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Kevin Kitzman &Scott Courtney
ALCOA, Inc.&
Walt Eifert
Roux Associates, Inc.
Overview Of Alcoa�sEnhanced Natural Systems (ENS)
Project
ALCOAMt. Holly, South Carolina
International AppliedPhytotechnologies Conference
Chicago, IllinoisMarch 3 � 5, 2003
Presented by:
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Alcoa, Mt. Holly Plant
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Alcoa, Mt. Holly Plant
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Purpose Of Mt. Holly ENS Pilot Project
! Identify and evaluate passive �green� technologies that can:"Enhance the stormwater quality
in on-site retention ponds;
"Reduce the quantity of water discharged from stormwater retention ponds;
"Eliminate process water discharges to the local POTW; and
"Enhance the quality of stormwater runoff from the
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!Demonstrate the viability of using passive
technologies at the Mt. Holly Site;
!Demonstrate the cost-effectiveness of ENS
technologies; and
!Develop full-scale applications for Alcoa sites
world-wide.
Purpose Of Mt. Holly ENS Pilot Project (continued)
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Zero Water Program Update
Goal: To develop/test/demonstrate zero water natural treatment systems, technologies, and minimization approaches for Alcoa use worldwide.
Focus on zero water discharge and protection of groundwater through chemical sequestration/degradation.
Partnerships between ATC, Primary Metals, Mt Holly, EHS Services, EHS Science & Technology
July 25, 2002
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Water Management Current Condition
WaterIntake
Rain
ProcessWater
Treatment$$$NPDES
Discharge
Treatment$$$
Storm SurgeBasins
$$$
NPDESDischarge
ContaminatedRunoff
River/LakePotential
Liability
Potential
Liability
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Alcoa�s Zero Water Discharge Conceptual Approach (Process and Storm Waters) Future Condition
POTW
Sanitaryww
Recycle
Minimize Runoff�Green Roofs�Grass Filter Strips�Porous Pavement
ReducedMake-up Permitted
DischargeDuring
ExtremeStormEvent
Rain
Natural Treatment Systems�Trees�Constructed wetland
Cooling Water Treatment & Discharge
�Non-chemical treatment
Note: Elimination of Contaminated Sewer Lines
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Components Of Mt. Holly ENS Project
! East Pond Area� Constructed Treatment Wetlands (CTW
! Former Spray Field Area� Phyto Pilot Plot� Grass Pilot Plot
! Pot Line Courtyard Areas� Vegetative Filter Strip� Control Plot
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Locations Of Pilot ENS Components
Process Lagoon
Constructed Wetlands Pilot PlotPotline Courtyards
East Pond
Trees
BufferBuffer
GrassGrassFormer Spray Field Area
Phytotechnology Phytotechnology Pilot PlotsPilot Plots
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East Pond ENS Pilot
CTW for Fluoride/Metals
Removal
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East Pond CTW Design
Key Design Elements:! No. Test Cells: 2
! Cell Size (each): 75� x 150� (11,250 ft2)
! Cell Types: Sub-Surface Flow
! Constituents Of Interest: Fl, As, Al, Mn, Ni, Zn
! Treatment Sequencing and Removal Mechanisms:
# Cell 1: Fluoride removal via adsorption
# Cell 2: Metals removal via sulfate reduction
/co-precipitation
! Design Flow: 10 gpm (14,400 gpd)
! Water Source: East Pond
! Discharge To: East Pond
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Outfall 002
Constructed Wetlands Pilot Plot
East Pond
Cell 1Cell 2
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Basis For Design
! Bench Testing To Evaluate:
" the effectiveness of experimental media to remove fluoride from stormwater;
" the effectiveness of spent-mushroom compas a metals treatment media;
" design hydraulic retention times;
" pilot cell sizing requirements; and
" sequencing requirements.
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East Pond Bench Testing Program
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East Pond CTW Pilot Layout
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Potline Courtyard
Grass Filter Strips For
Fluoride Removal
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Potline Courtyard ENS Design
Key Design Elements:
! No. Test Plots: 2# ENS Plot (3 grass filter strips)# Control Plot (gravel)
! Plot Size: 750� x 60� (45,000 ft2)
! Vegetation: Buffalo and Bahia Grass
! Water Source: Roof Drainage from PotlineArea
! Constituents Of Interest: Fluoride, Aluminum,
TSS
! Treatment Objective:# Enhance storm water runoff quality
and reduce quantity of runoff
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Roadway
Existing Catch Basin
Courtyard Vegetated Filter Strips
Vegetated Grass Filter Strip Pilot Plot
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Sprayfield
Phyto Plots For Water Consumption/Metals
Retention
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Alcoa-Mt. Holly Sprayfield Area & Process Lagoon
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Spray Field Phyto Pilot Plot Design
Key Design Elements:!No. Test Plots: 2!Plot Size (each): 258� x 225� (58,000 ft2)!Vegetation:‣ Plot 1: Tree/Grass Mix ‣Plot 2: Grass
! Irrigation Water: Retrofit of Existing Lagoon System
!Preliminary Application Rate‣ 16,000 gpd/plot
! Constituents Of Interest (COIs):Fl, Cu, Mn, Ni, Zn
! Treatment Mechanisms:‣ Consumptive water use through ET Loss
‣ COIs are retained in root zone
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Spray Field Phyto Plot Layout
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Sprayfield Phytotechnology Pilot Plots
Grass Pilot Plot
Hybrid Poplar Tree Plot
Irrigation Lines from Process Lagoon
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Basis For Design
! Rooting Test Experiments To Determine:
" the ability of site soils to support and sustain
a viable vegetative community;
" appropriate tree and grass species to be usedat the site; and
" the form and amount of soil supplements
required to support the selected species.
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Spray Field Phytotechnology (Tree) Plot Cross Section
1-year old hybrid cultivar polesExisting topsoil
2� wide x 4� deep planting trench (TYP.)
Irrigation spray head (TYP.)
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! Cost Advantages:" Cost savings of 50-80% can be realized in capital
investment stage; and
" Cost savings exceeding 90% are typical in the operation & maintenance stage.
! Other Advantages Include:" Simplicity of operation and maintenance;
" Tolerance to wide fluctuations in hydraulic and constituent loading rates; and
" Aesthetic attributes.
Projected ENS Benefits
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Enter TitleThe Far Side
�Well, actually, Doreen, I rather resent being called a �swamp thing.�
�I prefer the term �wetlands-challenged mutant.��