Document ID: EPA-HQ-OW-2004-0032-0446
Agency: epa
Document Type: Supporting & Related Material
Title: 
Posted Date: 2005-08-18T04:00Z

Tobacco
Products
Processing
Wastewater
Characterization
Sampling
Telephone
Interview
Form
Date
June
21,
2005
Facility
Name
RJR
Hanmer
Division
Facility
Contacts
Bill
Murphy
Facility
Contact
Information
Tel:
804­
751­
7806,
e­
mail
murphyb@
rjrt.
com
Interview
Questions:

1.
Does
the
facility
have
process
wastewater
treatment
or
pre­
treatment?
The
Hanmer
site
has
a
2.1
MGD
BNR
Activated
Sludge
Treatment
plant
Facilities
with
pre­
treatment
or
treatment
2.
Briefly
describe
the
treatment
processes.
Are
there
aerobic
or
anaerobic
zones,
pH
adjustments,
chemical
additions?
Process
wastewater
is
pumped
to
a
primary
clarifier.
Solids
are
removed
along
with
Waste
Activated
Sludge
and
stored
in
a
holding
tank
for
dewatering.
Clarifier
effluent
is
mixed
with
Return
Activated
Sludge
(
RAS)
and
flows
to
the
Bardenpho
BNR
process.
During
the
flowing
from
the
clarifier
to
the
Bardenpho,
nitrates
remaining
in
the
RAS
are
broken
down
by
the
organisms
to
release
the
bonded
oxygen
molecules.
Once
the
wastewater
is
inside
the
Bardenpho
process,
it
undergoes
5
zones
of
treatment
for
phosphorus
and
nitrogen
reduction.
The
zones
are
Anaerobic
(
for
phosphorus
treatment),
Anoxic
(
for
nitrate
reduction),
Aeration
(
for
Ammonia
to
Nitrate
reduction,
CBOD
reduction,
and
phosphorus
uptake),
2ns
Anoxic
(
for
nitrate
and
CBOD
polishing),
and
Re­
aeration
(
to
raise
DO
levels
to
prevent
phosphorus
release)
After
the
re­
aeration
zone
there
is
a
rapid
mix
chamber
where
ferric
chloride
is
added
as
needed
when
phosphorus
levels
after
biological
treatment
are
still
above
VPDES
discharge
permit
limits.
Also
a
cationic
polymer
is
sometimes
used
instead
of
or
in
addition
to
ferric
chloride
to
reduce
phosphorus
levels
when
suspended
solids
are
higher
than
normal.

The
wastewater
then
flows
to
a
secondary
clarifier.
Solids
that
settle
out
are
pumped
back
to
mix
with
the
primary
clarifier
effluent
or
wasted
and
mix
with
the
primary
clarifier
solids
prior
to
dewatering.
The
secondary
clarifier
effluent
flows
to
a
parshall
flume
where
the
volume
of
effluent
flow
is
measured.
A
compost
sampler
is
located
in
the
flume
where
flow
proportional
samples
are
collected
per
VPDES
discharge
permit
requirements.

3.
What
waste
streams
enter
the
treatment
system?
Process
wastewater
from
the
reconstituted
tobacco
process,
backwash
from
the
water
treatment
process
and
rainwater
that
flows
into
two
holding
ponds
are
the
only
waste
streams
that
enter
the
treatment
system.

4.
Is
the
treatment
plant
outfitted
with
a
single
influent,
where
all
plant
process
waters
are
combined
prior
to
treatment,
or
are
there
multiple
influents
discharging
wastewaters
from
different
plant
processes?
If
multiple
influents,
what
waste
streams
comprise
each
influent?

All
influent
into
the
treatment
process
is
pumped
from
a
single
pump
house
location.
The
pump
house
has
the
ability
to
allow
excess
flow
to
overflow
to
a
storage
pond
used
for
flow
equalization.
Water
is
then
withdrawn
from
the
pond
when
needed
to
maintain
treatment
plant
flows.

5.
Describe
the
influent
to
treatment
wastewater
characteristics.
Is
it
viscous,
highly
aerated,
odorous,
colored,
opaque,
acidic
or
basic,
etc.?

Wastewater
characteristics
prior
to
treatment:
pH
is
6.5
to
7.5,
Ammonia
levels
vary
from
10
mg/
l
to
30
mg/
l.,
CBOD
varies
from
700
to
1400
kg/
d,
total
phosphorus
varies
from
7
to
30
mg/
l.
The
water
looks
similar
to
a
cup
of
coffee
with
cream.
No
foaming,
Has
slight
tobacco
odor,
and
enters
treatment
system
between
20
and
35
degrees
C.

6.
How
is
the
effluent
routed
from
the
treatment
system
(
through
a
single
stream
or
multiple
streams)?
If
multiple
streams,
what
comprises
each
stream?

Effluent
from
the
last
stage
of
treatment
(
secondary
clarifier)
free
flows
approximately
500
feet
through
a
15
inch
concrete
pipe
through
the
parshall
flume
then
over
some
rocks
for
final
aeration
and
into
a
discharge
stream
approximately
100
feet
from
entry
into
the
James
River.
7.
Describe
the
effluent
from
treatment
wastewater
characteristics.

Treated
wastewater
characteristics:
pH
is
6.5
to
7.5,
Ammonia
0
to
2
mg/
l,
Total
N
7
to
19
mg/
l
(
15
to
30
kg/
d),
Total
Phosphorus
1.1
to
1.4
mg/
l
(
2.6
to
4.3
kg/
d),
TSS
from
14
to
41
kg/
d
and
CBOD
between
9
to
21
kg/
d
.
The
effluent
has
a
tea
color
tint,
no
odor
and
fairly
clear
to
look
though
as
compared
to
river
water.

Facilities
without
pre­
treatment
or
treatment
8.
What
process
wastewaters
are
discharged
from
the
facility?

9.
Describe
each
process
wastewater
stream
and
other
waste
streams
(
e.
g.,
domestic
or
processing
cooling
water)
that
are
discharged
(
direct
or
indirect).
How
are
the
process
wastewaters
commingled?
What
processes
or
parts
of
the
facility
discharge
to
each
waste
stream?
10.
What
are
the
characteristics
of
each
waste
stream?
Approximately
what
percent
of
the
waste
stream
is
process
wastewater?

General
Sampling
Questions
11.
Where
do
you
currently
collect
samples?
What
is
your
sample
collection
methodology
(
sample
tap
on
a
pipe,
automatic
sampling
machine)?

VPDES
required
sampling:
Daily
pH,
DO,
Weekly
CBOD,
TSS,
Ammonia,
Total
Phosphorus,
and
Monthly
Total
Nitrogen
(
TKN+
Nitrate­
Nitrite
+
Ammonia+
Nitrogen).
Daily
samples
are
grab
samples.
Weekly
and
Monthly
are
24
hour
composites.
We
also
do
operational
testing
based
on
grab
samples
for
phosphorus,
Ammonia,
TSS,
pH,
COD
at
different
times
through
out
each
day
when
we
are
discharging.
Sample
pumps
have
been
installed
at
various
stages
of
the
Bardenpho
process,
primary
clarifier
and
secondary
clarifiers
for
sample
collection.
Nitrogen
samples
(
Ammonia,
TKN,
Total
N,
Nitrate­
Nitrite)
are
sent
off
to
a
contract
laboratory
for
analysis.
All
other
testing
in
done
in
our
on­
site
lab.

12.
Briefly
describe
each
sampling
point.
What
waste
streams
comprise
each
sampling
point.
What
are
the
typical
flow
and
wastewater
characteristics?
Primary
Clarifier:
pH
(
6.8
to
7.1),
COD
(
700­
1600
mg/
l),
TSS
(
180­
300
mg/
l),
TP
(
7.5
­
29
mg/
l),
Ammonia
(
12­
56
mg/
l)

Anaerobic
tank:
pH
7.1­
7.3,
phosphorus
8­
56
mg/
l
Anoxic
pH
7.3­
7.6
Re­
aeration:
phosphorus
.3
 
17
mg/
l
Secondary
Clarifier
:
COD
125­
256
mg/
l,
pH:,
phosphorus:
.17
 
17
Outfall:
DO,
pH,
TSS,
CBOD,
COD,
Ammonia,
Nitrogen,(
values
listed
earlier)
13.
Do
you
collect
flow
data
from
any
plant
process
waste
streams
or
from
treatment
system
influents
or
effluents?

The
only
flow
data
collected
is
through
the
Parshall
flume
measuring
the
effluent
to
the
James
River.

14.
Do
you
have
sampling
points
that
are
only
accessible
through
a
manhole?
If
a
pump
is
needed,
what
head
would
the
pump
need
to
be
able
to
pull?

No.
Hand
pumps
are
lifting
the
sample
about
10
feet
to
the
discharge
point.

15.
For
facilities
without
treatment,
is
there
a
point
prior
to
commingling
with
any
stormwater
where
we
can
collect
samples?
Sampling
Logistics
16.
How
far
apart
are
the
sampling
locations?
If
far
apart,
what
is
the
best
means
of
transporting
sampling
equipment
to
and
from
the
sampling
locations?
(
Sampling
equipment
would
include
several
coolers
with
ice
and
up
to
46
sample
bottles.)

Sample
collection
points
are
several
yards
apart.
We
use
a
pickup
truck
to
drive
to
sample
points.
Samples
are
returned
to
the
lab
within
the
approved
sample
method
times.
Or
are
collected
and
preserved
or
placed
in
a
refrigerator
for
those
samples
which
we
do
not
test
here
on
site..
Samples
to
outside
lab
are
preserved,
refrigerated
and
transported
via
cooler
to
the
laboratory
for
testing.
Chain
of
custody
paperwork
follows
the
samples.

17.
Can
you
provide
us
with
a
staging
area
where
we
can
perform
sample
preservation,
field
tests,
and
sample
packaging?
Where
would
this
staging
area
be
and
how
much
room
could
you
provide?
Is
it
indoors?
Air
conditioned?
Ventilated?
Will
it
be
far
from
the
influent
and
effluent
sampling
locations?

Our
laboratory
can
provide
a
staging
area
and
sample
preservation
area.
We
have
done
this
many
time
in
the
past
as
part
of
VA
DEQ
site
inspections.

18.
Is
your
facility
interested
in
collecting
split
samples?
We
have
done
split
samples
in
the
past
with
VA­
DEQ.
We
are
also
participants
every
year
in
the
EPA
DMR­
QA
program.
If
requested,
our
site
would
participate
in
a
split
sample
study.

Facility
Health
and
Safety
Information
19.
Does
the
plant
staff
want
to
provide
an
on­
site
health
and
safety
briefing
prior
to
the
start
of
sampling?
A
short
overview
can
be
provided,
but
since
site
personnel
will
be
accompanying
your
party,
it
will
not
be
necessary
to
go
into
a
lot
of
detail.
20.
Will
we
be
escorted
to
and
from
the
sampling
locations?
If
not,
what
is
the
best
way
for
communicating
with
facility
personnel
in
case
of
an
emergency?

Yes
21.
Are
there
on­
site
emergency
medical
facilities
(
nurses
office,
EMTs?)
If
so,
where
are
they
located
and
how
can
we
reach
them?
What
is
the
name
and
location
of
the
nearest
hospital?

Our
site
has
first
responders
available
in
case
of
an
emergency.
The
guards
are
trained
to
call
911.
The
nearest
Hospital
is
John
Randolph
Medical
Center,
Hopewell,
VA
approximately
5
miles
away.

22.
Are
there
general
health
and
safety
concerns
(
physical,
chemical
or
thermal
hazards)
associated
with
the
facility?
Can
you
provide
us
with
MSDS's
or
tell
us
the
location
for
which
these
documents
can
be
obtained
for
chemicals
that
we
have
the
potential
to
come
into
contact
with.
The
only
hazard's
associated
with
the
wastewater
process
are
exposure
to
Ferric
Chloride
and
Acetic
Acid
used
for
phosphorus
reduction
and
for
COD
supplement
during
periods
of
shutdown
twice
a
year.
MSDS
information
is
available
via
computer
in
the
lab
or
hard
copies
can
also
be
made
available.

23.
What
are
the
sample
point
specific
health
and
safety
concerns?

During
summer
months
snakes
(
copperhead,
water
moccasin
and
black
snake)
are
present
in
the
discharge
area.
Agents
have
been
sprayed
to
kill
the
grass
and
weeds
in
the
area
to
keep
the
snakes
away.
The
other
sampling
sites
have
no
specific
safety
requirements
other
than
safety
glasses
24.
What
are
the
health
and
safety
concerns
associated
with
the
staging
areas?
Safety
glasses
or
face
shield
required
when
adding
acid
for
sample
preparation.

25.
What
PPE
is
required
by
your
facility,
and
specifically
for
the
sampling/
site
visit
areas?
Same
as
detailed
above,
Safety
glasses,
safety
shield,
rubber
gloves
for
handling
chemicals
for
sample
testing.

26.
Do
you
require
any
special
identification
information
for
sampling
personnel?

Personnel
will
be
accompanied
by
site
employees.
Only
a
visitor
badge
will
be
required
and
that
will
be
issued
at
the
guard
station
when
checking
in.

Request
for
Additional
Information
­
wastewater
treatment
system
diagrams
 
see
attached
PPT
slides
­
monitoring
data
from
wastewater
treatment
plant
(
influent
and
effluent)
(
including
chemistry
and
flows)­
See
attached
XLS
2005
summary
file.
­
directions
to
the
facility
From
North
 
I95
south
to
Exit
61A
(
Hopewell).
Go
approximately
6
miles
East
(
will
go
under
I­
295).
At
1st
traffic
light
after
I­
295
turn
left
(
Enon
Church
Road).
There
will
be
an
BP
Amoco
station
on
your
left.
Go
approximately
1.5
miles
on
Enon
Church
Road
till
you
see
Brown
&
Williamson
Tobacco
sign
on
you
right
just
before
a
wooded
area.
Turn
right
just
in
front
of
the
sign.
Go
straight
till
fenced
gate,
and
turn
left
and
follow
the
road
to
guard
station.
You
can
park
in
front
of
the
building
on
your
right.
(
Main
Office).