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Project Overview

Sandersville Plant Drainage


Thiele Kaolin Company
Outline of Presentation
Present Existing Drainage Basins &
Systems
Define Existing Problems w/ Systems
4 Possible Solutions to System
Problems
Existing Drainage Basins & Systems

Six Storm Drainage Basins


Seven Systems for Transporting
Waste.
Six Storm Drainage Areas
1. Yellow Area. This area contains the office buildings and parking lots, the
lawn east of Thieles drive, and the lower rail road tracks. The area is
approximately 27.97 acres. Storm water is 23.5 cfs. There is no process
water.
2. Orange Area. This area collects process water from both calciners, #4 spray
drier, #5 spray drier, and the calcined slurry make-down. The process flow
rate ranges from 400-600 gpm on average and can peak when both
scrubbers are running at #4 and #5 spray driers are running at approximately
800gpm. If railcars are being washed out the flow rate can spike as well. The
9.84 acre area is comprised largely of building structures, concreted tracks
and graveled tracks. The peak storm runoff is 22.5cfs.
3. Blue Area. The 4.1 acre area is comprised largely of building structures,
concreted tracks and graveled tracks. This area is largely impervious.
Process water flows at app. 1200gpm. The peak storm runoff is 11.1cfs.
Six Storm Drainage Areas
4. Red Area. The 1.9 acre area is comprised largely of concreted
tracks. This area belongs to Burgess but the drainage contributes to
the gravity sewer in the blue area. The Peak storm runoff is 4.77 cfs.
There is no process water from this area.
5. Green Area. The 5.07 acre area is comprised of the R&D building
and lawn. The peak storm runoff is 8.44 cfs. There is no process
water from this area.
6. Pink Area. The 11.5 acre area is comprised largely of industrial
structures, concrete, gravel and low permeability soils. This area is
largely impervious. The process water averages at 5.5 cfs.
9.84 Acres
27.97 Acres Water
Q=22.51 cfs Storm
800 gpm
Q=23.5 cfsProcess
Storm Water
Water

4.1 Acres
11.0864 cfs Storm Water
2.5 cfs Process Water
1.89 Acres
4.72 cfs Storm Water

11.55 Acres
21.62 cfs Storm Water
5.5 cfs Process Water

5.07 Acres
8.44 cfs Storm Water
Seven Systems
System #1. The gravity system for the yellow drainage area which
flows directly to Limestone creek behind Burgess.
System #2. The pressurized system which is located in the Orange
area and pumps to the gravity sewer beginning at Burgess. A retention
pond located on KTs property is part of this system.
System #3. This system is located in the blue area and is a gravity
system which flows thru Burgess and Huber then thru an open ditch to
the waste pond. This system has several bottlenecks. Both the blue
and red drainage areas contribute to this area.
System #4. This is the drainage area on Burgesss property (Red). This
transports water to the blue gravity system.
System #5.The storm drainage for the R&D area (green area).
System #6. The process and storm drainage for the main plant (pink
area).
System #7.The pressurized system that returns waste to the Avant and
Hall Mines via two Hazleton 4J pumps.
SYSTEM #1

SYSTEM #3
SYSTEM #7

SYSTEM #2
SYSTEM #4

SYSTEM #6

SYSTEM #5
Reject Pump to Avant Mine
SV- AM System Curves For Various Reject Line Combinations

2000
System Curve for 6in and 8in combo
2 Hazleton 4J @1490

8" line for total length(85000')

1500

1000
Head(ft)

500

0
0 100 200 300 400 500 600 700 800 900

-500
GPM
Reject to Hall Mine
SV-HM 6" REJECT SYSTEM CURVE
2000

Slurry Test Data Point


Water Test Data Point
Water to Tan Pond
1500 Water to Thigpen Pond
Slurry to Thigpen
(2) Hazleton 4J @ 1490rpm
Calc. Water Curve
Calc. Slurry Curve
1000
HEAD(ft)

500

0
0 100 200 300 400 500 600 700

-500 GPM
Problem Areas
Catch Basin at Burgess
Sewer Pipe by Beck Blvd. and thru
Huber
Open Drainage Ditch behind Huber
Drainage Summary Chart

-17.02
Possible Solutions
Presentation of Options
Pros and Cons of Options
Economic Analysis of Options
Miscellaneous
Presentation of Options
1. Install a parallel gravity sewer
through Burgess parking area,
along Beck Blvd., and through
Huber. Clean the open ditch
improve slopes and concrete
bottom or install pipe.
Option #1
30 Sewer Pipe

Stream-Line Sewer
Ditch Behind Huber
Presentation of Options
2. Install Clarifier and route all
process water and all storm water
with exception to the yellow area
to a larger pond at KT. Clarified
water will be released to creek and
solids will be pumped to mine.
1 Acre
1000GPM; 6 DAY RECOVERY

4.5 Acres
8.7MG
2400 GPM @2%
Presentation of Options
3. Install a high level overflow at the
upper gravity catch basin in
Burgess parking lot. Reroute any
storm water which exceeds the 18
pipe capacity to the lower existing
KT pond. The lower KT pond will
need to be dredged to
accommodate additional storm
water.
Presentation of Options
4. Send all of the blue area process
and storm water to the sump
pumps located in the orange area.
Pump the total flow across the plant
to the upper 42 sewer.
Pros and Cons of Options
Option 1 30 Parallel Sewer
Advantages Disadvantages
No additional Still in Joint Pond
pumping Initial Costs
Maintenance
Friendly
Prevents Overflow
to Creek
Option 2 Clarifier
Advantages Disadvantages
Free of Joint Waste Highest Initial
Pond Costs
Minimal Dredging Highest
@ KT Maintenance
Prevents Overflow Overall Reliability
to Creek
Option 3 Storm Water to KT
Advantages Disadvantages
Lowest Initial Cost Still in Joint Pond
Catches Additional Additional Volume
Pollution Point Required @KT
Ditch Needs Less Pond
Initial Cleaning Still Need to
Allows Full Pipe Maintain Ditch
Flow to Waste
Pond
Rainwater Only to
KT
Option 4 Blue Area to Sump
Advantages Disadvantages
No Ditch Still in Joint Pond
Maintenance Additional Volume
Prevents Overflow Reqd. @ KT Pond
to Creek Additional
Pumping Cost
3rd Pump Reqd.
Reliability on
Pumps
Miscellaneous
Line to Mines for Dredge
16 ID allows 3500gpm
Pump Solids Directly to Mine
Est. Cost at $3,000,000