Bloomington, Indiana PCB Inventory
Mass Balance

Draft

by Melissa Valentin, P. E.
MVA Consulting, Inc.
October 1997

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PCB Inventory Phase I Summary

Table 1 - Summary

1. Introduction

2. Principal Source Areas and Pathways: Phase I Estimates

2.1 Westinghouse Plant, Bloomington, Indiana

2.1.1 50 Million Pounds PCBs Purchased

2.1.2 Five PCB Formulations Used

2.1.3 1.4 Million Capacitors Manufactured

2.1.4 Pathways for PCBs to leave the Westinghouse Plant

2.2 Local Disposal Sites

2.2.1 Anderson Road Landfill

2.2.2 Bennett's Quarry

2.2.3 Lemon Lane Landfill

2.2.4 Neal's Dump

2.2.5 Neal's Landfill

2.3 Winston Thomas Treatment Plant

2.3.1 PCBs entering the Winston Thomas Treatment Plant

2.3.2 Rate of Raw Sewage Treatment at WTTP

2.3.3 Pathways for PCBs Leaving WTTP

2.4 Clear Creek

2.4.1 Lemon Lane Inputs to Clear Creek

2.4.2 WTTP inputs to Clear Creek

3. Summary of Phase I

4. References Reviewed for the Phase I Report

List of Attachments

Attachment 1 Calculation of the Amount of Inerteen in Capacitors Manufactured by Westinghouse in Bloomington During the Period 1958 Through 1977

Attachment 2 Calculation of Average Annual PCB Usage And Capacitor Production Rates

Attachment 3 Disposal of PCBs in Local Dumps

Attachment 4 Winston Thomas Wastewater Treatment Plant

Attachment 5 PCBs in Discharge from Lemon Lane Entering Clear Creek

1. Introduction

Polychlorinated biphenyl (PCB) contamination in the Bloomington, Indiana area is extensive. The principal PCB source areas and off- site migration pathways were first identified in the 1970s and early 1980s, but site characterization remains superficial. In order to ensure that future releases of PCBs from the source areas are minimized, it is necessary to improve our understanding of the amount of PCBs in each source area and the relative significance of each transport pathway.

The objective of this study is to map the distribution of PCBs in the Bloomington area. The process of creating a PCB inventory will assist remediation efforts in several ways. It will identify pathways that are capable of redistributing significant quantities of PCBs, it will serve as a benchmark against which remedial alternatives can be compared, and it will identify data gaps.

The PCB inventory will supplement site characterization work and remedial analyses already performed. Remedial strategies based on PCB concentration identify "hot spots", and concentrations are the basis for cleanup goals. But with persistent contaminants like PCBs that bioaccumulate in the environment, low concentrations can misrepresent the importance of certain transport pathways. For example, long- term continuous discharges of water with low concentrations of PCBs can produce the same amount of damage downstream as occasional discharges of higher PCB concentration.

This Phase I Report is the first of a series of studies aimed at documenting the distribution of PCBs in the Bloomington area. The first three phases of work are described below. Additional phases of work may be added as new information becomes available.

Phase I Phase I identifies the principal PCB sources and pathways, and contains a preliminary evaluation of available data. It includes estimates of

1) PCB usage at the former Westinghouse Plant,

2) PCB disposal at various dump sites,

3) PCB discharges to the Winston- Thomas Treatment Plant and

4) PCB discharges to Clear Creek from Lemon Lane Landfill and the

Winston- Thomas Treatment Plant.

In addition, important data gaps are identified.

Phase II Phase II will focus on PCB discharges to groundwater and surface water using NPDES records from the Westinghouse/ ABB Plant, the Winston-Thomas Treatment Plant and Neal's Landfill, plus all other available water, sediment or ecological sampling data. This report will also refine the Phase I estimates if additional information becomes available.

Phase III Phase III will involve the development of a geographic information system (GIS) to assist with the interpretation and illustration of data. Specific applications for the GIS include refining estimates PCB mass at

the various PCB- contaminated sites, and providing graphical documentation of residual PCB contamination that will remain at the sites following remediation. This report will also contain further refinement of the estimates reported in Phases I and II, if possible.

A summary of the important source areas and associated off- site migration pathways are listed in the Phase I Summary Table (Table 1). Preliminary estimates of the amounts of PCBs transported by specific routes are listed. Most entries in this table do not contain estimates of PCB mass: this is an indicator of data gaps to be addressed in subsequent phases of work.

Table 1: PCB Inventory Phase I Summary

2. Principal Source Areas and Pathways: Phase I Estimates

In Phase I, the known PCB source areas and pathways for off- site migration were examined, and available data was evaluated. A summary of the results was presented in Table 1. In the sections that follow, the source areas and pathways for which data was available are discussed.

2.1 Westinghouse Plant, Bloomington, Indiana

The Westinghouse Bloomington Plant is the starting point for the PCB Inventory. It is generally acknowledged that the PCBs in the Bloomington Consent Decree sites originated at the Westinghouse Plant in Bloomington.

2. 1. 1 50 Million Pounds PCBs Purchased

Westinghouse filled capacitors with liquid PCB formulations called Inerteen from 1958 until 1977, roughly 20 years. Monsanto was the sole U. S. manufacturer of PCBs. Purchase records documenting the quantity or type of PCB formulations used at the plant are not available. Therefore, production data was used to estimate the total amount of PCBs purchased.

Examination of production records for a 6.4 year period between 1966 and 1972 indicate that almost 16 million pounds of PCBs were used in production during those years alone (Kacir 1983). As shown in Attachment 1, extrapolation of these production rates to the entire period of study suggests that close to 50 million pounds of PCBs were used in the production of capacitors between 1958 and 1977. This does not account for spillage or waste.

2.1.2 Five PCB Formulations Used

Westinghouse purchased PCBs from Monsanto in various formulations. Information from a legal memo prepared in 1983 (Kacir 1983) indicates that from 1966 to 1971, Aroclor 1242 was used to fill capacitors. Aroclor 1016 replaced Aroclor 1242 in the Fall of 1971, and it was used through at least May of 1972. Information on PCB formulations used at the plant prior to 1966 or after 1972 is not available. The presence of high concentrations of PCB Aroclors 1248, 1254 and 1260 at Neal's Dump, Neal's Landfill, and Lemon Lane Landfill indicate that these PCB formulations were also used at the Westinghouse Plant.

2. 1. 3 1. 4 Million Capacitors Manufactured

Capacitors manufactured at Westinghouse's plant in Bloomington between 1958 and 1977 were filled with Inerteen (a liquid PCB formulation). Available production data for the period 1966 -1972 (Kacir 1983) indicates that 15,824,641 pounds of Inerteen was used to manufacture 461,256 capacitors. If this production data is extrapolated to the entire period of study (1958 -1977), the following estimations can be made:

• A total of 50 million pounds of Inerteen was used to fill 1. 4 million capacitors.
• Large capacitors contained between 16 and 106 pounds of Inerteen each, and an average
• of 63,500 large capacitors were produced annually.
• Small capacitors contained approximately 1.4 pounds of Inerteen each, and an average of
• 8,600 small capacitors were produced each year.
• Each year, approximately 2. 5 million pounds of Inerteen was used to fill 72,000 capacitors of various sizes.

2.1.4 Pathways for PCBs to leave the Westinghouse Plant

Many pathways have transported PCBs from the Westinghouse plant:

• Most of the PCBs were sent to customers in sealed capacitors. It is estimated that at least ninety percent of the capacitors manufactured were shipped to customers. 45 Million pounds of PCBs represents 90 percent of the PCBs used in capacitor production.
• Clay was used to purify Inerteen. Based on information in the Kacir memo (Kacir 1983), it is estimated that approximately 30,000 pounds per year of PCB- contaminated clay was disposed of locally at the landfills referenced above. Assuming a PCB concentration of 100,000 ppm in the clay, roughly 60,000 pounds of PCBs were disposed of locally in the clay. (See Attachment 3.)
• Some spills inside the plant may have been cleaned up with sawdust or other materials, and these materials would have been disposed of at local landfills. This pathway is not evaluated further due to the absence of information.
• Some spills of Inerteen inside the plant entered the sanitary sewer leading to the Winston-Thomas Wastewater Treatment Plant (WTTP). PCBs rinsed from the outside of capacitors or manufacturing equipment were also discharged to WTTP through the sanitary sewer. In the early 1970s, Westinghouse estimated the magnitude of these discharges to WTTP to be 25 pounds of PCBs per day (Munson undated, Munson 1972). After the WTTP plant was notified of these discharges in 1975, PCB discharges to WTTP continued but were rerouted. WTTP is discussed further in Section 2.3.
• Some waste PCBs were collected for off- site recycling or disposal. This pathway is not addressed further due to the absence of information.
• Some PCBs were, and still are, discharged from the Westinghouse/ ABB site to a nearby surface water/ sinkhole under a NPDES permit. There is a history of non- compliance with the conditions of this permit.
• Available data indicates that 5 to 10 percent of capacitors manufactured were scrapped due to defects or overproduction. Some capacitors were partially drained of Inerteen prior to disposal, but draining removed only half of the Inerteen. Prior to 1970, none of the small capacitors and only less than half of the large capacitors were drained. After 1970, all capacitors were drained prior to disposal (Kacir 1983). Taking this into consideration, approximately 2. 3 million pounds of Inerteen entered the local dumps when the capacitors were disposed of. Specific disposal sites are discussed further in Section 2.3.
• Some capacitors were taken to Fell Iron and Metal, a salvage yard in Bloomington. They may have been taken there directly or after initial disposal at local dumps. Capacitors and 27,000 tons of PCB- contaminated soil was removed from the Fell Iron and Metal site.
• Some PCBs were spilled onto the plant property during transportation, handling, or capacitor production. 25,000 tons of PCB-contaminated soil were removed from the former Westinghouse plant (now called ABB). Some PCB contamination remains in soil under the loading dock, and groundwater is contaminated.

2.2 Local Disposal Sites

2. 2. 1 Anderson Road Landfill

The Anderson Road Landfill accepted waste and capacitors from Westinghouse in the late 1960s and early 1970s. In the 1980s, the PCB- contaminated material (almost 5,000 tons) was relocated from Anderson Road to an Interim Storage Facility at the Winston Thomas Treatment Plant. It is estimated that 21 tons of PCBs were discarded at Anderson Road between 1968 and 1972 (see Attachment 3).

>2.2.2 Bennett's Quarry

Bennetts Quarry was used for dumping and scavenging of capacitors manufactured by Westinghouse after 1966. Accurate estimates of the number of capacitors or the extent of contamination at this site are not available. 252 visible capacitors were removed from the site as part of interim remedial measures. The Consent Decree required the removal of 55,000 cubic yards of material, but this material has not yet been removed. It is estimated that 169 tons of PCBs were discarded at Bennetts Quarry (see Attachment 3).

2.2.3 Lemon Lane Landfill

Lemon Lane Landfill accepted undrained and partially drained capacitors and other PCB-contaminated solid waste from the Westinghouse plant from 1958 to 1964. Records of wastes disposed and landfill operations are not available, but it appears that this was the only disposal facility used by Westinghouse during this time period. Limited sampling data indicates that PCB contamination in the landfill is extensive. Exposed capacitors were removed during interim remedial measures in 1987, and the site was capped. The Consent Decree required the removal of approximately 176,000 cubic yards of contaminated material, but this material has not yet been removed. It is estimated that 568 tons of PCBs were discarded at Lemon Lane Landfill (see Attachment 3).

2.2.4 Neal's Dump

Neal's Dump accepted partially drained capacitors from the Westinghouse plant between 1968 and 1972. Surface capacitors were removed during interim remedial measures in the 1980s and the site was capped. The Consent Decree required the removal of approximately 14,000 cubic yards of waste, but this material has not yet been removed. It is estimated that 145 tons of PCBs were discarded at Neal's Dump (see Attachment 3).

2.2.5 Neal's Landfill

Neal's Landfill accepted undrained and partially drained capacitors and other solid waste from the Westinghouse plant during 1966 and 1967. Surface capacitors were removed during interim remedial measures in the 1980s, and the site was capped. The Consent Decree required the removal of approximately 320,000 cubic yards of material, but this material has not yet been removed. It is estimated that 268 tons of PCBs were discarded at Neal's Landfill (see Attachment 3).

2.3 Winston-Thomas Treatment Plant

2.3.1 PCBs entering the Winston-Thomas Treatment Plant

The Winston- Thomas Treatment Plant (WTTP) received PCB discharges from Westinghouse from 1958 through 1982, when it was shut down. Virtually all components of the plant were contaminated with PCBs.

• From 1958 to 1965, the "main" sewer transported approximately 25 pounds of PCBs per day from Westinghouse to WTTP (Munson undated, Munson 1972), presumably at the head of the treatment works.
• Starting in 1965, wastewater from Westinghouse was carried by a new sewer line, the "southwest" sewer (Powell 1996). Between 1965 and 1975, the "southwest" sewer presumably discharged at the head of the treatment works.
• After 1975, the year that Westinghouse informed the City of its PCB discharges, the "southwest" sewer discharged only to the grit station - not to the head of the treatment plant. The "southwest" sewer was cleaned in 1980- 81 (Powell 1996).
• The "main" sewer was never cleaned to remove PCBs, so although it presumably stopped receiving flow from Westinghouse in 1965, residual PCBs in the pipe continued to enter WTTP at the head of the plant. Based on PCB concentrations taken from the "main" sewer in 1976, 5.4 lbs PCBs per day were still entering the plant via the "main" sewer (Powell 1996). (See Attachment 4.)

2.3.2 Rate of Raw Sewage Treatment at WTTP

According to the Powell report (Powell 1996), WTTP treated 6 million gallons of sewage per day from 1967 to 1982. Annual summary reports of sewage treatment operations for the period 1972 through 1982 indicate that WTTP treated an average of 7.78 million gallons per day during that period.

2.3.3 Pathways for PCBs Leaving WTTP

Several important current and historical pathways for PCBs leaving WTTP are listed below. The most obvious pathway is the discharge of treatment effluent containing PCBs to Clear Creek. Many other important pathways relate to the disposal of sludge that was contaminated with several thousand parts per million of PCBs. A memo by Evelyn Brophy (Brophy 1996) describes the practices of sludge disposal at WTTP in the 1960s:

• Spreading sludge on local farms and gardens
• Spreading sludge on soil on- site
• Filling on- site sinkholes with sludge
• Injecting sludge and liquids into ground

Additional pathways for PCBs to exit the WTTP property are:

• WTTP effluent discharged directly to Clear Creek, amounting to roughly 40,000 pounds of PCBs (Attachment 4)
• Lagoon overflows entering Clear Creek
• Surface runoff carrying dissolved or suspended PCBs to Clear Creek, or floodwater from
• Clear Creek contacting sludge disposal areas
• Leaky pipes introducing PCBs to surface or subsurface soil
• Volatilization of PCBs from the 17- acre lagoon, amounting to 60- 120 pounds per year (Rainbolt 1994)

2.4 Clear Creek

Clear Creek receives PCBs principally from Lemon Lane (via Illinois Central and Quarry Springs) and the Winston Thomas Treatment Plant, although other significant sources may be identified in the future.

2.4.1 Lemon Lane Inputs to Clear Creek

Currently, non- storm flows at Illinois Central/ Quarry Springs (ICS) carry approximately 4 pounds of PCBs per year to Clear Creek. Storm flows carry approximately 6 pounds PCBs per year, for a total of approximately 10 pounds PCBs per year. (See Attachment 5). The landfill was capped in 1987. Since Lemon Lane Landfill is basically two very large unlined sinkholes, groundwater can enter the landfill from below and from the sides. Some PCBs migrate by gravity out the bottom of the landfill and into the weathered and fractured rock at its base. When water flows through the rock, or through the landfill itself, it carries PCBs with it to Illinois Central/ Quarry Spring.

Current discharges at ICS are probably a fraction of what they were before the cap was installed - when 40 inches per year of rain was falling onto the 10- 11 acre landfill and flowing out the sinkholes at its base. A subsequent memo will address this current and historical pathway.

2.4.2 WTTP inputs to Clear Creek

The WTTP plant is bordered by Clear Creek, and effluent from the plant was discharged directly to the Creek. Data reporting the PCB content of the tertiary effluent is not available for the years prior to 1976. The average PCB concentration in tertiary effluent after 1976 (for the years 1977 through 1984) is five times lower than the average PCB concentration in 1976. It is presumed that control measures at the Westinghouse Plant and at the WTTP are responsible for this decrease. The Munson memos (Munson undated, Munson 1972) suggest that Westinghouse began implementing measures to reduce PCB discharges the City's sewage treatment plant in the early 1970s. Therefore, the average PCB concentration in WTTP effluent for 1976 is assumed to be representative of the years 1971 through 1976. Prior to 1971, PCB discharges were not controlled by Westinghouse or the WTTP. It is therefore assumed that the PCB concentration for the years 1958- 1970 is five times higher than the concentration in 1976. A priority for subsequent phases of this study is to refine the estimate of PCB discharges to Clear Creek from the WTTP.

Using the assumptions described above, over 40 thousand pounds of PCBs were discharged to Clear Creek in effluent from the WTTP. The basis for this estimate is provided in Attachment 4.

Other pathways for PCBs from the WTTP to enter Clear Creek may be significant, but are not quantified in this phase of work. They include PCB leaching from sludge that was spread all around the WTTP property, injected into sinkholes and wells, leaks in plant piping, and overflows from the tertiary lagoon.

3. Summary of Phase I

A summary of the PCB source areas and PCB transport pathways was presented in Table 1. Available data, listed in the References Section, was used to prepared the following estimates:

• Westinghouse purchased approximately 50 million pounds of PCBs from Monsanto for use at the Bloomington Plant;
• Westinghouse shipped approximately 45 million pounds ot PCBs to customers in sealed capacitors;
• Westinghouse discharged approximately 200,000 pounds of PCBs to the Winston-Thomas Treatment Plant via the sanitary sewer;
• Westinghouse disposed of approximately 42,500 pounds of PCBs at the Anderson Road Landfill;
• Westinghouse disposed of approximately 338,000 pounds of PCBs at Bennetts Quarry Dump;
• Westinghouse disposed of approximately 1,135,800 pounds of PCBs at Lemon Lane Landfill;
• Westinghouse disposed of approximately 290,600 pounds of PCBs at Neal's Dump;
• Westinghouse disposed of approximately 536,300 pounds of PCBs at Neal's Landfill;
• The Winston Thomas Treatment Plant discharged approximately 40,000 pounds of PCBs to Clear Creek in treatment effluent;
• Roughly 3,500 pounds of PCBs have volatilized from the surface of the Winston-Thomas Tertiary Lagoon.

Significant data gaps remain, and it is likely that the estimates listed above will be refined in subsequent phases of work. The second phase of work will focus on quantifying past, present and future discharged of PCBs to water.

4. References Reviewed for the Phase I Report