium Nitrate plants. The same is not possible as regards Ammonium, since it is an average of 597mg/1 which must be reduced to 60.7mg/1 as Ammonia (SOmg/l as Nitrogen). A specific treatment for the elimination of Ammonium from the effluent discharging into the public sewer, and possibly to recover Ammonia since a big percentage of the present production is going to the sewers, is subsequently recommendable. As regards the suitable technology for Ammonia depuration in a context such as NCZ Kafue factory we cannot appeal to the conventional biological plants, that are able to work only with a well defined ratio between organic substances load and Nitrogen (otherwise bacteria cannot survive), As this latter ratio is about 4, it would be necessary for the Ammonia load of: S97mg/l .SOOm3/hr .24 = 7.16t/day (SOOm3/hr being the overall flowrate under the hypothesis of 200m3/hr reduction of the waste waters). About 4. 7.16 = 29t/day of BODS/BODS is the amount of oxygen consumed at 20 Deg.C in five days for the oxydation of the organic substances present in waste water, by means of aerobic bacteria, in order to obtain stabilised compounds, Carbon Dioxide and water). 80 The problem involved in NCZ Rafue factory is that it includes exclusively inorganic plants producing only fertilisers or Sulphuric Acid, so that BODS of the relevant waste waters is nil; on the contrary in Europe or America the fertilizer production units are generally associated in a factory which comprises even a refinery or some petrochemical plants, so that supplying an organic load to the relevant waste waters, which can be conveyed, together with the fertilizer ones to a common biological plant. Infact the only organic compound handled in the factory is methanol, but it is utilised in the Rectisol process for the CO conversion plant (A306) and its presence into the discharges certainly is not agreeable and is practically very low. However, even if the methanol synthesis unit would run at the maximum capacity of St/day, it could not supply the necessary amount of 29t/day of BODS because 1Kg of methanol is equivalent to only O.SKg BODS. Even the organic load obtainable from the sanitary sewege would be very low in comparison with the needs. Infact even in the case of considering that all the 1500 employees utilize every day the public conveniencies of the factory, so supplying to the sanitary sewer the high amount of 50 grams/ day per person BODS, it would be possible to get, by joining the sewer systems only: 3 1500.50.10 = 75Kg/day BODS Among the other technologies stripping and ion exchange can be considered. Stripping can be performed by means of air or steam. However air stripping looks rejectable since it is the less efficient process as regards ammonia removal and requires very large air amounts, so involving a series of large diameter column; moreover it requires the consumption of cospicuos quantities of caustic soda in order to replace ammonium cations bound to Nitrate and Sulphate Anions with sodium in order to allow the stripping of Ammonia and then, if not followed by an absorption unit with Sulphuric Acid in order to produce Ammonium Sulphate, it transforms the water pollution problem into an air pollution problem. Unfortunately in the context of NCZ factory at present it is not possible to concentrate a dilute solution of Ammonium Sulphate since the Ammonium Sulphate plant is lacking of a crystallization section. On the contrary it is a very small unit only consisting of a reactor working with gaseous Ammonia and a centrifuge to separate the formed crystals. Even the steam stripping solution can hardly be applied at NCZ factory: it would be the simpler one, performing high efficiency (by means of a 25 plates column of 1.2mts diameter we can estimate less than 30mg/1 Ammonia in the effluent) but the limiting factors are the operating costs. Infact, apart from the 6 bar steam consumption (which amounts to about 7.2 tons/hr at the rate of 0.12 tons/m3 treated water, that might be supplied by the new Thermax Boiler), it is necessary to replace any Ammonium cations bound with strong Anions (Nitrates, Sulphates and Phosphates) with sodium by means of caustic soda addition prior to feed the stripping section, otherwise this latter cannot work (only Ammonium tied to carbonates and bicarbonates, apart from free Ammonia, can strip away without chemicals because of the low decomposition temperature). It means for every ton of Ammonium to be removed there are required 2.2 tons of 100% caustic soda that is very expensive in Zambia (it is imported at about US $700 per ton). Due to all the above reasons the more attractive solution to· reduce the Ammonia pollution is to apply ion exchange to selected streams from the plants, presenting higher Ammonia concentrations so collecting about 60m3/hr with 4000mg/l Ammonium concentration. This proposal is on the model of the choice, reported in literature (see bibliography 4), effected in the past by many US Fertilizer and Explosive producers (such as Chemical Farmers Industries Inc., Illinois Nitrogen Corp., American Cyanamid Co., Joliet Army Ammunition Plant and others), allowing simultaneously to solve a pollution problem and to recover valuable product. Infact by utilizing Nitric Acid, a chemical produced inside NCZ factory itself, as regenerant for the cationic resins to be installed for Ammonium fixing, it is possible to produce an Ammonium Nitrate solution. The concentration of this latter can vary from 12% iri the case of a fixed bed installation to 22% in the case of a continuous counter current unit, which allows to reach higher concentration. We suggest to resort to a fixed bed installation, as it is simpler to run, consisting of two cation exchangers in series, one carboxylic and one sulphonic. The selected streams, to be collected in a suitable storage tank, must be taken from the Ammonia, Ammonium Nitrate and Ammonium Sulphate plants. We believe that is better to leave NPK plant discharges out of this treatment in order not to introduce too many trash cations other than Ammonium in the treatment system and subsequently in the final Ammonium Nitrate solution produced. We trust that for NPK plant pollution a big benefit will come from the adoption of the industrial vacuum cleaning system, as suggested in paragraph 9.07.7. The acid effluent from ion exchange unit (containing all the anions, sulphate and nitrate, previously bound to Ammonia) can be delivered to the present neutra'lization plant of the factory. The produced Ammonium Nitrate solution at 12% would not overcharge the present evaporation section capacity of the Ammonium Nitrate plants as it represents a small percentage (about 25 tons/day; versus an overall design capacity of the AN plants of more than 500 tons/day); otherwise a strengthening of the evaporation section must be provided. If we examine the possible sources of Ammonia in the sewers plant by plant we realize that the major contributors are not the Ammonia production plants (for which only a process condensate from CO conversion of the new plant can be found as systematic discharge), but the Ammonium Nitrate plants and even the Nitric Acid plants (emptying of Ammonia Evaporators at shutdowns and so on). From the data collected in the laboratory file Ammonium concentrations up to 10 - 11000mg/1 (with free Ammonia up to 3000mg/1) can be found in single samples taken from the sewers just inside the Ammonium Nitrate plants. So that it looks quite reasonable to propose to collect every Ammonia concentrated discharge from the production plants by means of a proper closed sewer system, that we can call the "Ammonia Sewer" and convey all the streams to the proposed new ion exchange unit. 83 This new "Ammonia Sewer" system will collect any possible discharge containing Ammonia more than 200mg/l arising for process reasons or from operating or maintenance procedures and must be surely not contaminated by rainy waters or outward pollutants (as dusts, oil or other) • We estimate that, carefully choosing among the great deal of polluted streams corning from the production plants (Ammonia, Ammonium Nitrates and Ammonium Sulphate) the ones provided with similar characteristics and not susceptible of any internal recovery, a total amount of 60m3/hr of waste waters with a concentration of 4000mg/l of NH4+ can be found, which represents the design basis for the ion exchange Plant, which must include three lines (two on stream and one under regeneration) each one consisting of a series of two columns. 9.11 REVIEW OF SULPHURIC ACID PLANT EFFLUEN~TREATMENT FACILITY The actual effluent facility has been already described in chapter 7.00 on present effluent treatments paragraph 7.02. As already outlined the main deficiency of this facility is to be in strict connection with the calcine lagoon system which has not been provided as a final closed system for the disposal of solid materials (the cinders by product of pyrite roasting) since a liquid effluent is fed to the lagoon (that is why it is necessary to provide a carrier means for the calcine) and the excess water is not recycled to the plant but is allowed to over flow in the open land, so infringing the provisions of Zambian law as regards sulphates. Infact if we think that the main constituent of the effluent to the lagoon, apart from iron, is calcium sulphate, whose solubility in water at ambient temperature is about 2,500mg/l, we realize that the calcium and sulphate contents relevant to the lagoon overflow, as drawn from the analyses reported in Annex 8, are just in the stoichiometric proportions of a saturated solution of calcium sulphate (deriving from the neutralization of dilute sulphuric acid present in wastewaters with lime). From the above considerations it derives a simple idea about reviewing the sulphuric acid wastewater treatment, apart from eventual adoption of a proposal on possible utilization of solid wastes as outlined in paragraph 11.07, which hereinafter we illustrate. It is only a question of considering the lagoon as an enormous decanter for iron, heavy metals and even calcium sulphate from where the water carrier, saturated in calcium sulphate, is recycled to the SAP to dissolve calcine and enrich its calcium and sulphate contents above saturation limits, in order to allow precipitation of the excess at the lagoon site. For this purpose of obtaining the above mentioned the following interventions are necessary: - Elimination of every possible arrival of raw water (overflows from V502 precipitator over flow and V509 treated water storage tank) 85 into the Vl002 pit from where water is drawn to dissolve calcine in Vl0B mixer tank; this can be obtained first of all by installing a screen at water intake facility in order to be capable to draw the right amount of raw water necessary to run the plant and not a big excess (see paragraph 9.04). Moreover a suitable sewer rearrangement must be provided for the whole area in order to convey, in case of inevitable presence of raw water overflows despite of the above intervention, all the clean streams, before eventual mixing with any contaminated flows, directly to Kasenje River. - Equip the lagoon/effluent treatment system with a suitable pump (with the due spare one) possibly mounted on a platform floating above the liquid level of the lagoon, and a long 6" pipe in order to recycle the excess water to the plant (Vl002 pit). - Substitute the present liquid effluent discharge pump P902 A/B, very often out of order with a more reliable one; according to our opinion the actual pump is not suitable because it is a centrifugal with high number of rounds per minute. These pumps can be substituted by centrifugal ones equipped with decentralized impeller, which is suitable for fluids with high solids solids percentages, running at low number of rounds per minute. Another alternative is the eccentric screw type pump (so called "mohnott) operated at very low speed. - As regards the pipes it would be advisable to utilize the present 6 tt carbon steel line for the water return from the lagoon (pH of this water, saturated in calcium sulphate, is surely neutral) and to provide a new pipe made up of plastic material for the onward line to the lagoon, which is susceptible of some corrosion hazards in case of failure of the neutralization system. The proposal of review so is to leave the neutralization system as it is at present, apart from maintenance needs and substitution of the final pumps, to rearrange the sewer lines, to dissolve if possible the calcine mixing with less quantities of water and to operate this water in a sort of closed circuit with the lagoon. 86 As regards the material balance the streams that can be admitted to the various collection pits and from there to the lagoon are the following: - Precipitator blowdown sludge: 1m3/hr - Cooling tower blowdown: 24m3/hr - Valveless filters backwash: 2m3/hr Continuous and batch discharges collected in V901 and V1001 and sent to the lime neutralization system: 19m3/hr. These amounts are clearly not enough to realize the calcine dissolving and the subsequent discharge to the lagoon, 3kms far, of the over all effluent, stated that the design capacity of the relevant pump is 120mc/hr and the practical figures are 70 - 80cm/hr (with solid contents up to 3.5%) so that the remaining quantity to be mixed with the calcine must be supplied by raw water in close circuit. At the lagoon site the possible· losses are by means of evaporation (during rainy weather on the contrary there will be an increase of water) and of percolation into the surrounding soild (this latter is to be hoped nil or minimum otherwise serious problem of seepages and subsequent needs of impermeabilazation arise): in average the evaporated quantity for the calcine lagoon will be about 16m3/hr but sure during dry season this quantity will be more, while during wet seasons will be be less or even, after rainfalls, not a loss but an increase. It follows the necessity to provide the possibility of a make-up that we suggest to realize by means of an immission of raw water by the V1002 pit and of a blowdown, that we suggest to realize by means of a deviation pipe equipped with a butterfly valve connecting the return line from the lagoon with a sewer man hole of the sewerage system flowing to the main council sewer. In this way mixing this stream with the overall factory effluent the sulphate contents will be lowered below the low limits. Incase of necessity (dry season) a controlled make-up of raw water will be fed into the V1002 pit. 87 9.12 LIQUID EFFLUENTS MONITORING with immediate effect all the sampling points which were considered during the analytical campaign must be subjected to a regular monitoring programme. This programme must include the routine analysis mentioned in the following table 11. The analytical methods to be employed are the ones collected in the volume "Standard methods for the examination of water and waste water APHA 15th Edition 1980" considered official by the Zambian law. It is obvious that if some parameter will be found abnormally high in the overall discharges, it is necessary to carry out more frequent analysis of the partial streams responsible for these high figures as long as the phenomenon persists. Once a year it is advisable to carry out a more complete analysis of the overall discharge IWl SW7 and SW10 with reference as much as possible to the 54 parameters provided by the Statutory Instrument No 161 of 1985. This is in order to be ready for any eventual control by the Council. AS regards the Laboratory staff organisation it is advisable to train a dedicated crew of people to this specific job of waste water analysis. Needs for apparatus and reagents must be adapted to the routine monitoring programme herein illustrated. N.C.Z. KAFUE WASTEWATERS ROUTINE ANALYSES SCHEDULE PARAME HIS fn BE INOUSTRIAl WASTE WAIERS POINTS OF SAMPLING STORM WATER POINTS OF SAMPlIN~ ACIDPUNil IlVESflGAHB I 'PH' MflHOOl1 fJWT IYI2 IWl IW4 IW5 IW6 111,IIW7 IW9 W1QIIWll SW10 SW2 SW3 SW4 SW5 SW6 SW7 SW8 SW9 SAP] 's' Ul ~!I1A!~ A51ii-mt1' U no. I TEMPERATURE fO Ef(fr~~<D·\illlfCDN fillN ~a2.Einr;j)IO )IY1k~ :.~I5dR][ Q9':: S?f:1! >IL\NCEr-.c' '0' PI SIOIIN WATER 10 IANSENI!. STORM WAIf. TO 01[1 pH 0 <D <D <D<D CD CD CD CD CD Q I() <D <D 69 69 Q 69 69 0 I TOTAL NH4 'g. <D CD fa> <J?- CD Q? CD riD (Q _,g. __ _ -= - ~ 69 0 ~ 69 - __ fREE HH0 CD CD CD' CD <D CD <D - - 0 - - - 69 69 0 III 69 I TOIAl HARIJN1SSIO .(]) CD iQ(]) f-ar[:IDCD=-- --~rg2= 69 69 ~ I QS) IU _' NITRATES 0 <D <D CD <D CD <D CD <D <D 0 - - - ® 69 0 69 ® SUlPHAl£S -CD=-~r-::.- - CD CD 0(0 ~- - . - : : : : : - - . - 0 C)-cD I <D .. ~ - - I - <D <D 69~ 0 ® _~lKALlNllY g.-W .<D. ~__ - CD.- - .Q. CD <D <D ®0 _ 0 09 69 -._ PHOSPHATES <D - - - - 0 - - 0 <D I <D .---. - -f----.f------- - - - - -(J)_. r:::r--.- - - - - - -1-':'- -.- ~ 0 69 CYANIDES SULPHIDES 0 (J)tl <l.? <D - - -(])_=-=-- CD CD - - - - ,-:'-=_1- _ 0 69,=.=--_ 0 (J) . - --- ---. -(J) - -. r-: : --- ---I-::: - - ..-0 .69 - p - - CD '" -- . SElENIUM i----=-= () () () () - - - - . - _. - ---1- --t------ \ - -.- - <D <D ' - CD ® (J). ,-- r -- + - ---- ,--,;;- (J) ARSENIC () () () () - ~. -- - ---~ - - - - - 69 - - - ---1---. - - CD 1---- --- ' 1 - - , ; . - --_- - CD COPPER () () () () - - - - - - 69 CD (J) CD - -.CD - - <D ,~i1--··· ·1:1 ll~~~~~~-=t-'='-Q:iliTi~.•~ ~~f:~~l --CADMIUM ·---·---t--Cr---- -- - - - - - t·- - 1--1- ~ ""-j----.-- _ _ _-- ~I . - - - _ - - (f) I ~~:OMIUM III t-O<D' CD CD a; cD m a; CD-I a; =-1 ~~S@ I 0 _=_~-<D-- ® SUSPiNDEO SOLIDS .. -o~lcr) <I2,_ill.._<rL <D~t-cD:- CD Q-J=-r-=- 69 69-10 =- ~ 0 METHANOL - ---:: - - - w - - - -I - - - - I - - - TYPE Of S'MPLI~ 1< IIIJURS CDMf!lSIlE IEVERY lH."" ftEHUAL IUlt) ..•-~- , .. " ~ l,"£iG un 0.IIIE AllAmll PER EVERYl WEEIS '"'lYSlS APHA MElHOOI l'I".t PEifORM£D If IGl'l IH\' AID pH ARt mUID KIGH. O· UK[ UAlISl1 I111W! TO at INY[SIiGAffU DHlY If ALUI IS UN SJiEAM CD. DNE HAlYSIS PER DAY PH wm TABLE 11 ,lUO It P£ifORMEO II CAlf Df AOOPIIJII Of miM'lf ClIWillClillG fill COuliNG WAHl (t.on 'H'lYSIS PER MOIlH 89 9.13 ORGfu~IZATION AND TRAINING NEEDS As regards the job organization in NCZ factory it is advisable to appoint a responsible person for the specific task of environmental control, since the public attention to this problem is increasing even in Zambia and the problems arising from the factory are serious. The person to be responsible for the environment must urgently be identified and trained. Training can start at Kafue factory as counterpart of EA expatriate Environment Specialist. In future participation to the next eventual seminars on environment at Kafue or to specific courses and fairs abroad must be ensured. However the whole production staff (from the Managers to the General Workers) of NCZ factory must receive sound sensitization to the environmental problems and subsequent controls by means of written cOllUTIunicati'ons and! or specific meetings for explanation. 9.14 LAY-OUT (Drawings No A60S C-0009 and A60S-C-0011 ) Remarkable difficulties were encountered in order to find out a proper lay-out for the installation of the main facilities for the treatment of factory waste waters. That is why no free areas were provided at the time of the first factory planning for eventual environment protection plants and generally the whole area of the factory is crowded of plants, buildings and various facilities. Moreover the collection of dry weather and first rainy waters from the storm water sewer that we suggest in paragraph 9.03 is clearly obliged to be effected at the end of the path of the sewer, near the points of discharge SW7 and SW6, but this zone is pressed between the new boiler (whose ash bunker must be served by the road for collection trunks), the railway, the open drainage, the fence and a tract of calcine pipes to lagoon. Anyway as regards this facility, mainly composed- of the big 2,SOOm3 collection tank we believe that the best position is to get the intercepting chamber just comprising the concrete storm water outfalls SW7 and SW6 (in this way even SW6 is included in the deviation and collection but we can accept it because it is not a big contribution since this branch of sewer serves practically only the methanol storage area) and to realize the collection tank in the zone at present occupied partly by the drainage ditch itself and mostly destined to the coal storage yard extension. This job requires the partial re-routing of the open drainage and another small bridge to be realized down stream. The solution is shown in the drawing No AGOS C-009. As regards the clariflocculation unit and the ion exchange plant we suggest to realize these facilities between the zone at present occupied by the abandoned cyanide removal unit and the non-utilized Sulphuric Acid storage tank 60S-v07 and the free zone along one side of the A602 boiler plant and the water treatment dosing area. This solution allows the clariflocculator to be positioned near the neutralization plant and the ion exchange plant to be installed downstream the flow of the new "Ammonia" sewer that must collect concentration discharges from the plant in an area where other water treatment plants, so rather homogeneous to the one proposed, are already installed. 91 This solution involves the dismantling of the mentioned units (partly already planned) and may be some re-routing for the access way of the maintenance means for the boiler that must enter from another road. This lay-out proposal is shown on the drawing number A605-0011. 10.00 In the following tables the data relevant to investment cost estimates and realization times can be found. Of course these estimates are rough figures, as at present we are at the stage of a feasibility study and not of a detailed project. As regards the possibility of local supply, this latter is limited to civil works, manpower for the erection of the plants, some manufacturing of steel works ~nd electrical cables. INVESTMENTS INTERVENTION COSTS US)! REALIZATI ON CONS I SHNCY Of THE JOB TIME PARA TIT L E LOCAL IMPORTEO J.U1 SF\,[ll [;£-ARRIlI'Je<:I'ENT f'FPAIRING OF RFLAAACES BLDCKINGS. [}IOKINGS EUMINATICN I)' MIXINGS - CCNSTRUCTHl, [ f 35 1l1l0 35 000 G MONTHS NEW [LCBE 0 PIPES :1. II:' STUDY Fm THl COf'PLE 3 I1LNTHS WORK FOR NO.3 Nez EMFLDYllS PLLE TI IT, lJF SEl.Jt; RAe<: TEctlNTr:AL Mf\J'JI\GER (PART TIf'El COllRorNATICN f'F-Af(f1ANCEI'ENT eCNTR (COST ESTIMATE FOR THE INTERVlNTICNS TO BE [IF WATER CCNSUI'l'TICN PRCFr:Et:O II'l'CESIBLE AT PFLSENT AND TO BE CHARCEO ON MAINTIlI'J!'NCE BUDCET 1 Don :l Ma~THS '" w CCNSTRUCT IllJ OF INTERCEPTING CHAI'tlER. 2500 ~L03 fIRST RAINY WATER M3 [oLLECTHN T!'NK 250 M:J;HR PUI'l'ING STATICN [01.1 E en CN AND PUI'l' UIVERTICN [ f [PEN ORAINACE. [mAO URIOe<: CN INC FACILITY THE O-lIll'JNEL. FENCE !'NO CAL r:INE PIPE. 50 LIDO B[J [JOO [i 11[NTHS PIPING TO "0" EFFLUENT POND 9.04 STORM WATER DRAINAGE ClEARING & r;cSHAPING OF THE [PEN DRAINAGE SYSTEM IJ(WIJSTKEAM POINTS OF OISCHARCE SW 7·& SW 8 15 DOD 4 MONTHS ~l . (]I--) WATER INTAAE HPROV ISTALLATICN OF A SUF CLEA .HNG SCFEEN ING INTERVENTIONS r:YLIN[£R AT RIIiER WATER SITE SEA WEED 21 DOll [iD UUD f.i MDNTliS KIlLlNG PlR[}jASING ~. IJ Ii MrLlIlE or L SKIMMeRS PURO lASING OF TWO SH:f:l UELT SKIM'£RS FU[~ hEM[]VAL OF or L FllllM SE:WER PITS (I nnn GO [JAYS _ - ' ...... _~. _ _ _---1_ _ _ _ _ _ _ _ _ _ _ _ _--L_ _ _ _..L.-_ _ _--L_ _ _----I I NVEST~ENTS I NTERVENTI ON COSTS US ~ REALIZATION CONSISTENCY OF THE JOD TIWE PARA TIT L E LOCAL I ~PORTEO 9.07 IN PLANT TREATMENTS AND INTERVENTIONS .' 9.07.01 COAL PREPARATION AND PURCHASING OF A MOBILE INDUSTRIAL VACUUM 1 000 80 000 3 MONTHS GAS IFI CATION UNIT FOR DUSTS CLEANING AND MATERIALS RECOVERY (EQUIPPED WITH THE MAIN SPARE PARTS) . 9.07.02 AMMONIA STORAGE REFRIGERATION SYSTE~1 SETTLEMENT NOT WITHIN HE COMPETENCE - OF PRESENT TUDY. -0 9.07.03 OLD NITRIC ACID PLANT - 2M3 A1S1 304 STORAGE TANK " - NO 2 PUMPS 2M3/HR CAPACITY - A1S1 304 PIPE FOR CHLORIDES SPILLAGE 2 000 18 000 .' 3 MONTHS 9.07.04 NEW NITRI C ACID SUBSTI'IUITCJol OF V1201 PIT WITH A1S1 304 PLANT (A401) CLOSED TANK (2M3) AND NEW RECYCLE PUMP (2M3/HR) Cl\PACITY. 9.07.05 OLD At1MONIUM NITRATE 1.4M3/HR CONDENSATE RECOVERY STUDY IMPRO RESS NOT WITHI PLANT (501) THE COMPETE CE OF PRESENT STUDY. . CONNECT10N OF SAMPLING POINTS TO V25 RECOVERY TANK - ASPIRATION FAN FOR DRUMS , , BUCKET ELEVATORS 4 000 20 000 3 MONTHS _ .. INVESTWENTS INTERVENTION CONS I STENCY OF TilE Jon COSTS US ~ REALIlAT ION TIWE PARA TIT L E LOCAL I WPORTED ._ 9,07,06 NEW A~lMONJUM NITRATE RECOVERY OF 5.2M3/HR MULTIPLE EFFECT NOT WlTHIN HE COMPETENCE - PLANT (A501) CONDENSATE OF PRESENT ' TUDY. .' - SPEEDING UP OF THE CLOSED LOOP SYSTEM REALIZATION - - - ~.O7.07 AMMONIUM SULPHATE NEW COUPLE OF PUMPS (10M3/HR) FOR WASTE 2 000 8 000 3 MONTHS AtjO NPK PLANTS WATER TRANSFER FROM COLLECTION PIT OF AS PLANT TO THE AMMONIA COLLECTION TANK OF THE NEW ION EXCHANGE UNIT. - NEW COUPLE OF PUMPS ~OM3/HR) FOR THE NPK 2 000 8 000 3 MONTHS PLANT (TRANSFER FROM PIT-TO NEUTRALIZATION UNIT) - PURCHASING OF A MOBILE INDUSTRIAL VACUUM 4 000 85 000 . 3 ~'ONTHS UNIT FOR CLEANING AND MATERIALS RECOVERY AT NPK PLANT WITH WITH SPARE PARTS AND INSTALLATION OF FIXED ASPIRATION PIPES. . , , , .- I NVESTIoIENTS INTERVENTION COSTS US $ REALIZATION CONS I STENCY OF THE JOB TillE PARA TIT L ( LOCAL IIoIPQRTEO - 9.08 REVIEW OF LIQUID - DISMANTLEMENT OF OLD CYANIDES REMOVAL UNIT EFFLUENT DISPOSAL SYSTEM - REALIZATION OF CIRCULAR CONCRETE TANK FOR INSTALLATION OF CLARIFLOCCULATION EQUIPMEN' AND SLUDGE POND. - PURCHASING AND INSTALLATION OF CLARIFLOCC ULATION EQUIPMENT SUITABLE FOR THE TREAT MENT OF 500M3{HR WASTE WATER WITH 2000MG{L SUSPENDED SOLIDS (DIAMETER 20M) <> 0 COUPLE OF VERTICAL PUMPS (500M3{HR) TO BE INSTALLED INTO BALANCE lANK. - SLUDGE PUMPS (10 .IG/HR) TO THE SETTLING PONDS. - POLYLECTROLITE DOSING STATION PIPING, ELECTRICAL CONNECTIONS, MOUNTING 70 000 380 000 10 MONTHS 9.09 REVIEW OF EFFLUENT - INSTALLATION OF NEW 4 RUNNING BRIDGES{ (WIDTH 8MTS) AND PUMPING DEVICES ON THE , EXrSTING SETTLING PONDS FLOATING PUMPING STATION (80M3{HR) FROM .. THE LAGOON 6 000 130 000 1a r~ONTilS I NVESTIIENTS I NTERVENT I ON COSTS US. REALIZATI ON CONS I STENCY OF TIlE JOB , TillE PAllA TIT L E LOCAL IIIPORTED 9.10 AMMONIA REMOVAL ION - AlfotONIA SEWER SYSTEM COLLECTING ALL EXCHANGE UNIT AMI·IONIUM CONCENTRATED WASTEWATERS FROM AMMONIUM NITRATE, AMMONIA STORAGE, AMMONIA PRODUCTION, AMMONIUM SULPHATE PLANTS. UNDERGROUND STORAGE TANK (120M3) PUMPING STATION (60M3/HR) NO 3 ION EXCHANGE UNITS EACH CONSISTING OF NO 2 CATION EXCHANGERS FILLED UP WITH SUITABLE RESIN BEDS (CARBOXYLIC AND SULPHONIC). REGENERANT (NITRIC ACID} STORAGE DILUTION AND DOSING SYSTEM. AMMONIUM NITRATE SOLUTION RECOVERY TANK (100M3). TRANSFER LINE TO AMMONIUM NITRATE CONCENTRATION UNIT. 230 000 1 300 000 10 MONTHS 9.11 REV IEW OF SAP SEWER RE-ARRANGEMENT INSIDE THE PLANT. EFFLUENT TREATMENT NEW DISCHARGE PUMPS (BOM3/HR) TO THE FACILITY LAGOON. FLOATING PUMPING STATION (BOM3/HR) AT THE LINE. RETURN LINE FROM THE LAGOON 23 000 300· 000 B MONTHS r- --~----------~--------------~--------+-------~------+-----~ TOTAL LICUID WASI'ES 496 000 2 512 000 TOTAL: US ~3 OOB 000 98 11 .00 AIR POLLUTION The problem relevant to air pollution are beyond the scope of present study, since NCZ has already decided to face at least the biggest air pollution problem - eg NOX from Nitric Acid Plants - by means of a specific abatement plant, unless certain tests in the production plants, to be carried out changing some operating parameters will be successful. However it does not seem appropriate to end the environmental study on NCZ Kafue factory without an outline on air pollution. 11 .01 NECESSITY OF DISPERSION ~ It is recommendable to prepare an inventory of all the sources of gaseous streams to the atmosphere, reporting on a map position and height of the chimneys. Moreover it is necessary to plan a proper analytical campaign of the same kind of the one carried out for liquid effluents, in order to investigate flowrates and pollutant contents of such streams. With the help of meteorological data (ambient temperatures, directions and velocities of the winds) it is possible, by means of computerized methods of calculation, to draw maps of dispersion for each pollutant towards the outside environment; the interest in this maps is obviously very high. ~ 1 .02 THE PROBLEM QE AIR INTAKE LOCATION Just to remain inside the factory the marking out of such maps could suggest a more appropriate location of the air separation plant, which at present is positioned amidst Nitric Acid Plant and Ammonia Storage thus collecting partly the emissions from these facilities; this fact has been pointed out on the occasion of the last blowing of the air separation plant for defrosting purposes: 300ppm of Ammonia were found in the outcoming hot air. Apart from corrosion problems the emission of Nitrous Oxides into the air separation plant can cause explosion. For these reasons in Europe the location of air intake is usually many hundreds of metres outside the factory in a position considered safe by the maps of dispersion as regards pollution. 99 11 .03 POSSIBLE EFFECTS ON ~ ENVIRONMENT AND HEALTH As regards biological effects on man the Nitrogen Oxides, whose paradigmatic representative is N02 as the others (NO, N20, N20J, N204, N205) tend to transform into N02 due to chemical reactions in the atmosphere, cause odour nuisance and irritation of eyes and nose mucous membranes; this at concentration of J - 13ppm. Higher concentrations can cause heaviour consequences: 150ppm a bronchiolite, 500ppm for some minutes pulmonary oedema and death. As regards chronic effects there are mentioned pulmonary fibrositis and pulmonary emphysema for continuous expositions to 10 - 40ppm. As regards Sulphur Dioxide S02 in the atmosphere this compound is transformed into S03 that, in presence of humidity, becomes Sulphuric Acid causing the well known acid rains. S02 is high soluble gas, so itis absorbed in man by the mucous membranes of the first respiratory apparatus, reaching only partially the lungs: O.5ppm are noticed as unpleasant < odour; at lppm wrist and breathing quicken 10ppm cause irritation to eyes, nose and throat in case of first exposition of some subjects. As regards long taerm effects many cases of nose-pharyngitis, persistent cough and abundant expectoration have been noticed among workers exposed for years to S02 levels as far as 40ppm. The effect of carbon monoxide CO, which originates from not perfect combustions, is to tie with the heamoglobin present in the blood, so that this latter cannot achieve his task. The dangers depend on the CO concentration and on the exposition duration. At 12 - 31ppm CO psychomotory disturbances appear, while at 100ppm dizziness, headache and general weakness. In Annex 3 page 7 some analytical results are reported about Nitric Acid tail gases during the time of liquid effluent analytical campaign. As regards SAP tail gases the analyses are on page 4 of the same Annex. 100 12.00 OUTLINES ON INDUSTRIAL HYGIENE The term Industrial Hygiene (as it is called in the United States and Canada) or Occupational Hygiene (as it is called in United Kingdom) is often confused with Environmental Hygiene (or environmental health or environmental protection). It is necessary to point out that Industrial Hygiene or Occupational Hygiene deals with problems in the internal environment ie man, his working environment (plant, laboratory, workshop etc) and the interaction between the two. Environmental Hygiene on the other hand deals with the external environment and is directed towards the control of all factors in the environment which exercise or may exercise a harmful effect on man's physical development, health and survival. This protection of the environment essentially deals with the pollution impact towards the outside environment eg atmosphere, rivers, lakes and the soil where gaseous, liquid effluents and solid wastes are discharged to from factories. That is why industrial hygiene is beyond the scope of present study. However, while carrying out the environmental study, we would not do but notice some big problems of industrial hygiene hereinafter briefly mentioned that would require the proper examination of a specialist: - High Ammonia concentration at the site of Ammonia Plants. - Dusty atmosphere due to coal powder gasification. - Dusty atmosphere due to dust coming out from pyrite roasting. - Dusty atmosphere due to lime for workers opening manually the lime bags at the site of water treatment plants. - Excessive noise at the compressor houses and from the new nitric acid plant by the main guard post. It is presumable that, after rehabilitation programs completion, these problems will be reduced. However it is recommended that a specific study on this subject be carried out. 1 3. CO SOLID WASTES There is a main misunderstanding when dealing with solid wastes discharged from Kafue factory. Infact at present only coal ash is handled in solid form (trucks and trailers are transporting them from the factory to the lagoons), while SAP calcine and A321 slurry are transferred in liquid form through proper pipes, since they are pumped out mixed with considerable amounts of water as carrier means. This probably due to the choice by the previous Process Engineers of avoiding the installation of dewatering specific equipment applied to the factory slurries for exploiting that formidable dewatering machinery which is the african sun. However it would be quite reasonable dealing with small hourly amounts of slurries or more concentrated ones, but it is impossible to rely on african sum in order to dewater almost exclusively liquid streams as the ones actually conveyed to the lagoons disposal system of Kafue factory. As already shown with the simple calculations in paragraph 7.03 even the enormous recipient surfaces of the lagoons cannot dry all the water sent with the solids unless an overflow or a recycle is provided. Since the overflows to the open land are prohibited by the law (without written permission of the Council; see Article 3 of Statutory Instrument No 161 of 1985), only the practice of recycling excess water to the factory can avoid the installation of specific dewatering equipment and the subsequent handling of almost solid matetlals by means of trucks. It was not possible to find out any possible linkages in the treatment of the two kinds of wastes (liquids and solids). -:02 13.01 OTHER SOLID WASTES Many other forms of solid waste have been found to be produced in the factory premises. These included scrap metal in various forms, used empty drums and rashig rings. The latter (rashig rings) are at the moment properly disposed of (having no monetary value) by paving parts of the factory grounds to alleviate stagnation of water during the rainy season. Since we can see big deposits of rashig rings abandoned inside drums in certain areas of the factory, it is recommended to utilize them by filling in of depressions in the factory grounds for the same purpose as above. Moreover, consultations with Kafue District Council can be made in order to utilize these materials in mosquito larvae (malaria) contr,ol drainage works programme, as is the present arrangement for coal ash. Scrap metal and used' empty drums, however, have been stockpiling in the area south of the coal storage yard. Apart from contravening the law (Public Health Act Cap 535 of the laws of Zambia) in that they might facilitate mosquito breeding during the rainy season as well as harbour undesirable vermin, the stockpiling of scrap metal in the said area is an economic loss to NCZ. The metal may be saleable to Small Scale Industry Organization in Zambia as well as individual blacksmiths as raw material for making hoes, axes, braziers, knives and wash basins. It is recommended that research be made into the marketability of the scrap metal. 103 14.00 PRESENT QUALITY AND QUANTITY OF THE WASTES CONVEYED TO THE LAGOONS 1 4.01 CALCINE LAGOON with reference to design figures the effluent pumped out to the lagoon from the Sulphuric Acid plant effluent treatment facility has the following characteristics: Flowrate 105m3/hr Temperature Ambient Solids contents = 6000Kg/hr (=5.4%) Specific Gravity 1 .06 Practically, the actual flowrate is about 70 - 80m3/hr while the solids contents ranges from 1 to 3.5% and the specific gravity 1 - 1.03; Sulphates contents is about 5000ppm. For the complete analysis see column 2a, Annex 9. In addition to these reduced figures it is necessary to mention that the Sulphuric Acid plant is usually on shutdown for many months in a year, owing to in-plant problems or storage saturation and that often the effluent discharge pumps P902 A/B are out of order, thus forcing direct discharging into the Kasenje River. It follows that from the start-up of Sulphuric Acid Plant (September 1983) only about one third of the dedicated lagoon is full of solid materials. The remaining lagoon is filled with liquid effluent which, as already mentioned in the chapter 7.00 paragraph 7.03 dedicated to the existing waste disposal system, is overflowing along one side towards the open land by means of a pipe installed on purpose. The breakage of the adjacent pipe carrying the A321 slurry is worsening the situation because even black liquor is over flowing. The liquid portion of the waste disposed of into this lagoon seems to let rapidly its decanted solid contents since its aspect is clear (people from the surrounding villages are even used to fishing there), but the analyses of the lagoon overflow show a high Sulphate contents (see Annex 8, pages 1 - 6) and visibly contains coal dusts. As regards the quality of the product accumulated in the already soli"dified part of the lagoon is composed of: about 51% Iron; 6.4% Sulphates; 4.5% Calcium (as CaO); 1.5% Magnesium (as MgO). Moreover contains 9900ppm Copper; 842ppm Zinc; 107ppm Lead; 79ppm Arsenic; 40ppm Selenium (see column 2a analysis in Annex 2.). ',04 The relevant specific gravity is 1.17 loose pour and 1.40 if packed. 1 4.02 A321 SLURRY LAGOON !iliE. COAL li2.!:!. 14.02.1 The slurry delivered from A321 Z1201 settling ponds amounts to about 80m3/hr Suspended solids : 6% As regards the chemical composition of the solids an average analysis of the residue is: Carbon 51.4% Hydrogen 0.9% Sulphur 0.5% Nitrogen Nil Ash 47.2% 14.02.2 The ash plus slag collected from Gasifier chambers and transported to the lagoon by means of trucks amount to about 1.5t/hr and its composition is: 41% Carbon 59% Ash Ash analysis is as follows: Silica as Si02 41% Fe203 8% Al203 + Ti02 29% CaO 17% MgO 1% Cu 25ppm Zn 14ppm Pb 51ppm Se 213ppm AS O.33ppm 14.03 POSSIBLE EFFECTS ON THE ENVIRONMENT The noxious effects arising from the disposal of solid wastes in an open lagoon are that the eventual faulty impermeability of the bottom or of the walls of the pond may allow seepages towards the surrounding land and mainly may contaminate the water table. EXamining the chemical composition of the handled products this means a possible pollution of the water table from Arsenic, Lead, Selenium, Zinc and other metals, besides sulphates. ~ C5 The risk of possible overflows due to exceptional storms is remote, since even the maximum rainy intensity of 150mm/hr cannot allow the outlet of the solid material from the large ponds, provided that the above level is maintained 150mm below the top level of the walls. Moreover this problem is overcome since the Calcine lagoon, as already mentioned, is managed with liquid effluents and has a continuous overflow to the surrounding land. 14.04 ADEQUACY OF DISPOSAL PONDS If the present Calcine lagoon were operated properly with exclusively solid wastes, stated that these latter ones have a loose pour bulk density of 1.17g/ml, it would be possible to store totally: 192,OOOm2.3.5m. 1.170t/m3 = 786,260 tons It means, even considering the· exaggerated solids production of 6t/hr = 52560t/year from SAP, a duration of the disposal pond equal to: 786260 = 15 years 52560 Since the actual lagoon is at present about one third full it follows that a duration of 10 years at least is expected. Of course the above calculations presuppose that excess water in the solid wastes must be recycled to the factory, as proposed in the review of SAP effluent treatment plant (paragraph 9.11) As regards the slurry and coal ash lagoon, at present half full, the total storage capability is: 1 • 320000m2.2m • It/m3 = 320000t '2 The incoming solids are: £ . 80 + 1.5 = 6.3t/hr = 55200t/year 100 so the duration of lagoon No 4 may be: 320000 = 5.8 years 55200 106 The above programme is al~ays based on the hypothesis of recycling the excess water, as it was in the first design of the slurry lagoon system. It follows that this lagoon is scarce for the future needs. 14 .05 LEACHATE TESTS Some leachate tests, according to the procedure suggested by the American EPA (Environmental Protection Agency) with its EP (Extraction Procedure) toxicity test, were performed on the solid materials accumulated in both lagoons. The relevant results are shown in the following table 12 and Annex 9 (column 2b). Since the maximum concentration of contaminants for characteristic of EP toxicity are as follows (see bibliography 5): Arsenic 5mg/1 Barium 100mg/1 Cadmium lmg/l Chromium 5mg/1 Lead 5mg/1 Mercury O.2mg/1 Selenium lmg/l Silver 5mg/1 Endrin 0.02mg/1 Lindane O.4mgl/ Methoxychlor 10mg/l Toxaphene O.5mg/l 2.4 Dichlorophenoxyacetic Acid 10mg/l 2.4.5 - TP Silver lmg/l it follows that both products disposed of in the lagoons are toxic for selenium and cadmium and near the limits for lead. TABLE 1.l NCZ CHEMICAL LABORATORY EJ?. TOXrCrI'Y TES'l' -- LAGOON CALCINE LAGOON COAL MIXED ADMISSBLE PRODUC'I' ASH PRODUCT LAGOON MAXIMUM* . ---. CINDER/ CONCENTRATION COAL ASH OF 31.10.86 06.03.87 31.10.86 06.03.87 06.03.87 CONTAMINANTS -~- T ron as ppm Fe 60 81 40 78 134 - 2 C opper as ppm Cu 440 960 23 30 760 - 3 L ead as ppm Pb 4.0 3.26 3.0 2.17 4.35 5.0 '" ~ 4 Arsenic as ppm As 0.6 0.043 Nil 0.008 0.04 5.0 5 S elenium as ppm Sa 8.7 0.05 5.1 0.025 0.05 1.0 6 Zinc as ppm Zn 250 96 1580 36 92 7 Chromium as ppm Cr Nil - Nil 5.0 8 Cadmium as ppm Cd 0.67 2.2 - 3.7 2.5 1 .0 -.- * LEACHATE TEST ACCORDING TO E.P.A 108 14.06 SEEPAGES ~ POLLUTION ~~~ OF ~ WATER TABLE In order to check possible seepages from the floors and walls of the lagoons system, the digging of some wells on the surroundings of the calcine lagoon was organized with the purpose of reaching the water table, collect samples and analyze them. The wells were executed by the firm Water Wells, Lusaka from 4th to 15th March 1987; they were two in number and their approximate position is shown as BH1 and BH2 in the drawing 605-0032 "key plan showing location of slurry lagoons and slurry lines lay-out" already mentioned. As regards the borehole No 1 the first water table was found at about 22ft (approximately 7m) while for the second at 15ft (approximately 4.5m). The digging was then continued as far as GOm with the aim of encountering other lower water tables that could have been contaminated by possible seepages due to possible passages of pollutants through the very complicated network of ground water that occurs in Zambia. Of course by continuing the digging it was not possible to be sure of realizing when the second or the third water table has reached but the samples taken out were expected to be a mixture of the first and following water tables. Anyway if some sUdden differences in the course of analytical results relevant to the different depths occurred, we would have been able to realize that the difference was due to a seepage reaching the water table from a major depth. The most important parameters investigated were the metals: lead, arsenic, selenium, zinc, copper and iron. Anyway even other parameters common to water analyses, such as pH, alkalinity and so on, Were investigated. The complete results are reported in the following table 13. They show that no worrying reason from seepages to contaminate the ground water must exist as regards NeZ lagoons. All the metals were found present well below the limits of World Health Organization for drinking water (as regards lead this organization in 1972 raised the previous limit of 0.05 (1963) to 110 0.1mg/l), more especially considering the substantial dilution that can be offered to water tables by the portion of Kafue River between Mazabuka and Kafue Township, as pointed out even in the "Paper for the Annual Conference of the Local Government Association of Zambia" presented on 3 : 5 September 1986 at Lusaka by National Council for Scientific Research (NCSR) (see bibliography 6). It follows that no need for special artificial material lining exists to improve the imperrneabilization of lagoons. This latter fact is not obvious: infact, stated that the floors and walls of lagoons are constructed of "well compacted hard core" layer of clay, we would expect a permeability -7 coefficient not above 10 cm/sec,that, multiplied by the about 600,000 square meters covered by all the present lagoons, represents anyway a loss to the ground of about: -7 -2 10 10 ill • 600,OOOm2 3600 = 0.2m3 sec hI for every 1m of hydraulic head. Considering an average head of 3m this loss becomes: 3 • 0.2 = O.6m3/hr = 6001ts/hr = 14m3/day with possible entrainments of dissolved metals to the water table. On the contrary the analytical results shown on Tables 13 and 14 indicate that the nature of the disposed sludge is such as to create itself in an impermeabilized layer on the bottom and walls that auto defends even the layer of clay. 14.07 POSSIBLE UTILIZATION OF SOLID WASTES All the troubles resulting from the management of Calcine lagoon would be overcome if this roasting by-product from pyrite could be sent, as it happens allover the world, to a utilization with an Iron Industry. On this purpose it would surely be hazardous to propose to realize a small electrical blast furnace (6000KVA power) for the production of Pig Iron like in many countries occur from pyrite roasting by-products with 50 - 55% Iron contents. The amount of iron recoverable would be 3t/hr. However we suggest to carry out a feasibility study, involving even marketing researches in the countries bordering Zambia, in order to investigate the possibility of producing, by means of a proper investment, and selling abroad sponge iron 2£ desulohurized pellets from the pyrite cinders, thus exploiting their iron contents. 14.08 SOLID WASTES CONTROL PLAN Apart from the feasibility study suggested in the previous paragraph and from the suggestions contained in 13.01 relevant to "other solid wastes", as regards the needs of NCZ's facilities for the next fifteen years, we recommend to build up two new lagoons with the following capabilities: Calcine Lagoon 260000m3 Slurry/Coal Ash Lagoon 215000m3 The characteristics of these new lagoons can be more or less the same as the present ones: Depth =3 - 3.5m, Sides Slope 45 Deg. Preferably the new sites must be chosen in areas far from the Kafue River and Water Intake. Even the new lagoons must be equipped with pumps, mounted on platforms floating with above the liquid fraction of the lagoon contents, and subsequent lines which will recycle excess water to the factory for utilization as already mentioned in paragraphs 9.09 and 9.11. The pumps for the new lagoons can be transferred from the old ones, once the filling of the latter 1s completed. ~I 12 The reason for a floating pump is that with such a facility it is easier to adjust the position of the suction pipe for the water recycle not withstanding the continuous variation of the bottom level due to sludge deposit and progressive solidification of the material sent to lagoons, The other reason is that a floating pump would be more difficult to steal than a fixed one, We call attention to the impossibility of making higher the walls of the existing lagoons by means of the same material accumulated inSide; that is why these materials as verified by the EP Toxicity Tests, are rather close to the limits of toxicity (and even beyond as regards Selenium and Cadmium), Anyway as regards vandalism, possibility of robbery as well as the protectfon of people in order to avoid fishing in contaminated waters, cultivating on coal ash piles and, may be, to collect and ingest toxic materials, we suggest to spread a metal fence all around the present perimeter of the old and future lagoons and moreover to install a guard post ensuring the presence of Security Guards day and night to avoid these kinds of problems. The position of the guard post can be chosen such as to be able to guard even the Water Intake Pump House by means of suitable rounds, 3 15.00 SUMMARY OF RECOMMENDATIONS WITH COST AND TIME ESTIMATES-FOR THE SOLID WASTEs-CONTROL PLAN In the following table the data relevant to investment cost estimates and realization times can be found for the purpose of realizing new lagoons capable to cover, together with the present ones, the needs of the factory for the next 15 years. Of course these estimates are rough figures as at present we are at the stage of a feasibility study and can vary according to the suppliers contacted. --_._. ... INVESTWENTS INTERVENTION COSTS us j REALIZATI ON COIlS I STENCY OF TilE JOB TIUE PARA TIT l E LOCAL IWPORHD 14.08 j.lW CALCINE LAGOON CONSTRUCTION OF A 260,OOOm2 LAGOON, 3.5m QEPTH: ESTABLISHMENT, SETTING OUT, PREPARATION OF ~T AREA, EXCAVATION AND PLACING OF ElVIB r MATERIAL. 120,(XJO J MONTIIS NEW SLURRY COAL CONSTRUCTION OF A 215,000m2 LAGOON, 3.5m ASH LAGOON OfPTH: ESTABLISHM~~T, SETTING OUT, PREPARATION OF E,'l!l~1C:NT AREA, EXCAVATION AND PLACING OF l?1B 1ENT MATERIAL. 100,COO J r'10NTHS FENCE AND GUARD SPREADING OF ABOUT 7,OOOm OF METAL FENCE POST AND CONSTRUCTION OF A SMALL BUILDING FOR SECURITY GUARD ACCOMMODATION. 30,OX) - 2 r'lONTliS . , ------- TOl'I\L SOLID WASTFS r r, 255,0:0 ------ 1. "'HIRl<.."''' PE'rBCLEm.: LSTITc'l'E: "'~Ai(UAL ON DI",PCSAL OF REFINERY WAST::;"," VOL: ~, 5T:: EDI':IO;~ (1953) 2. EtiVIROm:::;;:TAL PROIEV::ICN AGE;,r.;y EFFLl:EI:': GUIDLINE", A;;D SIA!:lJARDS FOR FER:'I::'IZER }:A::UFAr.;:n:I::u (Fuoushec by the BcBEAIl UF ""':IOr,,.L AFFAIRS. 1;:<.., IIASlllr,GTCl:. cr: :"E CllLu\,;;.L REGcl.ATICN REPORTER 10.19.79 ;. llAl:DBCCK OF APFLIED HYDRAULICS. 3R::: EDiTION. MctiRAW-HILL CHAPT.::;R 40 ~CLtJ'!'ICN ·..::HA~ ~':OP.KSu presented to tne FERTILIZER n:STITtT"E Ef,VIRCn~~!.;,.TAL l:in':POBltr-:, l'H~W Orleans, Lout:li~n~. Jan 1-+.'15.1Y7b 5. EP r:oxICITY ':'ESr;: PROCEDt;RE ... CHl..1-aCAL REGULATIOu HEPCRTER 1C.9.~1 puolishea or Tr.E BUREAU OF NATIONAL AFFAIR" 1,,0. WASHINGTC~. F.C. 20037 6. NATIONAL COUNCIL FOR SCIENTIFIC RESEARCH (OF ZAMBIA): FAPER FOR THE ANNUAL CONFERENCE ASSOCIATION OF ZAMBIA - 3:, SEPTERMBER. 1986. LUSAKA , _~_ .. 1 I I 1 I .. l~ ~ t r "" ~ ~ tr I;t'~ ~ [\ ~ , ~ ~ ... ~ :::1"00 (') ! ~ t. r N ;'. (' . ~ ~~ r;. 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I I , , ; , ; , I , , I : I, , \ 1 I I I ANNEX 4 PRODUCTION UNITS RUNNING LAY DURING ANALYTICAL CAMPAIGN TIME DATE RUNN ING UN ITS PRO 0 U C T 1 0 N QUANT lTV (TONS) NH3 riA AN 15.7.86 ., rtl I Plants r"nn:ng '6.7.86 " " 17.7.86 " " " 13.7.96 " 19.7,36 " " 20.7.26 " " ::.. ,I,. 5tsppeG 22.7.86 23.7.26 26.7.86 27 .7.86 23.7.85 S.A. A401 Inew HN03) s:opoed 29.7.86 All Plants ~Jnning 30.7.56 MISSIng data 3:.7 .. 85 " " 1385 3225 4G44 (15+31.7) (15+31.7) (15,31.7) 1. 8.S6 ,l.501 (1ew ,".r-m. r;i:r.) s:cpped 2.8.86 3.B.86 MO 1 stopped 4.8.85 " 5.8.86 SA. MO 1 scooped 6.S.86 All Plants stopped. except SAP ,. 7.S.86 " " 8.8.86 All s:o;:lpec except ~.309, SAP 9.S.86 Only A309, NPK (Xl. SA. SAP runn,ng' 10.8.86 309, 401, 501 stopped '1.8.86 On:y A309, AS01, NPK. SA, SAP running 12.8.86 309, 501, ,"401 stopped '3.8.85 309, A401 stopped 14.8.85 Only A401 stopped 15.8.85 ~A31, r;PK s:opped i 6.:3.86 \501, ;:,401 stoppe;j ':.8.86 . . . . . ! :. ANNEX 4 Page 2 RUNNING UNITS PRO 0 U C T ION DATE QUANTITY (TONS) NH3 NA AN 20.8.86 SA. SAP. A401 stopped 21.8.86 2 2 11 22.8.86 309, 1'.401, A501, SA, SAP Stopped 23.8.86 309, A309, A401, AS01, NPK, SA,SAP StoDped 24.8.26 Ail steppea except NPK (X) 25.8.86 All Plants stoppec 26.8.86 All stopped except A309 27.8.86 All stopped except 309. A309 28.8.86 MOl. 501, A501, SA, SAP stopped 29.8.86 A401, 501, SA, SAP stopped 30.8.86 f1 issing data 2491 2537 2958 31.8.86 (AUGUST PRODUCTION) '.9.86 A401, Sal, SAP stopped 2.9.86 4 A 01, SAP stopped 3.9.86 " " " 4.9.86 " " " 5.9.86 " " 6.9.86 SAP stopped 7.9.86 SAP stopped 8.9.86 " 9.9.86 " " 10.9.86 NPK, SA, SAP Stopped 11.9.86 ',PK, SAP Stopped 11 II 12.9.86 13.9.86 A401, SAP stopped ~PK, 14.9.86 A401, SAP stopped 't 15.9.86 II 16.9.86 309, A309, SAP, A401 stopped 17.9.86 A401, SAP stoppeG ~9.9.86 " " " 2870 3410 4004 PRODUCTION (" 19 SEPT.) AIJIJEX 2. .NAlYSIS SCHEDULE O~~ ANALYSIS PEP. DAY - DURATiON OF CAUPA'GNI 1 - 2 WOHTHS POINT~ OF SAuPllNC PAAAUETER5 TO SE NUWBEA REFERENce '~YESTlG"'TEO TYPE OF (.STW wETHoosl SAUPL I"'; s. I. 1 S lOR" IIATER TO) TEWPERA TURE (ON SITE) 1 <ANSEN.Je AIYER) PH 55 OIL HH. FREE NH J ) HOj 5 SO. e. Cv NL Z. " ) SIt C. p~ A. F. ) DETERGENTS po. eN seH s.... ;3 ) 3 S.W. 4 " ) ) . 4 ) S.tt~ 5 STORlI WATER to) 3 .'PEN ORA' "AGE ) ) 5.'. 6 ) .. ) " ) .. 1 ) 5 ••• 6 ., ) 1 ) SALAries. T;\N~ ) ) I • W'. .£ "C" EFfluENT ) " 2 ) 1. ~O- ;) "0" HFLJENT ) • 2 ) '0" EFflUENT ) ., ) 1.". 5 'OJ EFF LUEHl ) oH 5S 01 L HM. FREE NH N0 3 J 3 I.If.6: 1\40'/A50' EFF pH 5S OIL NH. FREE NH J H0 3 3 I • fl. 7 A,01 H F LoEHT pH S SOIL NH. FREE NH J !III, 3 I.W. 8 p~ 55 OIL FREE HN CN HO J J 3 t:i1;:, OH 1.111. 9 !.REA 2 EHUIE ,n pH SS OIL FREE NH J eN N0 3 2 CH 0" J I .... 10 S"A. EfFLUENT PIl S5 OIL HH4 N0 504 J 3 1.<lJ. 11 PH SS Ol~ HM. N0 53. PO. J 3 V !OD~ EFfLUENT PH SS OIL 5°4 Cr en Nl Zn 3 5n Cd F~ Pb As S S.A.P 2 V901 HFL~ENT PH SS OIL 50 4 C. Cv HL Zn J ~n C~ F~ Pb As 5 Vf1'06 Eff.LUfNT Oil S5 Oil 5° Cr Co Nl Zr. 4 :.In Cd rfJ Pb As S AlLl EFFLUENT 5S, eDwPOSITION OF 10See 4 SLURRY RESIOUE, SAME ANALYSIS AS S••• , ON THE FI~TRATEO .'TER 3 ~..'L~t;.JRIC ;'c'IC! ~LANT TYPES OF SAuPLING 24 HOURS CO~POSITE "(EVERY TWO HOURS) 2 ALTERNATELY 24 HOURS CO~POS ITE SA~PLE AND INSTANTANEOUS ONE PEP SHIFT 3 INSTANTANEOUS ONE PER SHIFT (SPECIAllY AT THE MOMENT OF BATCH OIScHARGES) 4 INSTANTANEOUS ONE DAILY (SPECIALLY AT THE WOWENT OF BATCH OISCtlARGES) ~ • APART f"OM T;OSE PARAUETERS (FREE NH3 eN •••••• ) THAT HAVE T8 BE uETERMINED IM"EDIATELY DR PRESERVED 1. E!'.'VIRONMENTAL PFOBLEM CHARACTERIZATION INFORMATION QUESTIONNAIRE 1. DATA ORIGIN PRODUCTION GROUP PRODUCTION OR UTILITY UNIT PRODUCTION GROUP CHIEF UNIT OPERATING CHIEF OTHER PERSONNEL INTERVIEWED ./ . 2. 2. EMPLOYED RAW MATERIALS NAHE QUANTITY ORIGIN (SUPPLIER) 3. PRODUCTS/BY-PRODUCTS ~~D PLANT CAPACITY NAME AVERAGE ACTUAL QUANTITY ~lAXI~ OUANTITY 4. EMPLOYMENT OF UTILITIES AND VARIOUS ADDITIVES NAME QUANTITY REMARKS A) DEMlNERALISED WATER 8) RAW WATER C) COOLING WATER 0) STEAM E) FUELS F) CHEMICALS .~ . S. WASTE - WATER STREA~5 (FROH PROCESS, UTI LIn'. LEAKAGES AND VAR I OUS OPE RA TIO~S) NAME OR FLOW-RATE TUlE REQUI RED FREQUENCY TEMP. ·C VERIFIED OR WASTE WATEn REFERENCE AVERAGE MAXIM\JH (I r BATCll) EXPECTED COLLECTION COMPOS IT I ON SEwrn POLLUTANT P P~I REMARKS -~--~ OPERATING CONDITONS or 1111' PLANT AT 111E ~mlENT OF COLLECTION 01' nATE ----------~-.-~. rARTIClHAR onsr:rWI\TlONS --------- 4. 6 GASEOUS STREAMS (FROM PROCESS, t~ILITY, LEAKAGES AND VARIOUS OPERATIONS) NAME OR FLOW-RATE TIME REQUI REO fREQUENCY TEl'!' ·C VERIFIED OR REfERENCE AVERAGE HAXHruM (IF BATCH) F:XPECTED CO'lPOS I TlON POLLUNTANT pr~t REMARKS: OPERATING CONDITIONS Or- nlE PLANT AT niP. f-flMENT OF COLLECTION OF nAn - - - - - - - - - - - - - - - - - - -- ... PARTlClJLAR OBSERVATIONS ----- s. 7. SOLID WASTE PRODUCTION (FROM PROCESS, UTILITY, LEAKJl.GES AND VARIOUS OPERATIONS) NJ'JIE OR QUANTITY TIME REQUIRED FREQUENCY VERIFlI:D OR !'OINT OF COl.LECTION REFERENCE AVERAGE MAXIMUM EXPECTED COMPOSTION (IF SATCi1) COMPOUND % REMARKS: OPERATING CONDITIONS OF THE PLANT AT TIlE MOMENT OF COLLECTION OF DATA PARTICULAR OBSERVATIONS ~1:"~1,D,''"''''' ~''-'I''::E~.;'!t.~.''~ ~. .-" .. , .. ,,:,.,- " ';." ~'LT· .... t'-~'l''''''''.;:"'''~':-~ ••-- .'-. .... ""i"l~.... ';":' • .....,.-,,""':',.,. - •.• --, .. -.,- ..... ',... < o. 8. SIMPLIFIED PROCESS FLOW DIAG~~ ,, . 7. GENERAL INFORMATION .a) NORMAL OPERATING CONDITIONS OF THE PLA1,T - AVERAGE PRODUCTION CAPACITY _ _ _ _ _ _ _ _ _ % Max. cap. - R~~NING PERIOD _ _ _ _ _ _ _ _ _ hours/day _ _ _ _ _ _ _ _ _ days/week _ _ _ _ _ _ _ _ _ days/year _ _ _ _ _ _ _ _ _ hours/year b) PLANT ~iAINTENANCE PROGRAMMED STOPS PURPOSE TIME REQUIRED FREQUENCY c) PERSONNEL EMPLOYED DAILY SHIFT I>[)RMING SHIFT EVENING SHIFT NIGHT SHIFT e) ANY OTHER PARTICULAR PROBLEMS OF TIlE PLANT /-:t" .. S. a .,.",lJ.. 1 0.-:- So j Lo.:J""""' SIl ""f' £1.. c. • .tll.c.h..L ~Ur\ ~ ~ M,<1. '""-vJ.r S00.... r J:J.u- SITt" . U: E'Xl::rw";'" tLok r..rn Sell.'" (I. 1.a. 20 ~ 5.RP LC\.q~ c.-v..-J.v d!Aw.-..J. ~ 1;".s.:Jc.. tN. \,oll~F'E-'l -n U" ~ oJ: k:N- £ aA h'M .cJ ~ l. <.) 2b ~ . Ex A:<'o.J V<.:'" .t 'I:JQ../;' ~ 5 ~ I.. 2. Ct .k. 1.b 2a. U 177m T T(11oIt i'. Pf u.s fit. WI (j..i Fit. 10- 2.82 - • - . All t.. 51· 3'- . - - 4q'/f <?.orru- 0.5 Cu rr"" '3,5 . NIL qq!)1 lq, Z,t, . . 52 1·2 8lf.2 11 0.. Ito "2" """ L<;Lo..d 4.$ fb Pr"" Nil... NIL lOr 4-"1 r...;. • A,.·" ,'-' CLS fr"'" As 0·151 (H35& 1<1 4·1 37 ~. i:43 40 o·14-q $ll ~t nt':;""" C!.. 5." ffM SUarhQtc.. 0.." $011- Y. <.:? 151. () Jcr", 6-40 y. ".231. Ca. ~ (, :..w..-, a-.s <A <l/. tl·8~ .. /..i-., G - '>r1~.., LS.~ ~ Nlj-J (J '4-1 - I- 1+ 2 - 'J 1. ,g·o2'/. - 3.·201. -... L~!..;. .fY"\ )"t ':'t VI"""" Si 1\.<:'0. Q{ £i.O.l. 55·53 - ;;./0 - N)I':{QJ ,",;d .. s (fLo:, + M/~3) I. /'1' zq .........-' '16·63 - .~\,l~~ d<l.I1.. i.kj LoCJ:::.a.. Pc u r j/1'<lt - - '·It -- f o..<..kt J I' - - 1\4-0 - ~~EMTCHS OF ZAMSTA L';'D CEN"r'T~Ar, LA::O~A~(,~'! A:~ALy.sIS i:EPO'RT SAI·IPLE: SULPHURIC AOID ,LA,:T LA'JOC:: OVERFLOW ( SAllFLED Ct! 23/1/85 L ~i.H.O. Drinking ~'later Analysis ~esult Scecification (1nr~) 7.40 m-Alkalinity as Ca8C c J 83 ppm Total Hardness as CaC0 1621 " 3 Calcium Hardness as CaCC 7 1196 " 500 -' MagnesiWl! u " " 2_, 425 " 525 Sulphate (S04 / 1285 II 400 Chloride (01-) 16 ", 600 Fluoride (F-) 4.0 1.5 " 'Nitrate (NC,,-) 2.0· " 45 Phosphate (~043-) " 1.0 " Silica (5iO_) 2.4 " Ammonia (NH "+) .<:: 0.1 4 " Acid Soluble Iron (Fe) II 1.0 COpper (Cu) " 1.5 Zinc (Zn) " 15 ehr OIIIi WI! (er 6 +) N.D. 0.05 Lead (Pb) 0.1 ppm 0.05 Arsenic (As) ""'0£1 u 0.05 5eleniWII (5 .. ) o.c~ " 0.01 Sodium (lla +) 43 Pota13siWl! (r.+ ) " 8 " Chemical Oxygen Demand (COD) 3.3 " 10 Biochemical Oxygen Demand (BOD) 4.2 " 6 Total Solids 2992 " Total Dissolved Solidc 2962 II ~500 Suspended Solids 30 tf Turb idi ty 0.7 Units 25 lJnit:::; 'I'I"H.C. Specific,'1tiol"!s '1:'~ ~':~ rFlxi'<J..T. Dllowable limitG for d~irki7';- ~~tcr I J. MALCIIA I ACT. \lORKS OHDi:'§! NITROGEN CHEMICALS OF ZAMBIA LIMITED , 1 Sample 1. CENTRAL LABORATORV ANALVSIS REPORT S.A.P. Lagoon overflow 2. Area I lagoon sampled from eaatern eno of the lagoon Both semplea collected on 25.2.85 1 2 3 S.A.P. Area I W.H.O. !' Laooon Laooon 5 n eciflcatlot, pH 7.60 7.25 7.0 - 8.5 m-Alkalinity as ~aC03 ppm 74 121 Total Hardnesa dB CaC0 ppm 1475 608 3 Calcium Hardness aa CaC0 ppm 1072 525 500 3 Magneaium Hardneas as CaC0 ppm 402 83 625 3 Sulphate (504 2-) " 1470 505 400 Chloride (cl-' " 10 12 600 F'luoride (F-) • 1.6 1.5 Ni trete (N0 -) 3 • 3.B L 0.1 45 Cyanide (CN-) • 0.005 0.2 Thiocyanate (SCN-) • 0.20 Sllica (Si0 ) 5.7 3.7 2 Alllllonia (NH + ) 4 " <: 0.1 <. 0.1 0.5 Acid Soluble Iron (Fe) • 0.91 0.80 1.0 Capper (Cu) • 0.01 0.01 1.5 Zinc (Zn) • 0.02 0.02 15 Lead (Pb) 0.08 0.10 0.05 Arsenic (Ae) .. 0.005 0.05 Selenium (Se) 0.024 0.01 Sodium (Na+) .. 30 21 Potaasium (K+' 7 9.1 Chemicsl Oxygen Demand • 2.7 3.5 10 Biochemicsl Oxygen Demand • 1.2 6 Total Sollda " 2470 96B Totsl Dissolved solids 2378 952 1500 Suspended aolids " 92 16 TurOidlty 0.5 unita 0.1 units 25 ~ W.H.O. Specifications are the maximum allowable limits for drinking water. Results reported oB.03.85 CENTRAL LABORATORY ANALYSIS REPORT 3 SAMPLES: I) S .;\. P. Lagoon water overflow 2) Area 1 Lagoon water collected from eastern end of the lagoon Both samples collected on 5/6/85 , I , I , 2 3 S.A.? : Area I W.H.O. Lagoon Lagoon Speci fieatio , pH 7.80 7.70 7'() - 8.5 m-Alkal ini ty as CaCO_ ppm ~ 85 140 - Total ilardness as CaCO 3 ppm 1527 635 - Calcium Hardness as CaCO. ppm 1410 525 500 l'"lagnes ium Hardness as " CaCO. ppm ll7 llO 625 "2 Sulphate (504 ) ppm 860 400 400 Chloride (cl ) ppm 12 ;6 600 Fluoride ("-J ppm 3.5 8.5 1.5 :-IHrate (:-IO~) ppm - 9.60 45 Cyanide (CN-) ppm - '" 0.005 0.2 Thiocyanate (SC,-) ppm - 0.33 - Phosphate (PO;-) ppm Lo' 1.0 .L 1.0 - Silica (Si0 ) ppm 2 2.4 3.6 - + Ammonia (NH ) 4 ppm - 0.5 0.5 Iron ( Fe) ppm 1.98 1.95 1.0 Copper Cu) ppm 0.02 0.02 1.5 Zinc (Zn) ppm 0.08 0.16 15 Lead (Ph) ppm 0.11 0.11 0.05 1. Arsenic (As) ppm 0.002 0.008 0.05 Sodium (Na+) ppm 41 28 - Potassium (I( +) ppm 7.1 85 - Chemical Oxygen Demand ppm .36 1. 23 10 Biochemical Oxygen Demand ppm 24 23 6 ! Total solids ppm 3020 943 - Totol Dissolved solids ppm 27~O 908 1500 Suspenued Solids ppm 300 35 - Colour (fla:cn units) 68 130 50 \.B Ii',]!.\). Sp~clfil:ations arC' the ~laximum ,'\llowahle Limits for Jr!n)"in.i.~ W;itcr. ~tc~ults rcportcJ 21/6/85 ....... NITROGEN CHEMICALS OF ZAMBIA LIMITED CENTRAL LABORATORY ANALYSIS REPORT S,:"'\PLES, 1. SAP .. Lagoon water sampled on 7/11/85 from the eastern end of the lagoon . .\rea I lagoon water sampled on 6/11/85 from the eastern end of the lagoon. [f,-Alkalinity as C;.leo:) ppm 82 106 'lotal Hardness as CacO_ ppm 1843 672 Calcium .. J " " ~2SS 529 500 ~lagnesiu;n " 588 143 625 , Sulphate as SO- ppm 760 260 400 4 Chlonde as Cl ppm 7 14 600 fluoride as r ppm 1.5 14.8 1.5 Sitrate as ~O: ppm 18 11 45 J Cyanide as C~ ppm 0.005 0.2 Thiocyanate 30$ SeN ppm 0.11 3 Phosphate as 1'04 ppm < 1 .::: 1 Silica as SiO? ppm 1,6 3.4 ,~on ia as :-iH4 ppm g,O 0.8 0.5 ,;cid so lube Iron as Fe ppm 0.7 0,3 1.0 Copper as Cu ppm 0.03 0.01 1.5 Zinc as Zn ppm 0.05 0.05 15 Lead as Pb ppm 0.09 0.04 0.05 Arsenic as As ppm 0.003 0.003 0,05 Sodium as Na • ppm 66 66 Potassium as K • ppr.l 7,0 8.0 Chemical Oxygen Demand i'pm ;1,19 13.10 10 Bcochemica: Oxygen lJemand ppm 34.0 12.0 6 Total Solids ppm 3116 1202 Total Dissolved solids ppm 3050 1182 1500 Suspended solids ppm 20 :;,3. Ii.H.O. 1963 are the World Ilealth Organisation mu,imum allowable limits for Drinking water. ! '. , }-; -:·t\i:a';5.:~ ;,(J!U,S (!i[:\[ST ~):\TE: !9! 11/35 " ..... ''1'f " SAMPLE, NITROGEN CHEMICALS OF ZAMBIA LIMITED CENTRAL LABORATORY ANALYSIS REPORT SULPHURIC ACID PLANT LAGOON OVERFLOW SAMPLED ON 9/1/85 IlIZ, " KIN <. "''';- ~ " IS"£~ (YJUO Iq!>l) AN!l.LYSIS RESULT 1(111.)(, l1"waLIJ (fT'4.. pH 7.2 >r'\ - MA SI Total Hardness as Ca C0 1709 ppm 3 Calcium Hardness 'as Ca CO) 1334 soo " ",agr.eSltllll , ' " " . 375 . Sulphace (soh 580 .. Chloride (Cl- ) 12 " • " Fluoride (F- ) 3.4 " I ' /' , Nitrate (rIO; ) ./ ...::. 0.1 " " Phosphate (FO~-) .:::::.. 1,0 " Silica (SiO~) 1,0 ~ " Ammonia (t\H 4) L.. 0.1 " Iron (Soluble)(F,,) 1.5 " Copper (eu) ! .!: 0.02 " Zinc (Zn) 0.03 " • I' ~. Lead (Pb) 0,10 " Arsenic (As) L- 0.01 " Selenium S" 0.05 " S,.Q.4li um- -tIlr r'::' ..J 8.0 " Fotasei'trrt----K-+: ~-J ~ 46.0 " , r, Chern ieal Oxygen Demand C.O.D. 2.8 " ! \.. SiccheIT,ical Oxygen Demand E.O.D. 41 Total Solids 2356 '!'c'~",l Disso:ved Solids 2848 ,,,", < " , Suspen1ed Solids 8 Ad'::' .___ ~ __ VI n , I i ( " "" " ) I , KI'I'ROOEN CHEMICALS OF ZAMBIA LIMI'l'EI) CENTRAL I.AOORATOR'f ANALYSIS REPORT SAI1PLES: SUlphuric acid lcplanL effluent lagoon ,SM'ple 1, 2, 1'X1 3. d.~ted 14 JUl'l€ ~91>.1. A.'iALYSrs: 2 3 ?H 7.S0 7.50 7.55 T. flardness. ~ ~ 134.0 1130.0 1097.Qp.p.m I..-.lcium Hardness 618.0 'JC7 .0 823.0 .. H9. Hardness 316.0 223.0 274.0 " M. Allcalinity 115.0 64.0 55.0 .. ArSenie 0.1 0.3 0.2 " Iron (Soluble) 1.2 0.7 0.5 ~ . . Chloride 24.3 16.2 16.7 • 2 Sulphate 304 1350 1680 1480 .. H0 3 1.0 26 20 .. Fluoride (Y-) 0.8 1 .2 1.8 .. Total solids 2362 2190 2238 .. Total dissolved solids 2340 2132 2112 . suspended solid 22 58 126 p.p .... c:!Iemical oxygen 1.0 1.3 4.J p.p "" Denand C.O.D );>?ported 20.6.84 , ~V.~Cl-lv:~ ...................... ... ..... ~ ~~ 1001!J(S CHEMIST v:; \J , ... - _ ..__._----_._----------- ----_. __.-._- __~ IcJ:-J)~ ::::'j~_""'C!."'-.l.---C$""---_ _ _ _ _ _--'Q"'-,-"'-~_"'_3.... 1_:__- _ __ . _~._~lJ.lp"-:..lL-~v. l"h"" r:..~_lh,=<:,-----~-'I D' i f f m - - - - - -..- - - "1 Sit'), SUb-,-I'.e.-'_ _ _ _ __ ~, ..__________5.~~-------------- S'_8i '/. _____L __&~D-3------------~4r...::O~-'-'t-- _ _ __ ____l~_ _ c.,o. 0 ~ . .5 (, Y, --_JL,.__ --li\3 0 - O-S"'.:>Q.u'i'--_ _ _ _ _ __ ----..P-·---...s,,-"fr'J.~---0..--ff.... gTI--ff'-"--~---- _13_. ___ .1..~,,=--'\'_<w tb" 494-....,(""------- . yr.___ '2..:~_"__,"_ :z:" __...'i"!'? ., ____ ___ . ___/§_'___ CJvnr,., ~ " , ('rr N ,).. Ii. ,~,' r k. t c;..;S_N: NJ_l______ ~_______ _ --,-I,], (Il boll: a \ (o ___ N,}, __________ ____I.b_,_,s'1-~~..,_ 0'; .s9 "':,2 ./MML...._ _ _ _ __ rm -- ___--" -. ....Jrs\l.,,;-<..._~ As ___ .__ I._~.:...._ _ __ -----------/~~---------~---------- ------,--_._------- ~------------ --.------_.- - --t.. ..... I'7,76-------------------- =~-~j: _"'-J:<-Mi__ .~o..o ___ )4 W~f'~~-'J- ~ ~ .{1vJ.... ?o..s. :'';''~.d u:--l--u;...,______ _ ______-____ _ _ ~/ ., . I • I i . , ,,-" J f 8th November,11I86 .,......, I .... I." 171 > OOVERN1lENT OJ!' ZAMBIA S:U.T1l'.I'ORY IM"""U1lU1' No. 181 OJ'1985 The Local MlIIlfUtradoD Act (Act No. I~ 011986) The Local Admialatradcm (Trade BllIuent) Retaladone, 1985 IN lIS_a of the powenI oontaioed in ...otloo N:lr-/ou.r of the LocaJ Administration Act, 1980, the following Regn. JatioDa ..." hereby .-Ie, J. Theoe RepIatioDa may he cited aa the LooaI Ailmin- TiUe istration (Trade Emuent) ReguJa""..., 1985. 2. In theoe Regulations, Wll_ the context otherwise _ requires-- p. H &rea" me&n8 the .....,.. under the jurisdiotion of the Council; "average ...... ottength .. m_ aU _age, domeeti.o and trade emuent received at the Council'. _age purification worits; "chemical pIIl'aUIl!ters" meana the group oC substan_ tiated in items 7 te 53 of the li'Irst Schedule; " ColJDciI .. . - . . aay council to ..bieh th_ Regulations "".... been applied in ..,coman08 1t'Ith ~on tNr:ty-jlw oCtile Aot; " operating day .. _ the period of twenty-four holll8 eommencing at mi.dnlght and cding the foDowing mid night; .. phplOlll ~ .. _ the pbyaOlll oh&raeteriati.. Iioted in items 1 to • oC the I:I'irn 8ohedule; " publlo ....... " _ _ a ........ bekmglDg to the Council; .. 'tilde . u...... _ _ _tor or ....y otIler liquid ..hielt baa been uaed for 1Dedlc.l. trade or indutrial putt and AI! a reomlt of aaoh _ ..... been polluted 1t'Ithin or beyond tile IepIly ~ limiting ~ .mil ..........,t to ph;,aleal. ohemlcaI and microbloJosioal ehancterisli... aDd 10 req.ur. _t""",t before dis· clIarge into the envbmment. a. (1) No ~ ohaII. without the writIen penniooioo of the ~ .. CouDciI, dltIoIW"p my tnlde elIIuent in any water 0II'GnIe or .... any .....d in tbe _ . _ U. ~fI""""""l'" $_......... ... '.0. _lOla. - . """~ _9. 4CIoo a F 1.PriIMr, - .. /II ,. . . , ...... R'.'. 8111 November, 1eM ,1) TIle paint .. or ~ wtdoh er.da dI_t iii to be 6"...... .... be aab.... to the prior wri_ pormiMion of the Ooanall; and where appropriate. 0IW!h diIIoIw:ge aIuIIl be _r ....... iIuuugh ....... appond ~n to the &eWer .... is -...... IlllliDWned by tile 0cmnaII. Qg , •., 4. (I) A:sly cIIIohaIp of tnde d I _ Into .. pnbU. - ........ ~p obaIl ooafiIraI to the ~ and IIliIIDdud8 lOr ebemioal &:!J.:jy.loo.l ........,...... """ We. (I) A:sly di8oh.o.rp rom ...,y ....... _ b or ...,y diooharge € GOt in colnmn 2 of the Firat 0Iher 111m .. pro,ided iIr in aab·replr.tion (1) ebaIl oonform to the condlticmB aDd IIliIIDdud8 iIr obemioo.l md phyoloal JIIIA""'••' """ oat In colmDll I of tbe F'Int 8ebedole. .of"'" M~---"'-"'" II. The Oonneil _y p....rib, (a) the houn daring ."hIch trade efll.-.t _y be dis· ebr.rged Into ..."....; • (6) the mnlmnm honrly tate ..t ."bieb trade efIIuent may be ditcharged into .. _ ; ...,d - (e) tb& toW ~ of trade dI_t ."hIch .....y be dis· ... 6~ """""'" into .. _ dnriP« m operating day. 6. (1) A compooite ........... eh&Il be obtained by oollectlng dluent discharged from .. plant daring an operating day eite. :".o..a,.;. (a) ooatlnwolly dnriP« .. Mmpllng period of twenty·four be"", ..t .. tate in proportion to the dow rate of the dlu...t cIiIebMpd; or (b) in ....... _ _ t....t oqul velum.. of dli.ent are deliveted Into .. reooptecle ..t eqnal intorvala of not IoDp 111m one hour daring ......mpllng method of twenty·lO.... houn. (2) The treq....."Y of _..piing md .....!YMia of the oompooi~ ....... eh&Il be do"" on .. "'IJI1Iar bMla to be determined by the o,unoll. (I) The oonoentrat.lon In miIIigram_ per litre of my ...bstmoe d... oribed In ""y item of the Pint 8chedule in ....h oompooite ....mple eball be determined by the method oet out thtnin. (4) TIle proood_ pertr.iDinc ~. ~. ...........cf r.za.ob* of _p&. .. In the pnblioatioa Btt.rt.tIiml JlII:IIIJ" ftw 1M .I_i..,," oJ W.... ",.., If... If..... (15th Bdftion. 1 _ ) . r.ny ot.Im method ..pprond in 1IIlIhIrt by the .MlniItII'. ...... cd' ad to. i'i~p $ - t~ Ii;» Iitu fB f.lt il - - - I'~ , ~lH 'I Pf ij !1.r.tl It ~'iP'r t' rhr ~ • I rN i i!j r ·!H J'IJ~ ndh'; pf."l l - 1'. I'"i' 1 II Ii g. , It !l~ it! J "r! Ii";"· il [" i ': 11 I:, _1 . lar~' rt !iflJ!~ ~iit! b '1IJfJ iif iiI JIll ! . > ...!!!"_582 . SI =4)' 1_'1e 1IIIIo~. lIN ~.... othenIoe ~ . . . tile " ' _ of tbo trade em... cIiocbaqpod Into .. _ _ dadIIa tile J.IIIIod from tile ""W _ . the a.pJIIIZUaa .... 1Ml ~ b)' tile CollDoil • 'beiDa'-- up to the dale ......... : ' _ "" ...,.. .-pt.ecI bJ the 000maII • 'beiDa __ lie fIIt'O ,.""", IICIC!Ol'dInc to the ~ ...........ppota........ 1Ml_Dted bJ the CollDoliu bodDg 0CImIIGt. - 11. Any penaa 1Obo ~ trade eID_t Into the poblic == "'"""" far ........ Ihall pay to the O>a:uail .. tnd6 em... ohaqJe 1fhloh IIbroIl be oalouI.o.&ed In aooordaruIO with tbe farm..... l1li; out In. the -.ad Schedule, ProvIded that tbe minjmum cIwp for th" diapooal of my ""y. _", tnd6 elDllllllt. not ex.......w.c one cubic _ per IIbroIl be , IIft.y bn.oha per caIend....,........ - An-Ia Ill. Any Jl"fIIOIl ~ or ad-'y alfeDted by Any deoIaiou oJ: " Cooaoil mAy a~ to the lfiniator. -- ~ ~ 13. (1) Any p8IlIOn 1Oho OOIltn_ my provisio~ of th_ Begul&tiooa IIhaJl be guilty of m offimce and IIhaJl be liable. u,pon couviotion (0) in the ..... of a 11m offimoe. to " fine not ex.......w.c. three hUlld.rlld kwaeha; and (b) in the ..... of .. -.ad or IObeoq_t oIfunoe to .. fine not ex.......w.c IIiI: hUlld.rlld kwaeha or to iDlpriaon. ment for " period not e".......w.c oi.J: mont"', or to both lOoh fine and iDlprioonment. _ (I) In addilion to or in onhetiiution for the poII<y preooribed. in IOb·regulation (I), the court _y onIm- that any ,,~ lnournd by the CounoiI in OOIIIIOJqtlll!lce of IOoh contravention ... 00 1'" , be paid by the couvieted penaa. U. (1) In any order made under oeotion N:I!t-Ji"" of the Act a.pplylng ~ Begul&tiooa to any _ . a period of not 10M \han b'el.... montho IIhaJl be .peol1led during whioh UDder IiBIdnp ait.uMell in tho ..... are required to otvt complying with tbeoe Begul&tiooa. and if no onoh period is apeol1led. a period of f;n\..e mOlltilo IIhaJl be deemed to ha.... ~ apeol1led. (I) No penaa IIhaJl be oouvieted of _ oIfenoo under regale lion 13 if.uoh oIfenoe .... committed during the period apeol1led under oub·regulatlon (1). DB. B. S. M.......... L1llI.ut.l !11th October. 1_ [LOB.IOt/U/II} Mi....,.,.of~ IMIlNov.mbor.llN11 ·581 _I lI'IlIIIT 1IOIlIIDm& (. . ' : t'J T..............,....... Tau. UD o...JCnowIlllft _t _.3 - A._ T».An~1If'PO saw.ct. d1> Onln hllLlO.... ~nN't 1.'1Iom_ ... 10'0. ~ JI!Ibdoc fit .... ~-. -- ',:0.0 .... ..0 Mliobepoialllo( -- -.u.s I m- 1. _ _ ) - --'plea' lIutiMt CIaUIIO linT .,....... = 'I --- _ _ ,'lJlo(&be (1Ipeotoop'-) . . . .dkwll 3. _ _ _ (TbIMII<>I4 _ lIudaot- C&WII: ....,. C\IIitItI!!I &a7 IlWsanoo _ I n ..... N_) or odmtt ... oom~ ....u.h t.ho nMural ....t& ::c::4od - Toto! .. (a........ _) 1200 mcfh (A..ot ~_, 60 "'IlL. II........ f~olat\ldpOt' efr:oat low) ... in J'tIrOeiving .u.m. --I I. _ _ oodi. _ _ ml/L(Im. 8. 1!OIioil7/Ro1idno mgfL 1Il00 mgfL. Tho> ooIi. ~.and l'o.:!'iml,...... (A . f1II ..... ol!'l!Mst,.,. -) bI. . . . . ., ""7 ..... - - Oravhueido method) . ' " dWolmrp -.d 0.5 :milt. in t ... Man. Mud 1l0~ CI&Q:t8 tor", malioa of atudp in tMIIIivina ...tor S 000 mglL. Tho .unitT or ..... ~ mua' not .aV8M!1ly ~'or""'" .a_...rl'A<!r6 _W tMir ftmc. . . . . . 0.1' 0I0ning --I B. Cuxm.u. 1. plJ (0-1'..., , _ . 6-10 6-. ---- B. DiIooInrd O~ ~( W -) t,~~ -.! ( _hbdood . ) (lliah. No n,q;~ .. I BOO mslL -- ADler oompl_ m.ixiug, t.ha U:II:7P'Q ~II ... - ...... ".,..:::f;; DM.7 ftIINlII in lowet OOD ~ '"' 0lM mud JlOl be ................_Ibr ............0<1) orpoIlo .......... eo.OO ~&_for _ili_.. U .0. Dr, t ..... Gay,.. IlwooaII (BOD) , .00 "'CIL ......."'" OJL 60 oV$t'.U t=: --I ~- - . . . ...d _ _ =....rlo-' .... -.-me ~t" "rtboll_"'"..... 8&h Nov....._. 1I11III S/4IwIIoItr 1",. 1111'. ... 0"""".. 1 Col....,. t Col""", 3 "l"a&... ~r.a'fIO BanrAQi d'D 0 . 8uM'tUIc.t:: Pmoouo_ I!:rn_ 0 . -.... .!4. Alaminium ocmpounda <!Omg/L < 100000f. (Alomie AIavption motbod) f4. nti.mony{A.tomie A O.I-,/L (mbibitilon 0,4mg/L .u-.,.- motho<i) of oD:la&ion~ H,A-ue~ 1.0mgtL 1.0mg1L (Atomic Abaorptaoo~/ _bOO) 27. Bari\U'l1 ~poundll 1.0mg1L UmglL (..-lJOluble eGnt"en_ _ I ( A...... A t.rqJt ion met hod} 28. "yllium ,.Jta ADd O.li " .fL (inhlbittoo. of . 0.1-0.1'1 maiL (MICOl"~ oompDWld, (Aiamtc oUiatton) dini to ¢i.n)~' A'lMorption. methodj n. Borun CO¥Qpoqnde <MmgfL <IO""llIL (HfX'I"'hv pbq~tric methc~~C.fi"umiD. _<hod) 30. Catlmium campaumh 1.lImgfL ro "'marL (Atoomio AbIIorption mc<hod) 31. Chromium Hesavahmt. li.Omg!I. o.lmg!I. Tri¥a1ent (Atomic AIl$Qrptioh method} 32. Oobalt. cumpoundl O··mgIL 0,6 mall. .......... (Atomiil Ab.>rptiun ) 33. C:)ppnroompounda 3,OmgfL 1.0ms/L CAtoJnle Abeorptwll JJ)OthOfl~ 3 •• Iron oomPIJuDds U.OmalL <2mgJL (At.omio AbtIIorpdoIl -) 3". (Aton:Ue Ablurpl i()1l ~ eompmwdK 1.&ng!L Umg/L mMhod) '3$. )f~l1m (Atomic <1000mg!L '<_.0 mall. Abotorptloll ~ And }'ItIlM ptW)iqrprltrio method) 37.~(A_'" 10.0 maiL d.OmalL Abto'1.ttoll method) 38. Morw'7 (At<m:Ue Abttorpt.ion method) o.olmg/L •.<'" Img/I• 39. MoI,bdreq~",. (Atomio '.Om!I!L O.II-5.0mg:'L Abtto",tktn method) 40. Wte1cel (AtoW.l'I 2.0 .../1. 2..0mgII. Abwoorpt.lIOIlmothod} 41. &kmium (AfOU <1.0 mall. <0.0..../1. Abeorpt.ktn met.hod) 4t, liver (Atomia S Ahowl"".;...., f'l'tj!!thocfl o.J~l_or .................. , "'..,,1. -, ~i(, 8ftJIwIorr I,.""....... ~ N_ber•. llIU - .. "_~"'("o-lo ... Tio _ _ 0_1 ~_hodl ~"~'ibn ...,...,- t'a.d. JbIn:.vlarf tIf'I'O 1'0"'ll1L 2.Oma/L 0"'-1 ~s Saw. . . AIlI) Ormra -... <0.....". ' .• ma/L -u.odl 45. V...............,.....t.. 1.0 mg/I. I .....:11. (At..... Aoorption -.bodl ••. z"'_0<10 2>.0"'41/1, lo.o"'lllL (AI.omic AbeorpUon _&hod) n. Oao4JUCfJ 47. Total hydrocorbona 2O.llgro/L to.Otl'lglL (~phio mo&hod) 'S. 0iI0 (1liIIeral ODd Crude 100.0 "'IfiL , . _ 1-2ma/L (~bio i .....i.iouof4llll a.tboduaG~vi. """,-'J<l.h",/L me&ric metbvd) (aftetu.tau.tion of derQ."lai&t) .t. Phaoll (Jlt.eIIm d,it", 6.O"'IIiL Umg/L _le) (Non·.....m diNDed) 1.OmglL 0.05 "'II/L (Co........... I»O&hodI 10. , . and _poni&hle :No requirvmeDt bul 2D.O.mg/L oi1t(Oravimet.rio iJ:wt;&lIa&ioo of oU and lD8tbod and Chromato· fat .".,.&01'11 OJ. Do_.. graphic method) (At.omio~D (AnIonlc) 10.0mg/LAlky_ 2.0"'11 (I.......... lU1!onaw Dol pe:rmiUed ahould f)Ontam ...... 6peetropho"".ric) =raw.eom~ 62. ·PM..... ¥Id PCJ)'R U)mg!L U"'IJ/L i _ l o . (To<ol) (Ob......."'· m.iftimum) _lUolQPthodJ 13. TrihAlolOnns (Cbroo:aa. 1.n ml:t/L U .../L (Rod.... I<> • .....p1Uc1 . minimum) E. a.....,.""." ~ If. ~vell)l8faiatt Noditeh.rge~l Not peorroit.k!d ""pI'!'Oifled by lARA -Then an -.ppa'''' ".lyof 000 peet~ ~ and PC&. The nron::.l - , _ . &he won. of Ntonmft heNi.u&ftoI' I:rkefttiooned ahaIl be \I4Ied ia ~ "1* BoJ--: 1._ I...... . - . -... _ . AaorM>J'-oodo Prot .... of E.YifoaInmt Putoa 1 to Ht. US ~t "'oJ UM(I''IlII. S....._ . c.-dIt-_ _ _ W_P.U_Oomn>I~~.Codooand of'--' . . , _ (EP8-I) l'IolOOOlo. ~ rrin&.i..ol OIB_. 3. !tJo&eI, 1I.1)a1\ W_ PoIIuOjjm Control ..... ~. Z_ _ (1111). •• Land, n: F, - Iocladrial PolMio. Coni.., _book" 1[eO_-_ Book CoaIP""7,1t71). t. APBA. AWW~ 'WPCF• .,Star,." JrIIIICboda COl' 'hoK.a.mlnatIGD fill W_andW_ _ I6$hE_(IIHlO)... I J J i J I • I . I