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HomeMy WebLinkAboutNC0089621_Report_201812054,10 Dewberry kereiAt� Dc-r S,za1B AP otv P Feb, 9, "I Best Available Technology (BAT) Economically Achievable Analysis NPDES Discharge Permit to Cedar Creek Novozymes, North America, Inc. SUBMITTED BY: Dewberry 2610 Wycliff Road Suite 410 Raleigh, NC 27607 PREPARED FOR: Novozymes North America, Inc. SUBMITTED TO: NCDEQ TABLE OF CONTENTS TABLEOF CONTENTS..................................................................................................1 .. LIST OF ACRONYMS..................................................................................................... 4 1. INTRODUCTION...................................................................................................... 5 ., 2. INDUSTRIAL PROCESS DESCRIPTION................................................................7 2.1 Facility Description....................................................................................................................7 2.2 Wastewater Treatment and Discharge Permits.......................................................................7 3. NOVOZYMES' CURRENT WASTEWATER TREATMENT.....................................9 3.1 Influent Wastewater Characteristics.........................................................................................9 3.2 2010 — 2014 WWTP Operation.................................................................................................9 3.3 2015 to Present WWTP Operation.......................................................................................... io 3.4 Historical WWTP Performance................................................................................................ 11 4. TREATMENT TECHNOLOGY ALTERNATIVES EVALUATED ............................13 .. 4.1 Treatment Technologies..........................................................................................................13 5. Treatability Testing...............................................................................................14 .� 5.1 Treatability Testing Approach.................................................................................................14 5.2 Treatability Testing Protocol................................................................................................... 15 5.3 Performance Testing Results................................................................................................... 16 uq 6. PROPOSED PROCESS TREATMENT DESCRIPTION........................................19 6.1 Primary Clarification...............................................................................................................19 6.2 Bioreactors.............................................................................................................................. zo 6.3 Aeration Equipment............................................................................................................... 20 .� 6.4 Secondary Clarification........................................................................................................... 20 6.5 Dissolved Air Flotation(DAF)................................................................................................. 21 6.6 Ultra -Filtration (UF)/Reverse Osmosis (RO) System........................................................... 21 _ 7. BIOLOGICAL PROCESS MODELING..................................................................22 8. EQUIVALENT ANNUAL COST ANALYSIS..........................................................24 9. BAT LIMIT DETERMINATION...............................................................................26 9.1 Total Nitrogen BAT Limits......................................................................................................26 9.2 Total Phosphorus BAT Limits................................................................................................ 30 10. CONCLUSIONS.....................................................................................................32 11 Dewberry, Novorymes North America. Inc. I Best Available Technology Analysis I 1 ^ LIST OF TABLES ^ Table 2.1 Industrial User Pretreatment Permit Limits Table 3.1 Novozymes' Influent Wastewater Characteristics ^ Table 3.2 Novozymes' Historical Effluent Wastewater Comparison Table 3.3 Historical IUP Limits ^ Table 5.1 Treatability Testing Nitrogen Speciation Parameters Table 5.2 Calculated Variability between Measured Internal Process and Certified Lab Data . Table 53 Treatability Testing 95th Percentile and Maximum Reactor Effluent Results Table 6.1 Novozymes' Influent Wastewater Average Conditions to SND Activated Sludge Process .. Table 7.1 Biowina Kinetic Values Table 7.2 Biowin® Effluent Nitrogen Results Table 7.3 Modeled and Estimated Effluent Nitrogen Conditions Table 8.1 Equivalent Annual Costs Comparison Table 9.i Calculated Effluent Total Nitrogen BAT Limits Table 9.2 Equivalent Annual Costs Normalized to Nitrogen Removed ^ Table 9.3 Incremental TN Removal Cost Comparison Table 9.4 Proposed Total Nitrogen BAT limit Table 9.5 North Carolina Municipal Total Nitrogen Surcharge Rates ^ Table 9.6 Proposed Phosphorus BAT Limit Table io.r Summary of Equivalent Annual Costs Normalized to Nitrogen Removed ^ Table 10.2 Proposed TN and TP BAT Limits LIST OF FIGURES ^ Figure 1 2010 - 2014 Wastewater Treatment Configuration ^ Figure Current Wastewater Treatment Configuration Figure 3 BiowinO Model Diagram Figure 4 TN Effluent Results Comparison Figure 5 Normalized Nitrogen Removal Costs _ Figure 6 Effluent Phosphorus Concentrations vs. Metal Coagulant to Phosphorus Dose It Dewberry- Novozymes North America, Inc. I Best Available Technology Analysis 12 APPENDICES Appendix A Wastewater Irrigation System Permit (Permit # WQ0002806) Appendix B Industrial User Pretreatment Permit (Permit # 0112) Appendix C Approved Corrective Action Plan Correspondence Appendix D DEQ December 14, 2016 BAT Correspondence Letter Appendix E Novozymes September 7, 2018 Correspondence to the Division .. Appendix F Novozymes' W WTP Existing Site Layout - Appendix G Novozymes' 2010 — 2014 Historical Wastewater Effluent Data .. Appendix H Novozymes' 2015 — 2018 Historical Wastewater Effluent Data Appendix I Certified Lab Data Appendix J Dewberry Treatability Reactor Logs Appendix K Proposed Novozymes Wastewater Treatment Plant Upgrades Block Flow Diagram .0 Appendix L Preliminary Equipment Specification Table Appendix M Biowin© Model Inputs and Outputs Appendix N Capital and Recurring Cost Estimates Appendix O Vendor Quotes .o fj Dewberry Novozymes North America, Inc I Best Available Technology Analysis 13 LIST OF ACRONYMS ADF Average daily flow rate NCDEQNorth Carolina Department of Environmental Quality .� BAT Best Available Technology NH3-N Ammonia measured as nitrogen BFD Block flow diagram NPDES National Pollution Discharge BOD Biological oxygen demand Elimination System CEAM Center for Exposure Assessment NSW Nutrient sensitive waters .. Modeling POTW Publicly owned treatment works COD Chemical oxygen demand PVCA Present value cost analysis C.F.R Code of Federal Regulations RAS Return activated sludge DAF Dissolved air floatation RO Reverse osmosis DO Dissolved oxygen S.U. standard units (pH) EAA Engineering alternatives analysis .. SND Simultaneous nitrification and EPA Environmental Protection Agency denitrification gpd gallons per day TDS total dissolved solids gpm gallons per minute TP total phosphorus HWA Headworks Analysis TSS total suspended solids IUP Industrial user permit TKN total Kjeldahl nitrogen lb/d pound per day TN total nitrogen lb/wk pounds per week USGS United States Geological Survey MGD Million gallons per day WAS Waste activated sludge mg/L milligrams per liter W WTP Wastewater Treatment Plant .. MLVSS Mixed liquor volatile suspended solids 9 Dewberry. Novozymes North America, Inc. I Best Available Technology Analysis 14 nn 1. INTRODUCTION Novozymes North America, Inc. (Novozymes) has applied for a National Pollutant Discharge Elimination System (NPDES) permit for direct discharge of wastewater from its manufacturing facility located in Franklinton, North r� Carolina. Novozymes is seeking a NPDES discharge to Cedar Creek, a tributary to the Tar River located in the Tar - Pamlico River Basin. Currently, Novozymes discharges all process wastewater from the facility by one of two methods: (t) land application on agricultural fields pursuant to Non -Discharge Permit (WQ0002806) (Appendix A), .. and (2) indirect discharge to the Franklin County Wastewater Treatment Plant (W WTP) pursuant to Industrial User Pretreatment (IUP) Permit 0112 (Appendix B). PO Novozymes applied for the NPDES permit to comply with the provisions of the Corrective Action Plan for the North Carolina Department of Environmental Quality (NCDEQ) Division of Water Quality (Division) Incident Number 86545 that was conditionally approved by the Division Director on January 31, 2017 (Appendix C). Per the + requirements of the approved Corrective Action Plan, Novozymes must reduce land application rates of treated wastewater from 30 inches/yr to 8.5 inches per year and also must recover and treat approximately go,00o gpd of groundwater. The Division's approval of the Corrective Action Plan requires Novozymes to obtain the NPDES permit to satisfy these requirements (Appendix C). Additionally, the NPDES permit will allow Novozymes to establish a fully conjunctive wastewater system and increase operational flexibility by giving it three methods for disposing of wastewater: (1) land application on nearby farm fields, (2) discharge to the Franklin County W WTP, and (3) direct �+ discharge to surface water. Last, Novozymes would like to expand the facility, increase production capacity, and add manufacturing jobs in a rural community. Expansion of the facility will require significant additional discharge capacity that would be provided by the NPDES permit. + A revised NPDES permit application, which included an updated Engineering Alternatives Analysis (EAA), was submitted to the North Carolina Division of Environmental Quality (DEQ) Division of Water Resources (Division) on + 11/30/18. The NPDES application requested tiered flow limits for 1.0, 1.5 and 2.o million gallons per day (MGD). Cedar Creek is located in the Tar -Pamlico River Basin and is classified as a nutrient sensitive water (NSW) pursuant to North Carolina Administrative Code Section 15A NCAC 02B.0223. Due to the discharge location is in the Tar - Pamlico River Basin and as discussed in correspondence from the Division dated December 14, 2016 (Appendix D), the Division requested that Novozymes prepare and submit a Best Available Technology Economically Achievable .. (BAT) analysis to assist in establishing permit limits for total phosphorus (TP) and total nitrogen (TN). The following report presents that BAT analysis and proposes permit limits for TP and TN based on treatability testing, available treatment technology, and equivalent annual costs. BAT Economically Achievable limits represent, in general, the +� best existing performance of treatment technologies that are economically achievable within an industrial point source category. (See EPA NPDES Permit Writers' Manual, 20to, EPA-833-K-10-oot). The BAT analysis described below was conducted pursuant to the protocol specifically agreed upon with the Division and as outlined in + correspondence dated September y, 2018 (Appendix E). To establish and support proposed BAT TN limits for the proposed Novozymes NPDES permit, three (3) treatment + technologies were evaluated based on treatability testing, and the capital and annual recurring operational costs to remove nitrogen were compared amongst each technology evaluated. A review of historical operating and technology performance data was performed to establish and support the BAT TP limit for the proposed Novozymes NPDES permit. ' Dewberry Novozymes North America, Inc. I Best Available Technology Analysis 16 Aft MMh Along with the final determination, the following information is contained herein to provide the Division with the .r BAT Analysis: . Industrial process description, Wastewater characterization, . Wastewater treatability testing, . Proposed wastewater treatment processes, and . Cost Analysis Me iDewberry- Novozymes North America, Inc, I Best Available Technology Analysis 16 as 2. INDUSTRIAL PROCESS DESCRIPTION 2.1 Facility Description At Novozymes, industrial enzymes are produced using a process called submerged fermentation. This involves growing carefully selected microorganisms (bacteria and fungi) in closed vessels containing a rich broth of nutrients. As the microorganisms break down the nutrients, they produce the desired enzymes. The fermentation process r requires nutrients based on renewable raw materials like corn starch, sugars, and soy grits The first step in harvesting enzymes from fermentation medium is to remove insoluble products, primarily microbial r. cells. This is normally done by centrifugation or microfiltration steps. As most industrial enzymes are extracellular — secreted by cells into the external environment — they remain in the fermented broth after the biomass has been removed. The spent biomass can be recycled as a fertilizer on local farms, as is done under a residuals disposal permit rr at Novozymes' Franklinton site. The enzymes in the remaining broth are then concentrated by evaporation, membrane filtration or crystallization depending on their intended application. Certain applications require solid enzyme products, so the crude enzyme is processed into granules for convenient dust -free use. The wastewater .. discharge at Novozymes consists of discharge from the fermentation and recovery production processes and from site utilities such as cooling tower and boiler blowdown. From the facility, the waste streams are characterized into two groups: permeate (e.g. filtrate produced from the membrane filtration step) and non -permeate (e.g. all other waste .� streams). Both the permeate and non -permeate waste streams are treated onsite at the Franklinton facility at Novozymes' W WTP. Based on Novozymes' SIC Code 2869, the facility's industrial discharge is regulated under the Organic Chemicals, Plastics, and Synthetic Fibers (OCPSF) effluent limits for Subcategory G Bulk Organic Chemicals (40 CFR 414.70). However, Novozymes' manufacturing process is a fermentation process, and 40 CFR 4101(e) states the provisions of .. 40 CFR 414 do not apply to discharges from the manufacture of organic chemical compounds solely by fermentation processes. It should be noted that even if the provisions of 40 CFR 414 did apply to the Novozymes facility, BAT limits are not established in 40 CFR 414 Subcategory G for nitrogen. .. 2.2 Wastewater Treatment and Discharge Permits Novozymes employs onsite wastewater treatment prior to discharge. Over the past decade, Novozymes has historically operated its treatment facility in two different modes of operation. From 2010-2o14, Novozymes used a multi -stage activated sludge process consisting of moving bed biological reactors (MBBRs) with high chemical oxygen demand (COD) loading followed by an extended aeration lagoon for COD removal, nitrification and denitrification (see Section 3, Figure r). The extended aeration system used was the Biolac® lagoon aeration system that provides automatic dissolved oxygen and aeration control to create multiple oxic and anoxic zones in a single treatment basin, .� eliminating the need for separate anoxic mixers and MLSS recycle flow and pumps. In 2015, Novozymes installed an anaerobic treatment system upstream of the MBBRs (See Section 3, Figure 2). The primary project driver was to improve sustainability metrics at the wastewater plant by reducing energy consumption and sludge generation. This process modification resulted in a reduced capacity to treat nitrogen compared to the previous configuration, but also reduced the amount of biosolids produced. The MBBRs were converted to nitrification and denitrification polishing tanks with supplemental carbon addition. The existing Biolac lagoon system is still utilized when additional COD reduction or nitrification is required. For reference, a more detailed IfDewberry Novozymes North America, Inc. I Best Available Technology Analysis 17 discussion of the existing treatment system configuration is provided in Section 3 below, and an existing W WTP site layout is presented in Appendix F. .. Novozymes currently discharges treated wastewater via two discharge permits: (1) land application through Non - Discharge Permit (W000028o6), and (2) indirect discharge to the Franklin County W WTP via IUP Permit o112. IUP Permit oi12 was issued by Franklin County, effective November 14, 2o18. The table below summarizes the effluent parameters listed in the IUP with numerical limits. Table 2.1. Industrial User Pretreatment Permit Limits Parameter Flow Units MGD IUP Permit Limit 0.525 Biochemical Oxygen Demand (BOD) m /L 100 Total Suspended Solids (TSS) m /L 150 Ammonia-N(NH3)m /L 10.0 Total Nitrogen TN Ibs/ month 1,825 Total Phosphorus P Ibs/ month 295 Potassium Ibs/ month 65,956 Sodium Ibs/month 50,608 Temperature °C 40.0 H S.U. 6 - 10 Turbidity NTU 15 Antimony m /I 1.0 Cadmium m /I 0.008 Chromium m /l 0.020 Copper m /I 0.05 Cyanide m /I 0.010 Lead m /I 0.0125 Nickel m /I 0.0313 Zinc m /I 0.390 Novozymes has also been re -issued a Non -Discharge Wastewater Irrigation System Permit by the Division, effective date of June 8, 2017 for land application of 30 inches per year. Novozymes prepared a Corrective Action Plan conditionally approved by the Division on January 31, 2017 (Appendix C) requiring Novozymes to reduce its land application rate from 30 in/yr to 8.5 in/yr after the receipt of a NPDES permit and after construction and commissioning of their upgraded treatment process and approved NPDES discharge. The Corrective Action Plan as approved by the Division requires the NPDES discharge permit. The NPDES permit will allow Novozymes to establish a fully conjunctive wastewater system and increase operational flexibility by giving it three methods for disposing of wastewater: (1) land application on nearby farm fields, (2) discharge to the Franklin County W WTP, and (3) direct discharge to surface water. fast, Novozymes would like to expand the facility, increase production capacity, and add manufacturing jobs in a rural community. Expansion of the facility will require significant additional discharge capacity that would be provided by the NPDES permit Dewberry Novozymes North America, Inc. I Best Available Technology Analysis 18 3. NOVOZYMES' CURRENT WASTEWATER TREATMENT 3.1 Influent Wastewater Characteristics The table below summarizes Novozymes' influent wastewater characteristics. The concentrations are based on historical average influent data and are expected to be representative of future wastewater characteristics. As such, these concentrations are utilized as the influent design criteria for the BAT analysis. �.. Table 3.1 Novozymes' Historical Influent Wastewater Characteristics 3.2 2010 — 2014 WWTP Operation From 2010-2014, the Novozymes W WTP configuration (Figure i) included a primary clarifier, followed by biological treatment, clarification, and dissolved air floatation (DAF) for phosphorous removal. The primary clarifier is 35-ft in diameter, and treats non -permeate based waste streams for solids and grit removal. Biological treatment for organics and nitrogen was accomplished in two 240,000 gallon aerobic reactors (To2 and Tot), which operated in series as .. MBBRs. Effluent from Toi was discharged to an in -ground treatment lagoon with an effective volume of 1.94 million gallons (MG). The lagoon was equipped with a Biolac® aeration system. An internal recycle pump station was used to recycle nitrate from the effluent end of the lagoon to the influent end. The Biolac® system was cycled on/off via timers to create anoxic "zones". Sludge was returned from the secondary clarifier to both the lagoon anoxic reactor zone and Toe. Clarifier effluent .. was either discharged to the effluent storage system prior to land application or to the DAF system for phosphorous removal prior to discharge to the Franklin County W WTP. Novozymes has a 52 MG effluent storage lagoon located onsite for land application. .. 9 Dewberry Novozymes North America, Inc. I Best Available Technology Analysis 19 LZ Primary Oadfier T02 T01 Aerobic H Aerobic Eflu Storage emal Nitrate Re le I I—► ToldndAppgOOon Secondary u Clarifier Anoxic Aerobic Dlviol ed Air Lagoon Flotation F4TOFranln Camry Figure 1. 2010 - 2014 Wastewater Treatment Configuration Historical data from this period is provided in Appendix G and is summarized by monthly averages for flow, COD, VSS, nitrate/nitrite (NO3/NO2), ammonia (NH3), total Kjehldahl nitrogen (TKN), and total suspended solids (TSS) parameters. The lagoon configuration presented some process challenges. For example, the mixed liquor biomass exhibited tendency to settle within the lagoon when the Biolac® laterals were cycled off resulting in mass transfer limitations and reduced treatment capacity within the anoxic zone. Furthermore, the lagoon is shallow (<ro feet) and the oxygen requirements often exceeded the supply capacity of the Biolac® system. These low DO conditions impacted the rate of nitrification. 3.3 2015 to Present WWTP Operation Novozymes currently operates under the treatment configuration depicted in Figure 2 below. As previously stated above, the addition of the anaerobic treatment system reduced W WTP energy consumption and sludge generation, but also reduced the capacity of the W WTP to remove nitrogen compounds. A summary of historical Novozymes effluent data from January 2015 to October 2o16 is presented in Appendix H. The data listed in Appendix H was calculated from historical monthly data after tertiary (DAF) treatment. ---------------------- take Anaerobic System Primary Nacrob1c �a Uarifier pro Addgiutlan T02 T01 Aerobic MAkIL/ Tart neroMc I eate ,__________'___________, Sludge Return Anoxic Aeraak lagoon naEd as 112moe Figure 2. Current Wastewater Treatment Configuration Elluent Storage To 1md Secondary Appgoyen a.d0er Dhaohed Air Flotation \ county r Cwnty Dewberry Novozymes North America, Inc. I Best Available Technology Analysis 110 ` �J 3.4 Historical WWTP Performance Table 3.2 provides a summary of Novozymes' W WTP effluent operating data from the 2010-2oi8 historical data set provided as Appendices G and H. The table lists the calculated average and maximum monthly average effluent �. concentrations from reported daily and monthly data contained in the historical data set for COD, TP, TN, TKN, NH3 and NO3/NO2. The values are separated into two sections: before the implementation of the anaerobic system (2010- 2014) and after the anaerobic system was brought online (2015-2018). Table 3.2. Novozymes' Historical Effluent Wastewater Comparison' 'Data presented in this table represents the average and maximum of average monthly effluent values from Novozymes effluent data shown in Appendices G and H. For the period of 2010-2014, the TN and TP effluent concentrations discharged from the Novozymes' W WTP averaged 15 mg/l and 2.2 mg/l respectively. For the most recent period following installation of the anaerobic system .. (2015 — 2018), effluent TN concentration increased to i9 mg/L, and the effluent TP concentration decreased to 1.4 mg/l. It should be noted that the influent TN and TP average 208 mg/I and 90 mg/l, respectively (Table 3.1), which translates to >go% TN removal and >98% TP removal. For both periods, the average ammonia concentrations s achieved were less than 3.0 mg/l, indicating significant nitrification was occurring. The nitrate/nitrite concentration increased from 5.8 mg/l to ro mg/l following the anaerobic system installation. This indicates reduced denitrification efficiency. Although the current treatment processes provide partial nutrient removal, enhanced nitrogen removal was not targeted, as Novozymes' effluent permit limitations did not require this level of treatment. The historical IUP TN and ... TP limits are summarized in the table below. As shown below, from IUP inception through August 2016, Novozymes was not subject to TN limits, and the ... concentration limits for ammonia ranged from 48 mg/1 to 5 mg/l. TP limits for that same period ranged from 18 mg/1 to 5 mg/1 to a mass based limit. For land application, per Novozymes' Non -Discharge Permit, treated wastewater is land applied at agronomic loading rates but the permit does not contain numerical limits for TN or TP (Appendix A). .. ® Dewberry Novozymes North America, Inc. I Best Available Technology Analysis 111 r Table 3.3. Historical IUP Limits Date Event NH3 Limit TN Limit 15 mg/I monthly 40 mg/I monthly September Initial IUP average, 18 mg/I daily average, 48 mg/I daily None 2008 Issuance maximum 10 mg/I monthly _maximum 40 mg/I monthly November IUP average, 12 mg/I daily average, 48 mg/I daily None 2011 Modification maximum maximum November 40 mg/I monthly IUP 5 mg/I monthly average, 2012 average, 48 mg/I daily None Modification 6 mg/I daily maximum maximum Winter. 29.4 mg/I weekly average, 10.0 December mg/I monthly average IUP 5 mg/l monthly average, 2014 Summer. 15.0 mgA None Modification 6 mg/I daily maximum weekly average, 5.0 mg/I monthly average Winter., 29.4 mg/I weekly average, 10.0 295 Ibs/month monthly Ibs/d monthly August 2016 IUP average, 67.8 Ibs/week mg/I monthly average average, 349 Ibs/d aver Modification average Summer: 15.0 mg/I weekly average weekly average, 5.0 m /I onthly average November 295 Ibs/month monthly Uniform Limits. 1,8251bs/d monthly IUP 29.4 mg/I weekly 2018 average, 6 Ibs/week average, Irage Modification average, 10 mg/I average ra onthl average monthly weekly average ge r ® Dewberry Novozymes North America, Inc. I Best Available Technology Analysis 112 4. TN TREATMENT TECHNOLOGY ALTERNATIVES EVALUATED 4.1 TN Treatment Technologies Three (3) treatment technologies were evaluated to identify the BAT Economically Achievable limits for TN, which in general represent the best existing performance of treatment technologies that are economically achievable within an industrial point source category (EPA NPDES Permit Writers' Manual, 2010, EPA-833-K-to-ool). The three (3) treatment processes evaluated were simultaneous nitrification and denitrification (SND) processes in the following continuous activated sludge configurations: extended aeration, conventional aeration, and high -rate aeration. SND continuous flow activated treatment facilities operate at lower DO concentrations (0.50t0.2 mg/Ion average), and are able to achieve nitrification and denitrification in the same bioreactor tank. Recent studies have presented data demonstrating over go% COD removal, and at increased carbon to nitrogen (C/N) ratios, nitrogen removal efficiencies higher than 98% SNDI ram. The three technologies evaluated as part of the BAT analysis are best defined and differentiated by their food -to- _ microorganism (F:M) ratios. The F:M ratio is a significant design and operational parameter of activated sludge systems. The three technologies evaluated include extended aeration, conventional aeration, and high -rate aeration. These three technologies typically are designed with the following F:M ratios: • Extended Aeration, o.05 < F:M < o.15, (units of mg COD/mg MLVSS•day) • Conventional Aeration, 0.25 < F:M < o.6o • High Rate Aeration, o.5o < F:M < 1.5 Novozymes has successfully operated high rate aeration, SND continuous flow W WTPs at its Kalunborg, Denmark and Tianjin Shi, China facilities. The W WTPs at Kalunborg and Tianjin Shi achieve SND using automated DO control ^„ based on feedback from nitrate and ammonia sensors installed within biological reactor trains. The facility in China has successfully operated for the last 20 years. The W WTP there includes reactors which are ..a continuous flow that cycle and control aeration based on ammonia and nitrate concentrations to achieve SND while operating at low dissolved oxygen concentrations. If ammonia concentrations increase above the specific set point, aeration is turned up to increase DO to enhance nitrification. If nitrate concentrations increase above the specific set point, aeration is turned down or off to create more favorable anoxic conditions to support denitrification. Multiple reactors are utilized in parallel, and the reactor effluent discharges to secondary clarifiers. 010 Overall, the SND activated sludge process is an innovative process that reduces energy use by operating at decreased DO concentrations and eliminates costly recirculation pumps and carbon addition compared to conventional sequenced nitrification and denitrification activated sludge process. Three different technologies were evaluated for operation using the SND process: (i) extended aeration, (ii) conventional aeration, and (iii) high rate aeration. The evaluation included treatability testing, biological process modeling, and a comparison of equivalent annual costs. r_-INE 9 Dewberry Novorymes North America, Inc. I Best Available Technology Analysis 113 5. Treatability Testing To establish and support proposed TN limits for the proposed Novozymes NPDES permit based on an analysis of the Best Available Technology Economically Achievable, treatability testing was performed on three (3) treatment technologies capable of achieving biological nitrogen removal. TP limits were established independently of treatability testing, as described in Section 9.2. Although the existing treatment process provides partial nutrient removal, enhanced nitrogen removal was not targeted, as Novozymes' effluent permit limitations did not require this level of treatment, thus treatability testing was necessary to establish the TN limits attainable. .. 5.1 Treatability Testing Approach - - Treatability testing was performed to establish the soluble refractory organic nitrogen and nitrate effluent concentrations for each of the three technologies evaluated. The ultimate goal of treatability testing is to determine the effluent refractory organic nitrogen and nitrate to support effluent limits for TN for the Novozymes NPDES permit based on analysis of Best Available Technology Economically Achievable. While ammonia and particulate organic nitrogen concentrations were tracked during the treatability study, it is anticipated that these sub -components of total nitrogen will be based on water quality and limits of technology. It is expected that the NPDES permit will contain a water quality based ammonia limit of i.o mg/1. For particulate _ organic nitrogen, it is assumed Novozymes will install tertiary filtration to remove particulate organic nitrogen. As - such, a technology based limit is proposed for this component of total nitrogen. Tertiary filtration is expected to produce an effluent TSS of <3.o mg/Lll Assuming the TSS is biological in nature, e.g. biomass at 12% nitrogen, the _ estimated particulate organic nitrogen expected from the filter effluent is 0.36 mg/l. For the purposes of the BAT analysis, it is therefore assumed that the effluent ammonia limit will be r.o mg/l and the effluent particulate nitrogen concentration with tertiary filtration is estimated to be o.36 mg/L. - - The treatability testing protocol was developed to best simulate this full-scale treatment technology. Since automated DO control is difficult to implement within bench scale testing, a sequencing approach was utilized to simulate the reactors and demonstrate treatability. The bench scale reactors were operated as true batch reactors, without - continuous feed/draw, due to the challenges associated with balancing flow rates to maintain continuous flow conditions on a small scale. -- Initially, to mimic continuous flow in a batch reactor vessel, the testing involved several cycles of aeration/anoxic _ conditions. Early testing results revealed ineffective denitrification with this approach, as nitrate concentrations were high at end of batch. This is likely due to the lack of COD for substrate in the later anoxic cycles. In response, the protocol was revised to operate with only one aerobic and anoxic cycle per batch. This change in protocol would mimic the control logic of the Novozymes reactors and confirm that robust SND could be achieved with the Novozymes Franklinton, NC wastewater. _ Under the revised protocol, bench scale reactors were operated with a distinct aeration phase which was terminated upon achieving an ammonia -nitrogen concentration less than r.o mg/L to simulate the full-scale control logic when - - aeration is activated. The bench scale reactors were then operated with an anoxic phase with supplemental carbon _ addition until the nitrate reached a concentration less than Lo mg/L to simulate the full-scale control logic when the aeration is deactivated and the reactors are in mix phase. This sequence represented one reaction batch in the bench -- scale reactors. Full-scale, this sequence would repeat continuously in small time increments in the continuous flow through reactors. ItDewberry Novozymes North America, Inc I Best Available Technology Analysis 114 5.2 Treatability Testing Protocol The treatability testing protocol was approved by the Division in 2017. Treatability testing was performed in 24iter reactors mixed on a Phipps & Bird jar tester. Reactors were aerated with diffuser stones and miniature air pumps. Each reactor was operated at different F:M loading rates to mimic the three evaluated technologies: • Reactor t = Extended Aeration at F:M of o.l (units of mg COD/mg MLVSS*day), • Reactor 2 = Conventional Aeration at F:M of o.5, and • Reactor 3 = High Rate Aeration at F:M of 0.7. Initially, from July 12-July 20, 2017, reactors were operated with multi -phased nitrification/denitrification by cycling the aerators on/off in 30-minute intervals. This protocol was intended to simulate continuous flow SND. After running multiple batches under this configuration, effluent data indicated nitrate concentrations were higher than .+ expected and that sufficient carbon was not remaining during the later anoxic cycles to support complete denitrification. These results were not entirely unexpected, as the reactors were not operated with continuous influent feed and therefore the rate of denitrification was very low. This differs from the approach that will be rr implemented full-scale, which includes continuous feed to provide carbon to support higher denitrification rates. In addition, the aeration/anoxic phases on the bench scale were operated on a timed basis rather than utilizing real time data (NH3 and NO3) to control DO as will be the operational approach full-scale. .� For testing performed from July 21— August 4, 2017, the protocol was modified for each batch to operate with a single aerobic cycle followed by a single anoxic cycle. Supplemental carbon was added to the reactors at the beginning .. of the anoxic cycle to support higher denitrification rates. The final protocol included the following sequence: t) Feed a) Feed Novozymes wastewater at volumes required to achieve the three food -to -mass loading conditions 2) Aeration Cycle a) Aerate the reactor until the reactor ammonia concentration is < 1,o mg/L 3) Anoxic Cycle a) Stop aeration and continue mixing the reactor b) Dose supplemental carbon (acetic acid) to support denitrification at a Chemical Oxygen Demand (COD) to Nitrate ratio of 6 c) Mix the reactor until the reactor nitrate is < 1.0 mg/L ... 4) Settle a) Stop mixing and allow biomass to settle 5) Decant a) Decant reactor and collect effluent samples for analysis Effluent samples were analyzed both by a certified laboratory and by Dewberry personnel. Dewberry analyzed samples using Hach test kits to identify the end of aeration/anoxic cycles and to assess reactor performance in real time. The results presented within this report used to establish effluent limits are based solely on certified laboratory data. Due to large sample volumes required by the certified laboratory, effluent from approximately two to three reactor batches were composited to create a certified laboratory sample. r `.. Dewberry Novozymes North America, Inc. I Best Available Technology Analysis 115 f The reactors were analyzed weekly for total suspended solids and volatile suspended solids. Reactors were also — monitored regularly for pH and dissolved oxygen. Reactor pH was adjusted as needed to maintain the pH at _ approximately 7.5-9 standard units (s.u.). Reactor batch effluent samples were analyzed by the certified laboratory for the following parameters: Soluble COD NH3 . Soluble Carbonaceous 5-day BOD . Soluble TKN . NO3/NO2 . Soluble sTKN Table 5.2 presents the nitrogen species evaluated during the treambility testing and the source of the results (measured versus calculated). Effluent soluble total nitrogen (sTN) and soluble organic nitrogen (sOrgN) were calculated using Equation 1 and Equation 2, respectively. Equation 1: STN(tetcmtated) = sTKN(mea red) + NO3(meamred) + NO2(measured) Equation 2: s0rgN(tdm1at.d) = sTKN(measured) — NH3(mea red) nu Table 6.1. Treatability Testing Nitrogen Speciation Parameters sTKN NO3 No, NH sTN sOrgN — 5.3 Performance Testing Results Performance testing was performed over a 19-day period beginning July 21, 2017 and ending August 9, 2017. During this time, six (6) wastewater influent samples were collected from Novozymes to utilize in feeding the reactors. Using the collected Novozymes wastewater batch samples, seventeen (17) treatability testing batches were performed, .. Mr through M17, using the protocol previously described. Effluent reactor results were analyzed by a certified laboratory, and the results are presented in Appendix I. Reactor logs and process control laboratory analyses performed by Dewberry are presented in Appendix J. Results in Appendix J were used to aid in reactor operations (e.g. when to terminate cycles, adjust pH, etc.) and were not used to calculate BAT TN limit. Only certified laboratory results were used to calculate the BAT TN limit. A comparison of certified lab data to internal process control lab data identifies a positive correlation for the 17 treatability test batches performed, with the exception of Reactor 3: High Rate Aeration (0.7 F:M), which exhibited a poor correlation for batches M6 — M11. Table 5.2 below provides the calculated variability between average internal process and certified lab data. ffDewberry Novozymes North Amence, Inc. I Best Available Technology Analysis 116 Table 5.2. Calculated Variability between Measured Internal Process and Certified Lab Data (1) oft WData presented in Table 3 is represents the absolute difference between the average value of internal process measurements and average value of certified laboratory analysis. WOmits data from Batch Run M6 - Mu. Internal process data collected for Reactor 3 during the six treatability batch runs, batches M6-Mu, indicates average e NH3 and sTKN concentrations of 0.47 and io.8 mg/1 respectively. Certified laboratory results indicate average NH3 and sTKN concentrations of 16.5 and 28.6 mg/1 respectively. This is a variability of over 15 mg/1 between internal and certified laboratory data for both parameters. In comparison, the variability of batch tests M1- M17 for the three (3) reactor configurations, omitting data from Reactor 3 batches M6-Mil, results in an average NH3 and sTKN variability of less than 0.32 and 3.73 mg/l, respectively. Due to the high variability between internal process and certified lab data for Reactor 3 batch tests M6-Mu, the certified lab data for these batches are to be omitted in the final ^ calculations to determine the BAT limits for nitrogen. It should be noted that inclusion of the Reactor 3 batches M6- Mil would result in a higher BAT limit for that technology. The decision to omit these results from the BAT limit calculation was approved by the Division in September 2018 (Appendix E). Table 5.3 summarizes the 95'h percentile and maximum reactor effluent certified lab data results. The 95'h percentile reactor effluent is presented, as that data is used to develop the effluent total nitrogen limit. This is consistent with the r•. EPA's methodology for establishing monthly average effluent limits. The 951h percentile is the basis for long-term average in order to accommodate reasonably anticipated variability within the control of the facility (EPA NPDES Permit Writers' Manual, 2oro, EPA-833-K-io-ooi). Table 6.3. Treatabillty Testing 961h Percentile and Maximum Reactor Effluent Results 11t WData presented in Table 3 is based on certified laboratory data. NnIalue represents 951h Percentile (-[Omits data from Batch Runs M6 - Mu. With the exception of nitrate, the effluent nitrogen species increased in concentration with increasing food -to -mass, as expected. The 95th percentile effluent refractory soluble organic nitrogen ranged from 1.28 -11.6 mg/l, increasing with increasing food -to -mass, and comprised 40%-96% of the total nitrogen. If data from batches M6-Mu was included in the Reactor 3 analysis, the maximum effluent concentration for soluble organic nitrogen would increase fjDewberry Novozymes North America, Inc. I Best Available Technology Analysis 117 oft from 12.7 to 13.2 mg/l. Using the 951h percentile data yields a more stringent, yet achievable, BAT TN limit.. -- Maximum concentrations were at most to% greater than 95'h percentile results and as such further modeling and BAT calculations for each alternative technology were performed only using the 9511 percentile data. The effluent refractory soluble organic nitrogen and nitrate were then used to develop an effluent total nitrogen limit for each technology evaluated (see Section to below). fDewberry Novozymes North America, Inc. I Best Available Technology Analysis 118 oft 6. PROPOSED PROCESS TREATMENT DESCRIPTION Following treatability testing, Dewberry performed preliminary design calculations for each technology to evaluate W WT'P upgrades necessary to achieve TN removal at Novozymes' projected direct discharge flow of 2.0 MGD. In �. addition to processes largely responsible for TN removal, other unit processes were evaluated as necessary to comply with expected limits for BOD5, TP, and TSS and to accommodate the higher future flow rates. For the purpose of this BAT analysis, it is assumed that the existing anaerobic up -flow reactor will continue to be used for side stream pre- .r treatment of COD of the permeate stream. Per the anaerobic system design specifications, it is assumed that use of this system will provide COD reduction of 24,00o lb/day. Treated effluent from the anaerobic reactor will mix with the remaining influent wastewater prior to the proposed SND treatment process. The raw influent wastewater r characteristics, as well as the influent to the proposed SND process, are presented in the table below. Table 6.1. Novozymes' Influent Wastewater Average Conditions to SND Activated Sludge Process r Flow ®�M MGD 2.0 2.0 COD m /1 5,389 3,950 COD lbs/day 89,900 65,900 TKN m /1 197 197 NH3 m /I 63 63 NO3/NO2 m /I 29 29 TP m /I 90 90 "After anaerobic pretreatment of 24,000 lbs/d COD. r r r A block flow diagram detailing Novozymes' proposed wastewater treatment upgrades is attached as Appendix K. The following section provides sizing criteria for major equipment required to upgrade the existing facility to a SND activated sludge process. This section also identifies which unit processes were included in the economic analysis to r identify proposed BAT TN limits. Major equipment to be installed is summarized in the attached preliminary equipment specification table in Appendix L. Detailed discussion related to biological process modeling is provided below in Section 7. .. 6.1 Primary Clarification A new primary clarifier is required to supplement the existing primary clarifier due to the increased hydraulic and solids loading to the treatment process. The primary clarifier shall reduce solids present in the influent wastewater. The primary clarification unit process step shall also include capacity for phosphorus removal through chemical precipitation, such as the addition of ferric chloride. Using October 2016- October 2o18 flow data, the historical average flow to the primary clarifiers was 0.76 MGD, resulting in an overflow rate of 790 gal/ft2/d for the existing clarifier. This historical overflow rate of 790 gal/ft2/d is r nearly within the recommended loading rate of 800-1,200 gal/d/ft2 for primary clarifiers (Metcalf @ Eddy, pg. 398). This loading rate has provided sufficient settling of solids for the Novozymes facility in the past, and the same overflow rate was used to size the new primary clarifier. f4. Dewberry, Novozymes North America, Inc. I Best Available Technology Analysis 119 r The proposed upgrade for this unitprocess will be consistent between all three treatment technologies evaluated, and therefore is not included in the BAT economic analysis to determine BAT TN limits Me 6.2 Bioreactors Above ground, bolted stainless steel bioreactor tanks shall be provided for the proposed SND activated sludge system. .. Bioreactor tanks were sized for each evaluated technology to provide the required process volume based on the selected F:M ratio, mixed liquor volatile suspended solids (MLVSS) concentration and influent COD loading. For the purpose of the BAT analysis, it is assumed that each technology shall operate a MLVSS concentration of 4,000 mg/1 with an influent COD concentration identified in Table 6.1. Setting the MLVSS and COD concentrations constant allows the bioreactor volumes to be calculated from the selected F:M ratio. .. Therefore the bioreactor volumefor each technology evaluated will differ as identified in the attached preliminary equipment specification table (Appendix L). The required bioreactor configuration for the conventional aeration treatment technology, e.g. F:M = 0.5, was provided to vendors for pricing. Bioreactor costs for the extended aeration and high rate aeration technologies were scaled accordingly from received vendor quotes. Such costs shall be included in the BAT economic analysis to determine BAT TN limits. 6.3 Aeration Equipment Bioreactor tanks will be equipped with fine bubble diffuser aeration grids and surface mixers. Air supply will be provided by positive displacement or centrifugal blowers for the required design air flow and pressure as identified in r the attached preliminary equipment specification table (Appendix Q. Each bioreactor tank shall have dedicated aeration grids and blowers. Mixing shall be provided by fixed or floating direct drive mixers. As the different technologies operate at varying F:M ratios, the required oxygen supply will also vary due to variable solids retention time (SRT) and biosolids generation rates. The required aeration equipmentfor each technology will differ as identified in the attached preliminary r specification table (Appendix L). The required design air flow rate and pressure, tank size and TSS concentrations for _ . the conventional aeration treatment technology, e.g. F:M = 0.5, was provided to vendors for pricing on diffused aeration grids, centrifugal blowers, and tank mixers. Additional pricing was also identified for the positive displacement aeration blowers for the extended aeration process, e.g. F:M = 0.1. Blower and tank costs for the _ extended and high rate aeration technologies were scaled accordingly from received vendor quotes. Such costs shall be included in the BAT economic analysis to determine BAT TN limits. r 6.4 Secondary Clarification A new concrete secondary clarifier is required to supplement the existing secondary clarifier to treat the higher future flow rate conditions. The return activated sludge (RAS) and waste activated sludge (WAS) pump station will also require modifications and upgrades. The new RAS pumps will provide r5o% of influent flow return, while the WAS r pumps will be sized to maintain the desired MLVSS concentration. Both pumps will be self -priming pumps. The proposed secondary clarifier is sized based on the historical solids loading rate. Historically, the existing seconday clarifier operated at a solids loading rate of o.51 pounds per day per square foot (gal/hr/ft'). The historical solids loading rate was calculated based on an existing clarifier diameter of 87 ft and an average historical clarifier influent flow rate of 0.73 MGD. The historical solids loading rate is below the recommended loading rate of 1.0-1.5 r f) DewbiJerry. Novozymes North America, Inc. I Best Available Technology Analysis 120 r 7 lb/hr/ft2 for secondary clarifiers (Metcalf & Eddy, pg. 687). Using the projected flow of 2.0 MGD, the secondary clarifier was sized to maintain the historical solids loading rate for all three technologies. The proposed upgrade for this unit process will be consistent between all three treatment technologies evaluated, and therefore is not included in the BAT economic analysis to determine BAT TN limits. 6.5 Dissolved Air Flotation (DAF) r� oft r� Chemical precipitation is currently employed onsite for phosphorus removal and additional treatment capacity is required for the flow increase. Novozymes currently utilizes a loo ft' DAF with ferric chloride and lime addition for OR phosphorus removal. Historically, the DAF has been operated at an average surface loading rate of 2.9 gpm/ft2. This surface loading rate is calculated based on the 2014-2015 average effluent flow rate to Franklin County of 0.423 MGD. The historical surface loading rate is within the recommended range of o.2 — 4.0 gpm/ft2 for dissolved air flotation .0 (Metcalf & Eddy, Pg. 423)• Two additional DAFs at 250 ft' each are proposed to supplement the existing DAF. The surface loading rate for the NO new DAFs and the existing DAF at 2.0 MGD will be 2.3 gpm/ft2, which is below the historical surface loading rate and within the recommended range. In addition, Novozymes will have the ability to vary the ferric addition rate as needed to achieve phosphorus removal. + Since the sizing criteria for the DAFs is flow -based, the proposed upgrades to the DAF system and the upgrade costs will be the samefor each treatment technology. Also DAF costs areforTP removal and not TN removal, thus such .. costs shall not be included in the BAT economic analysis to determine BAT TN limits. .r 6.6 Reverse Osmosis (RO) System The reverse osmosis system is included to reduce the concentration of total dissolved solids (TDS), principally potassium, in the Novozymes' discharge. It is also anticipated that the RO system will provide, on average,1.o mg/1 .� total nitrogen removal. RO reject will be sent to an evaporator, with bottoms disposed of at an approved facility. Novozymes is currently ne seeking environmentally advantageous disposal options for evaporator bottoms, but has yet to finalize reuse options at this time. r Since the sizing criteria for the RO system is based on TDS removal, principally potassium removal, costs associated the RO system and associated evaporators are not included in the BAT economic analysis to determine _ BATTNIimits. ItDewberry Novozymes North America, Inc. I Best Available Technology Analysis 121 7. BIOLOGICAL PROCESS MODELING Dewberry performed biological process modeling using Biowin® for each proposed technology. The purpose of biological process modeling was to evaluate the ammonia, nitrate/nitrite and organic nitrogen concentrations present in the effluent wastewater stream; effluent TT concentrations were not evaluated through process modeling. The influent conditions used in each model are presented in Table 5.2, with the 951h percentile soluble refractory organic nitrogen influent concentrations determined from treatability testing as presented in Table 5.4. A biological process model was constructed for each technology assuming a SND process. Appendix M is a summary of input and output parameters from Biowin. Each model consists of a bioreactor with a DO concentration ranging from 0.3 to o.5 mg/L. Using a mixed liquor suspended solids (MLSS) concentration of 4,000-4,500 mg/1, the bioreactor for each technology was sized to achieve the appropriate F:M ratios. The existing above ground and in -ground 0.24 MG tanks (Tot and Toe) were incorporated into the model for polishing SND treatment of ammonia and nitrate downstream of the bioreactors. The biological system was modeled as completely mixed, aerated reactors modeled in series, using a DO concentration ranging from 0.2 to 0.5 mg/L. The total required surface area of the two secondary clarifiers are included as one clarifier in the model. Figure 3 provides a schematic of the model unit processes. A Nnk Figure 3. Biowino Model Diagram To simulate the SND process, Dewberry utilized a low dissolved oxygen concentration approach, along with Biowin's typical biological process kinetics, with exception of select kinetics rates and constants modified from default values as indicated in Table 7A below. Modified values were determined from a literature review)". Dewberry Novozymes North America, Inc. I Best Available Technology Analysis 122 0 Table 7.1. Biowln®Klnetic Values The results of the process modeling indicate that ammonia and nitrate/nitrite concentrations are reduced to less than 1.o mg/L for each technology. Table 7.2 below lists the predicted effluent concentrations of ammonia, nitrate/nitrite, and recalcitrant organic nitrogen for each technology evaluated. Therefore, it is anticipated that the proposed treatment technologies evaluated can meet the speculative water quality limit for ammonia of 1.o mg/l. Table 7.2. Biowin Effluent Nitrogen Results The results of process modeling represent effluent from secondary treatment and are not representative of final tertiary treated wastewater. Process modeling predicts a secondary effluent TSS concentration of approximately 17 mg/l for each technology evaluated. Tertiary filtration is expected to produce an effluent TSS of <3.0 mg/L. Assuming the TSS is biological in nature, e.g. biomass at 12% nitrogen, it is estimated that the tertiary filter will .. reduce the secondary effluent TN concentration by 1.7 mg/I for each technology, calculated as follows: (17.0 mg/l — 3.o mg/l)*.12% =1.7 mg/l. Table 7.3 provides the estimated tertiary effluent TN concentrations as well as the modeled secondary treated effluent TN concentrations. These values correspond well with the proposed BAT TN ... concentrations determined from treatability testing as presented in Section 9.o. Table 7.3 Modeled and Estimated Effluent Nitrogen Conditions Secondary Treatment Effluent TN Extended Conventional Aeration Aeration 4.49 10.1 High -Rate Aeration 14.4 Secondary Treatment Effluent TSS 16.5 17.4 17.2 Tertiary Filter Effluent TSS 3.0 3.0 3.0 Tertiary Filter TN Reduction 1.6 1.7 1.7 Tertiary Filter Effluent TN < 3.0 8.4 12.7 ff Dewberry. Novozymes North America, Inc. i Best Available Technology Analysis 123 Aft 8. EQUIVALENT ANNUAL COST ANALYSIS Utilizing the results of the preliminary design and process modeling, capital and operating opinions of probable cost r were developed for each technology evaluated to establish the equivalent annual costs for TN removal. Costs for TP removal were not evaluated. Opinions of probable cost were developed for the following technologies: . Alternative 1— Extended Aeration .. . Alternative 2 — Conventional Aeration . Alternative 3 — High Rate Aeration Capital costs were included for treatment equipment and appurtenances which are related to TN removal, and included estimates for installation costs, with allocations for contractor overhead, profit, and general conditions, engineering, and construction labor and construction management. Annual recurring operational costs were .. estimated for chemicals, residuals disposal, utilities, sewer use fees, maintenance and nutrient offset fees. Capital costs were estimated for Alternative 2 based on vendor quotes and installation factors. For Alternatives 1 and i 3, the capital and annual recurring costs for Alternative 2 were scaled when appropriate. For example, the capital costs for the bioreactors were scaled as the required reactor volume will increase with a decreasing food -to -mass. A discussion of which costs were included was presented previously in Section 6.o for each proposed unit process. For ! this reason, some of the items presented in the cost estimates included in the concurrently submitted EAA report are not included in the BAT cost estimates. The BAT cost estimates only focus on capital equipment costs necessary for biological TN removal, thus making the BAT cost estimates a subset of the BAA cost estimates. Capital and recurring opinions of probable cost for each alternative are presented in Appendix N. The opinions of probable cost were converted to an equivalent annual cost based on a 5-year period and an annual discount rate of ! 7%, which are the standard assumptions used by Novozymes to evaluate project financials. Table 8.1 summarizes the capital, operating, and equivalent annual costs for each alternative. 19 Dewberry Novozymes North America, Inc. I Best Available Technology Analysis 124 Table 8.1. Equivalent Annual Costs Comparison Extended Conventional ,. - • Aeration r r Capital Costs Equipment Installation and Construction $25,507,000 $7,969,000 $6,199,000 -40% Contingency $10 200.000 $3,188,000 $2,480,000 Enoineenno and Construction Management $3,570,000 $1 116,000 $868 000 Total Re uired Ca Ital Costs $39,277,000 $12,273,000 $9,647,000 Reoccurring OBM, including chemicals, labor and maintenance $473,000 $313,000 $303,000 Laborato Costs $42,000 $42,000 $42,000 Residuals Disposal Costs $3,035,000 $3,550,000 $3,893,000 Sewer Use Fees $365,000 $365,000 $365,000 Tar -Pamlico Nutrient Off Set Fees $173,000 $173,000 $173,000 Utility Costs $4,019,000 $892 000 $746,000 Total Annual Recurring Costs $8,107,000 $6,336,000 $6,622,000 Equivalent Annual Costs (EA C) 10 Dewberry. Novorymes North America, Inc. I Best Available Technology Analysis 126 ON nr oft 1••1 oft 9. BAT LIMIT DETERMINATION 9.1 Total Nitrogen BAT Limits Novozymes commissioned the treatability testing to support development of BAT TN limits for the proposed NPDES _ discharge. To determine BAT TN limits for the discharge, the treatability testing results and cost estimates were used to compare the economic factors for the alternatives evaluated. This process is summarized below: r. Identify achievable effluent total nitrogen limits for each technology evaluated. 2. Develop Equivalent Annual Costs for each technology evaluated. 3. Calculate normalized nitrogen removal costs for each design technology evaluated based on the equivalent annual cost and total annual mass of nitrogen removed. 4. Compare the normalized nitrogen removal costs for each technology evaluated to each other. .. The effluent total nitrogen limits presented in Table 9.1 were developed based on the sum of the following sub- _ _ components: soluble organic nitrogen, nitrate/nitrite, ammonia, and particulate total nitrogen. The effluent soluble organic nitrogen and nitrate components presented are based on the 9P percentile treatability testing results for each technology evaluated. The 95th percentile reactor effluent concentrations were used to develop the effluent total nitrogen limit to be consistent with the EPA's methodology for establishing monthly average effluent limits. The ammonia effluent limit is assumed to be water quality based at i.o mg/l. The particulate total nitrogen is estimated to be 0.36 mg/l for tertiary filter effluent based on assuming a biological TSS filter effluent of 3.0 mg/l. Table 9.1 presents the calculated effluent total nitrogen BAT limits proposed for each technology evaluated. AN Calculated effluent total nitrogen BAT limits are also presented graphically in Figure 4. Em Oft Table 9.1. Calculated Effluent Total Nitrogen BAT Limits Achievable effluent ammonia concentrations have been confirmed through biological process modeling s The particulate TN is estimated assuming filter effluent solids are 12% nitrogen and based on tertiary filter performance estimates from Metcalf & Eddy Inc. (2003) Wastewater Engineering Treatment and Reuse (4m Ed). New York, NY: McGraw- Hill. IIIDewberry- Novozymes North America, Inc. I Best Available Technology Analysis 126 14 AIL 3Q 12 ' _ a5 10 ! / I E Ali. z / z I � E 8 J / Z / I / 1 a 6 / m / / 1-eaend. Alt. 1 Alternative 1: Extended Aeration 4 Alternative 2: Conventional Aeration Alternative 3: High Rate Aeration 2 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 Operating F:M Figure 4. TN Effluent Results Comparison T For reference, the use of maximum treatability testing results in lieu of 951h percentile results would increase the proposed effluent BAT TN limits to 3.9,1o.6 and 13.9 mg/1 for Alternatives 1, 2, and 3 respectively. This accounts for the t.o mg/1 RO credit. Using the 95'^ percentile results in lieu of the maximum results represents percent decreases Of 3%,17%, and 9%, respectively of three technologies evaluated. For each technology evaluated, the annual mass of nitrogen removed was calculated based on the design flow rate, the influent TN, and the effluent BAT total nitrogen limits provided in Table 9.1. A normalized nitrogen removal cost was then calculated based on the mass of nitrogen removed and the annual equivalent cost. Table 9.2. Equivalent Annual Costs Normalized to Nitrogen Removed MM Influent Total Nitrogen mg/I AerationExtended Conventional Aeration r r 226 226 High Rate . r 226 Effluent Total Nitrogen Limit mg/I 3.8 8.8 12.7 % Nitrogen Removal % 98.3% 96.1 % 94.3% Flow MGD 2 2 2 Annual Mass of Nitrogen Removed Ib/yr 1,352,798 1,322,357 1,298,613 Equivalent Annual Cost $ $17,700,000 $8,300,000 $7,900,000 Normalized Nitrogen Removal Cost $/lb 13.08 6.28 6.O8 As indicated in Table 9.2, the normalized nitrogen removal cost ranges from $6.o8 for Alternative 3 to $6.28 for Alternative 2 to $13.o8 for Alternative 1. The cost for Alternative 1 is more than double the costs for Alternatives 2 Dewberry Novozymes North America, Inc. I Best Available Technology Analysis 127 17 r and 3, while providing minimal increase in nitrogen removal efficiency (<4%). Figure 5 below illustrates the normalized nitrogen removal costs for each alternative. The graphical relationship depicts a much steeper slope between Alternatives 1 and 2 compared to Alternatives 2 and 3. This indicates that there is significant additional incremental cost to achieve the limits proposed for Alternative 1 compared to Alternative 2 and 3. $14.00 Z Alt.1 Legend: $13.00 9 Alternative 1: Extended Aeration Alternative 2: Conventional Aeration ^ $12.00 Alternative 3: High Rate Aeration o v $11.00 o E $10.00 % v � c $9.00 m o � $6.00 z � H $7.00 ` Alt. 2 Alt. 3 E $6.00 �'�------0 `o z $5.00 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 Operating F:M Figure 5. Normalized Nitrogen Removal Costs no P Table 9.3 below provides a summary of the cost differential between the Alternatives and the increase in mass of nitrogen removed. Table 9.3. Incremental TN Removal Cost Comparison A review of the costs and associated information indicates that Alternative 2 is the best available alternative that is economically achievable. The basis for this analysis is summarized below: The Alternative 2 normalized nitrogen costs are 52% less and 3% more compared to Alternatives r and 3, respectively. The graphical relationship between the costs indicate significant incremental cost increase between Alternatives 2 and r. Relationship between Alternatives 2 and 3 reveals a much lower incremental costincrease. Dewberry Novozymes North America, Inc. 1 Best Available Technology Analysis 128 The additional annual costs to remove 23,774 Ibs of nitrogen, the difference between Alternatives 2 and 3, is approximately $ 16.9 per additional lb TN removed. This is deemed to be economically feasible and reasonable. oft s The additional annual costs to remove 30,441 lbs of nitrogen, the difference between Alternatives r and 2, is approximately $309 per additional lb TN removed. This is deemed to be economically infeasible and unreasonable. .� • Estimated utility costs for Alternative 2 is 78% less than Alternative 3. Utility costs for Alternatives 2 and 3 are similar. r. • The total annual reoccurring costs for Alternative 2 is 34% less and 3.0% less compared to Alternatives i and 3, respectively. Factors considered in assessing BAT include the cost of achieving BAT effluent concentrations, the age of equipment and facilities involved, the processes employed, engineering aspects of the control technology, potential process changes, non -water quality environmental impacts (including energy requirements), and economic achievability. .� Based on the equivalent annual costs and normalized nitrogen removal costs, Alternative 2, Conventional Aeration, F:M = 0.5, proves to be the best performing alternative evaluated that is economically reasonable, and thus is deemed the basis for the Best Available Technology Economically Achievable (BAT) limit for TN. Therefore, the proposed R monthly average total nitrogen limit is provided in Table 9.4. This value assumes a t.o mg/l reduction from the reverse osmosis system. Table 9.4. Proposed Total Nitrogen BAT Limit Monthly Average Parameter Proposed Limit ... Total Nitrogen 8.8 mgll For reference, municipal TN surcharge rates within the State of North Carolina were compiled and are presented in Table 9.5. Nitrogen removal unit costs for industrial wastewater treatment plants are not publicly available, so municipal TN surcharge rates were used for this comparison. Municipal nitrogen surcharge rates represent the costs �. municipalities impose on industrial dischargers to treat nitrogen in excess of typical municipal concentrations within their POTWs and provide an indication of reasonable and economically achievable treatment costs. The average total nitrogen surcharge rate based on 5 municipalities in North Carolina is $1.96/lb of nitrogen. The maximum surcharge �r rate based on the 5 municipalities is $5.00/lb of nitrogen. The normalized nitrogen removal costs for the three technologies evaluated for the Novozymes facility exceed the average and maximum municipal surcharge rates. While the normalized nitrogen removal costs for Alternatives 2 and 3 are 22-26% higher than the maximum �. municipal surcharge rate, Alternative t costs are more than 2.5 times the maximum municipal surcharge cost. This analysis provides additional support for the selection of Alternative 2 as the basis for BAT total nitrogen limit. r Dewberry Novozymes North America, Inc. i Best Available Technology Analysis 129 - u .. Table 9.5. North Carolina Municipal Total Nitrogen Surcharge Rate Comparison Town of Cary $1.30 Franklin County $5.00 City of Raleigh $1.85 Town of Conover $ 0.63 City of Greenville $1.04 Maximum $ 6.00 Average $1.96 Alternative 2: Conventional Aeration, 0.6 F:M $6.28 9.2 Total Phosphorus BAT Limits Review of recent TP data (Appendix G) indicates a sixteen month period where the monthly effluent TP averaged less than i.o mg/I. This demonstrates that phosphorous removal to less than i.o mg/I is technically feasible with chemical precipitation. The data is not consistently below the proposed limit because Novozymes is not currently required to meet a monthly average TP limit of t.o mg/L and therefore does not dose chemical at the rate required to consistently maintain that level of treatment. Theoretically, for chemical precipitation of phosphorous, the effluent ortho- phosphate concentration is directly related to the chemical dose (Metcalf & Eddy, pg. 5o6). Figure 5 below presents the effluent TP concentrations as a function of the metal coagulant dose•. It should be noted that the data in Figure 5 is presented on a logarithmic scale; therefore to achieve additional effluent TP of o.i.o mg/L requires approximately x-ro times the chemical dose to achieve TP of i.o mg/l. In the future, Novozymes will increase the chemical dose to consistently achieve effluent TP < t.o mg/L. A BAT of 1.0 mg/L is deemed appropriate as significantly higher chemical dose ratios are required to produce nominal decreases in effluent TP in the range below t.o mg/L, as demonstrated in Figure 5. In addition, the proposed W WTP upgrades will include chemical addition in the primary clarifiers to support chemical phosphorus precipitation and tertiary filtration to provide particulate TP remm-al. Therefore, Novozymes proposes an effluent BAT limit of r.o mg/L TP. Table 9.6. Proposed Phosphorus BAT Limit AverageMonthly Parameter -. Limit Total Phosphorus 1.0 mgll tjDewberry Novozymes North America, Inc, 1 Best Available Technology Analysis 130 8 10,o0o E m 101 m 1,000 m 0 2 v v 100 , •, ' 7 -------------- o • • 2• • �' m ¢ 0.001 0.010 Effluent P (mg/1) 0.100 1.000 Figure 6. Effluent Phosphorus Concentration vs Metal Coagulant to Phosphorus Dose PW a 10 Dewber"- Novozymes North America, Inc. I Best Available Technology Analysis 131 M 10.1CONCLUSIONS The proposed discharge location on Cedar Creek is located in the Tar -Pamlico River Basin. As a result and as .. discussed in correspondence from the Division dated December 14, 2o16 (Appendix D), the Division requested that Novozymes prepare and submit a Best Available Technology Economically Achievable (BAT) analysis to assist in establishing limits for TP and TN. Three (3) treatment technologies were evaluated to identify the BAT Economically r. Achievable limits for TN, which in general represent the best existing performance of treatment technologies that are economically achievable within an industrial point source category (EPA NPDES Permit Writers' Manual, 201o, EPA- 833-K-10-ool). The treatment technologies evaluated were: Alternative r: Extended Aeration at F:M of o.1(units of mg COD/mg MLVSS'day) • Alternative 2: Conventional Aeration at F:M of 0.5 • Alternative 3: High Rate Aeration at F:M of 0.7 Treatability testing was performed to determine the effluent soluble refractory organic nitrogen and nitrate for each _ technology evaluated. The technically achievable effluent total nitrogen concentrations were calculated from the sum of the 95th percentile effluent soluble refractory organic nitrogen for each reactor, the 95th percentile effluent nitrate from each reactor, the ammonia monthly average limit of 1.o mg/L, and the estimated particulate total nitrogen of 0.36 mg/l. The technically achievable effluent total nitrogen concentration for the three design conditions were determined to be 3.8 mg/1, 8.8 mg/l and 12.7 mg/1; this includes a nitrogen removal credit of 1.o mg/I from the RO treatment process. Biological process modeling was also performed that identified that each alternative would produce secondary effluent with NH3 and NO3 concentrations of less than r.o mg/L, each. - - The EPA definition of a BAT limit requires it be both technically and economically achievable. Capital and annual recurring costs were estimated for each of the three technologies evaluated and were used to determine annual .► equivalent costs. For the BAT TN limit, the annual equivalent costs were normalized per pound of nitrogen removed OR for each alternative evaluated and are summarized in Table to. i. Table 10.1. Summary of Equivalent Annual Costs Normalized to Nitrogen Removed Equivalent Annual Cost $ $17,700,000 $8,300,000 $7,900,000 Normalized Nitrogen Removal Cost $/Ib 13.08 6.28 6.08 Based on the equivalent annual costs and normalized nitrogen removal costs, Alternative 2, Conventional Aeration, F:M = o.5, proves to be the highest performing alternative evaluated that is economically achievable, and is deemed the Best Available Technology Economically Achievable limit. Normalized nitrogen costs for Alternative 2 are 52% less and 3% more compared to Alternatives r and 3, respectively. The graphical relationship (Figure 4) between Normalized nitrogen costs indicate significant incremental cost increase between Alternatives 2 and 1. The graphical relationship between Alternatives 2 and 3 reveals a much lower incremental cost increase. The Equivalent Annual Costs for Alternative 2 is 53% less and 5% more compared to Alternatives i and 3 respectively. The additional annual costs to remove 23,774 Ibs of nitrogen, the difference between Alternatives 2 and 3, is approximately $16.9 per lb TN removed. This is deemed to be economically feasible and reasonable. The additional annual casts to remove 30,441 Dewberry Novozymes North America, Inc, I Best Available Technology Analysis 132 lbs of nitrogen, the difference between Alternatives i and 2, is appro)dmately $3og per lb TN removed. This is deemed to be economically infeasible and unreasonable. For TP, a BAT of i.o mg/L is deemed appropriate as significantly higher chemical dose ratios are required to produce nominal decreases in effluent TP in the range below i.o mg/L. In addition, the proposed W WTP upgrades will include chemical addition in the primary clarifiers to support chemical phosphorus precipitation and tertiary filtration to _ provide particulate TP removal. Therefore, Novozymes proposes an effluent BAT limit of i.o mg/L TP. Table 10.2. Proposed TN and TP BAT Limits ur r. I Rodrigo F. Bueno, Roque P. Piveli, Min Campos & Pedro A. Sobrinho (2018) Simultaneous nitrification and denitrification in the activated sludge systems of continuous flow, Environmental Technology, 39:20, 2641-2652, DOI: lo.ro8o/oosog3z0.2017.ig6g82o 0 II Metcalf & Eddy Inc. (2003) Wastewater Engineering Treatment and Reuse (4th Ed). New York, NY: Mc-Graw-Hill. it Knapp, L. A. (2014). Study of Process Control Strategies for Biological Nutrient Removal in an Oxidation Ditch. Graduate Theses and Dissertations. Iv The International Waster Association. (2018, November 28). Coagulation and Flocculation in Water and Wastewater Treatment. Retrieved from The International Water Association: Publishing: https://www.iwapublishing.com/news/coagulation-and-flocculation-water-and-wastewater-treatment oft ItDewberry. Novozymes North America, Inc. I Best Available Technology Analysis 133 Appendix A: Wastewater Irrigation System Permit (Permit # WQ0002806) www.dewberry.com ROY COOPER Governor N ., MICHAEL S. REGAN _ Secretary Water Resources S. JAY ZIMMERMAN ENVIRONMENTAL OUALITY Director June 8, 2017 FRED REIKO W SKY - SENIOR DIRECTOR OF PRODUCTION .� NOvOZYMEs NORTH AMERICA, INC. 77 PERRY CHAPEL CHURCH ROAD FRANKLINTON, NORTH CAROLINA 27525 Subject: Permit No. W00002806 Novorymes Franklin County Facility Wastewater Irrigation System Franklin County Dear Mr. Reikowsky: In accordance with your permit minor modification request received May 3, 2017, we are forwarding herewith Permit No. W00002806 dated June 8, 2017, to Novorymes North America, Inc. for the continued operation of the subject wastewater treatment and irrigation facilities. The modifications to the subject permit are as follows: 1. Addition of two new Schedule Conditions because of the Corrective Action Plan conditionally approved by the Division on January 31, 2017. The new Schedule Conditions are Conditions .. 1.3 and 1.4. 2. Modifications in Attachment B to (1) Fields EJ9 and GFI have reductions of yearly maximum irrigation rate to 0 in/yr; and (2) Field GF4 has a reduction of wetted acreage from 33.1 to 31.1 acres. This permit shall be effective from the date of issuance until May 31, 2020, shall void Permit No. W00002806 issued June 25, 2015, and shall be subject to the conditions and limitations as specified therein. Please pay particular attention to the monitoring requirements listed in Attachments A, B and C for they may differ from the previous permit issuance. Failure to establish an adequate system for collecting and maintaining the required operational information shall result in future compliance problems. Please note the following permit conditions are new since the last permit issuance dated June 25, 2015: ➢ Condition 1.3. — Twenty-one (21) new wells to be added. ➢ Condition I.4. — Overall capacity reduction from 30 in/yr to 8.5 in/yr. ➢ Attachment B — Fields EJ9 and GF4 have loading rates reduced from 30 in/yr to 0 in/yr; and the net wetted area of Field GF4 is reduced from 33.1 acres to 31.1 acres. %-�'Nothing Compares7, State afNoM Caroline I Environmental Quality I wear Resources I Water Quality Permitting I Non -Discharge Permitting 1617 Mail Service Center I Raleigh, North Carolina 27699-1617 919-807-6332 Mr. Fred Reikowsky June 8,2017 Page 2 of If any parts, requirements or limitations contained in this permit are unacceptable, the Permittee has the right to request an adjudicatory hearing upon written request within 30 days following receipt of this permit. This request shall be in the form of a written petition, conforming to Chapter 150B of the North Carolina General Statutes, and filed with the Office of Administrative Hearings at 6714 Mail Service Center, Raleigh, NC 27699-6714. Unless such demands are made, this permit shall be final and binding. If you need additional information concerning this permit, please contact Troy Doby at (919) 807- 6336 or troy dobyna.ncdenr. ov. Sincerely, _ �S. 7ay �Zimmerman,��G., Director Division of Water Resources cc: Franklin County Health Department (Electronic Copy) .. Raleigh Regional Office, Water Quality Regional Operations Section (Electronic Copy) Digital Permit Archive (Electronic Copy) Central Files r M r 0" an on NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION DEPARTMENT OF ENVIRONMENTAL QUALITY RALEIGH WASTEWATER IRRIGATION SYSTEM PERMIT In accordance with the provisions of Article 21 of Chapter 143, General Statutes of North Carolina as OR amended, and other applicable Laws, Rules and Regulations PERMISSION IS HEREBY GRANTED TO fm Novozymes North America, Inc. Franklin County FOR THE ,M operation of an extended aeration wastewater treatment facility with nutrient removal capability, discharging to the Franklin County POTW as permitted by the County and to an average 700,000 gallon per day (GPD) wastewater irrigation facility consisting of the: continued operation of a collection system consisting of approximately 1,335 linear feet {LF} of 8-inch gravity sewer; approximately 1,600 LF of 4-inch gravity sewer; approximately 705 LF of 3-inch force main; approximately 9 LF of 3-inch wastewater collection piping to allow the collection of food preparation wastewater a 112,800 gallon primary clarifier, and all associated piping, valves, controls, and appurtenances; the am continued operation of a 2,100 gallon concrete wet well and approximately 900 LF of 8-inch force main and conversion of one existing 300 gallons per minute (GPM) pump to transfer primary clarifier effluent to the concrete weir box receiving a mixture of high -strength wastewater and recycled activated sludge and serving basins TO and T02; and all associated piping, valves, controls, and appurtenances; the continued operation of an influent flow meter and sampler for Lagoon No.1, the existing 4.7 million gallon (MG) aeration basin, and operation of the Biolac diffused aeration system in Lagoon No. l which is supplied air by three 200 horsepower (hp) blowers an approximate 185,000 gallon anoxic zone; a floating baffle curtain to physically separate the anoxic and aerobic zones, which shall be installed at the Permittee's discretion; an aerobic zone with a relocated 1,920 gallon per minute (GPM) pump for internal recirculation, and a motorized weir gate; and all associated piping, valves, controls, and appurtenances; the continued operation of an anaerobic treatment system consisting of a 400,000 gallon covered pre - acidification tank (PAT) which is supplied by two 700 GPM feed pumps and a 3,500 GPM centrifugal jet . mix pump; a 24,000 gallon covered recirculation tank (RT tank) with two 900 GPM centrifugal feed pumps and 1,100 GPM recirculation/mixing pumps; a 208,000 gallon covered internal recirculation anaerobic reactor (IC Reactor) with three heat exchangers; a bulk lime 6,350 gallon storage and metering tank for pH �. and alkalinity adjustment for process control in the PAT, IC/RT and T02. The anaerobic treatment system may be used at the discretion of the Permittee to replace or reduce the treatment load on Lagoon No. 1; and all associated piping, valves, controls, and appurtenances; the �+ WQ0002806 Version 3.1 Shell Version 151201 Page 1 of 12 0" continued operation of: a 564,000 gallon secondary clarifier and associated pumps (A pit: return sludge ow pumps, B pit: waste sludge pumps, and C pit: effluent pumps) with approximately 600 LF of 8-inch force main; and all associated piping, valves, controls, and appurtenances; the continued operation of a 250,000 gallon aerated basin (T02) with coarse bubble diffusers, served by three existing 200 hp centrifugal blowers; a 240,000 gallon aeration basin (TO1) with a diffused aeration system; foam suppression systems for TO and T02 served by a submersible pump and associated nozzles; a recycle pump station with centrifugal recycle pumps; and all associated piping, valves, controls, and appurtenances; ,.., the Continued operation of: a 6 MG storage lagoon (Lagoon No. 2); a 36 MG storage lagoon (Lagoon No. 3) and associated pumps; a flow meter for waste storage; transfer of evaporator condensate from the plant .. facilities directly to the wastewater storage Lagoon No. 2 without pretreatment in the aeration basin; and all associated piping, valves, controls, and appurtenances; the continued operation of: approximately 10,800 LF of 8-inch diameter force main to supply treated effluent from Lagoon No. 3 to a phosphorus removal system prior to discharge to the Franklin County POTlh1; a 25 hp submersible pump located in the wet well at Lagoon No. 3; and approval for occasional bypass or overflow from the phosphorous removal system into existing Lagoon No. 2; the transfer of groundwater from a remediation system for use as cooling tower make-up and process water prior to being treated in the existing wastewater treatment facility; and all associated piping, valves, controls, and appurtenances; and the continued operation of a wastewater irrigation system consisting of. 906.3 acres of spray irrigation fields served by a 700 GPM irrigation pump; a 1,500 GPM irrigation pump; an 800 GPM pump; a center pivot ^! irrigation system; a reel type irrigation system with portable spray guns; approximately 1,320 LF of 6-inch diameter force main; approximately 1,900 LF of 8-inch force main with hydrant connections; approximately 1,375 LF of 12-inch irrigation piping with hydrant connections; approximately 15,500 LF of 8-inch irrigation piping with hydrant connections; approximately 1,220 LF of 6-inch irrigation piping with hydrant connections; 1,400 LF of 6-inch irrigation line, 3,800 LF of 8-inch irrigation line and twelve 6-inch hydrants serving the R.J. Joumigan property and portions of the E.H. Journigan Farm; 5,400 LF of 6-inch irrigation line with 10 hydrants serving the Charles Goswick property; a center pivot serving Fields W7 and W9 and a Model 8000 Valley Center Pivot system with a Nelson 100 end -gun providing 670 LF of wetted area and 250 GPM to irrigation Farm 3, Field G2, and 2,600 LF of 6-inch irrigation piping and seven 6-inch hydrants serving Novo Farm #2; two center pivot irrigation systems consisting of a Model +� 8000 Valley Center Pivot system with a Nelson 100 end -gun providing 1,194 LF of wetted area and 450 GPM, 950 LF of 6-inch irrigation piping, 10 LF of 8-inch irrigation piping, and five 6-inch hydrants serving Novo Farm 43:2 2,000 LF of 6-inch irrigation piping, 4,200 LF of 8-inch irrigation line with 19 hydrants and three areas to be irrigated by reel type sprinkler equipment serving the Novo Farm #4; temporary, above -ground piping from the Novo Farm #2, Novo Farm #4, and the E.H. Journigan Farm piping systems serving the William E. Pearce Farm; the remaining acreage of these listed fields will be handled by portable irrigation equipment from existing irrigation piping; and all associated piping, valves, controls, and .. appurtenances; to serve the Novozymes North America, Inc. Franklin County Facility, with no discharge of wastes to .� surface waters, pursuant to the application received May 3, 2017, and in conformity with the project plans, specifications, and other supporting data subsequently filed and approved by the Department of Environmental Quality and considered a part of this permit. This permit shall be effective from the date of issuance until May 31, 2020, shall void Permit No. WQ0002806 issued June 25, 2015, and shall be subject to the following specified conditions and limitations: am WQ0002806 Version 3.1 Shell Version 151201 Page 2 of 12 �+ M" I. SCHEDULES 1. Upon completion of construction and prior to operation of this permitted facility, a certification (attached) shall be submitted from a licensed North Carolina Professional Engineer certifying that the ,., permitted facility has been installed in accordance with this permit, Division approved plans and specifications, and other supporting documentation, including the location of all monitoring wells as applicable. If this project is to be completed in phases and partially certified, the Permittee shall retain the responsibility to track further construction approved under the same permit, and shall provide a final certificate of completion once the entire project has been completed. Mail the Certification to the Division of Water Resources, Water Quality Permitting Section, 1617 Mail Service Center, Raleigh, NC 27699-1617. [15A NCAC 02T .0116(a)] 2. The Raleigh Regional Office, telephone number (919) 791-4200, shall be notified at least 48 hours in advance (excluding weekends and holidays) of operation of the installed facilities such that an in -place inspection can be made. Notification to the regional supervisor shall be made from 8:00 a.m. until 5:00 p.m. on Monday through Friday, excluding State Holidays. [ 15A NCAC 02T .0108(b)(2)] 3. Per the Corrective Action Plan conditionally approved by the Division on January 31, 2017, the ` Permittee shall submit a request for modification to include twenty-one (21) new compliance monitoring wells upon completion of installation and commissioning. (Anticipated completion in September 2017). [15A NCAC 02T .0108(b)(2)] 4. Per the Corrective Action Plan conditionally approved by the Division on January 31, 2017, the Permittee shall submit a request for modification for the overall capacity reduction of the facility from 30 in/yr to 8.5 in/yr upon receipt of a direct discharge permit and construction and commissioning of the upgraded process wastewater treatment facility. (Anticipated completion at the end of Quarter 1, 2019). [15A NCAC 02T .0108(b)(2)] 5. No later than six months prior to the expiration of this permit, the Permittee shall request renewal of this permit on official Division forms. Upon receipt of the request, the Division will review the adequacy of the facilities described therein, and if warranted, will renew the permit for such period of aw� time and under such conditions and limitations as it may deem appropriate. Please note Rule 15A NCAC 02T .0105(d) requires an updated site map to be submitted with the permit renewal application. [15A NCAC 02T .0105(d), 02T .0106, 02T .0109, 02T .0115(c)] H. PERFORMANCE STANDARDS 1. The subject non -discharge facilities shall be effectively maintained and operated at all times so there is no discharge to surface waters, nor any contravention of groundwater or surface water standards. In the event the facilities fail to perform satisfactorily, including the creation of nuisance conditions due to improper operation and maintenance, or failure of the irrigation areas to adequately assimilate the effluent, the Permittee shall take immediate corrective actions including Division required actions, such as the construction of additional or replacement wastewater treatment or irrigation facilities. [G.S. 143- 215.1, 143-213.3(a)] 2. This permit shall not relieve the Permittee of their responsibility for damages to groundwater or surface water resulting from the operation of this facility. [ 15A NCAC 02B .0200, 02L .0100] 3. All wells constructed for purposes of groundwater monitoring shall be constructed in accordance with 15A NCAC 02C .0108 (Standards of Construction for Wells Other than Water Supply), and any other jurisdictional laws and regulations pertaining to well construction. [15A NCAC 02C .0108] moo 014 WQ0002806 Version 3.1 Shell Version 151201 Page 3 of 12 r 4. The wastewater collection facilities shall be properly maintained and operated at all times. The r• Permittee shall maintain compliance with an individual system -wide collection system permit for the operation and maintenance of these facilities in accordance with 15A NCAC 02T .0400. If an individual permit is not required, the following performance criteria shall be met: a. The sewer system shall be effectively maintained and operated at all times to prevent discharge to land or surface waters, and any contravention of groundwater or surface water standards. b. A map of the sewer system shall be developed and actively maintained. c. An operation and maintenance plan shall be developed, implemented and maintained. d. Pump stations not connected to a telemetry system shall be inspected every day (i.e., 365 days per year). Pump stations connected to a telemetry system shall be inspected at least once per week. .� e. High -priority sewers shall be inspected at least once every six months. f. A general observation of the entire sewer system shall be conducted at least once per year. .. g. Overflows and bypasses shall be reported to the Raleigh Regional Office in accordance with 15A NCAC 02B .0506(a), and public notice shall be provided as required per North Carolina General Statute § 143-215.1C. h. A grease control program shall be developed, implemented and maintained. i. Right-of-ways and easements shall be maintained. 0M j. Inspection and maintenance records for Conditions I1.4.a. through IIAL shall be maintained for a period of at least three years, except for Conditions II.4.b. and 11.4.c., which shall be maintained for the life of the system. 0. [15A NCAC 02T .0403] 5. Effluent quality shall not exceed the limitations specified in Attachment A. [15A NCAC 02T .0108(b)(1), 02T .0505(b)] 6. Application rates, whether hydraulic, nutrient or other pollutant, shall not exceed those specified in Attachment B. [15A NCAC 02T .0505(c), 02T .0505(n)] 7. This disposal system was individually permitted prior to December 30, 1983; therefore, the compliance boundary is established at either 500 feet from the effluent disposal area, or at the property boundary, 011' whichever is closest to the effluent disposal area. An exceedance of groundwater standards at or beyond the compliance boundary is subject to remediation action according to 15A NCAC 02L .0106(d)(2) as well as enforcement actions in accordance with North Carolina General Statute 143-215.6A through 143-215.6C. [15A NCAC 02L .0107] 8. In accordance with 15A NCAC 02L .0108, the review boundary is established midway between the compliance boundary and the effluent disposal area. Any exceedance of groundwater standards at the review boundary shall require action in accordance with 15A NCAC 02L .0106. [15A NCAC 02L .0106, 02L .0108] 0M 9. The Permittee shall apply for a permit modification to establish a new compliance boundary prior to any sale or transfer of property affecting a compliance boundary. [ 1 SA NCAC 02L .0107(c)] 10. In accordance with 15A NCAC 02L .0I07(d), no wells, excluding Division approved monitoring wells, shall be constructed within the compliance boundary except as provided for in 15A NCAC 02L .0107(g). [ 15A NCAC 02L .0107] .. ` Q0002806 Version 3.1 Shell Version 151201 Page 4 of 12 R' A 11. Except as provided for in 15A NCAC 02L .0107(g), the Permittee shall ensure any landowner who is not the Permittee and owns land within the compliance boundary shall execute and file with the Franklin County Register of Deeds an easement running with the land containing the following items: a. A notice of the permit and number or other description as allowed in 15A NCAC 02L .0107(f)(1); b. Prohibits construction and operation of water supply wells within the compliance boundary; and c. Reserves the right of the Permittee or the State to enter the property within the compliance boundary Oak for purposes related to the permit. The Director may terminate the easement when its purpose has been fulfilled or is no longer needed. oft [15A NCAC 02L .0107(f)] 12. The facilities permitted herein shall be constructed according to the following setbacks: am a. The setbacks for irrigation sites permitted under 15A NCAC 02H .0200 shall be as follows (all distances in feet): i. Any habitable residence or place of public assembly under separate ownership: 400 ' i i. Surface waters: 100 iii. Any well with exception of monitoring wells: 100 iv. Any property line: 1502 v. Public right of way: 50 ' Per pre-existing waivers, setbacks to habitable residences or places of public assembly under separate ownership have been reduced for the following: ` M Site Setback Approval Pearce Farm 200 feet to Field PF3 July 1, 1997 Goswick Farm 200 feet to Field GF 1 November 17, 1995 'f 2 Per pre-existing waivers, setbacks to property lines have been reduced for the following: am Site Setback Approval Pearce Farm 50 feet to Field PF3 July 1, 1997 Goswick Farm 50 feet to Fields GF1, GF2, GF3 & GF4 November 17, 1995 Novozymes Farm 4 50 feet to Fields S2, S3 and S4 July 1, 1997 [15A NCAC 02H .02190)] b. The setbacks for storage and treatment units permitted under 15A NCAC 02H .0200 shall be as ' follows (all distances in feet): i. Any well with exception of monitoring wells: 100 ii. Any property line: 50 [15A NCAC 02H .02190)] on. 0" MR WQ0002806 Version 3.1 Shell Version 151201 Page 5 of 12 c. The setbacks for the 250,000 gallon aerated flow equalization unit permitted under -15A NCAC 02T .0500 shall be as follows (all distances in feet): i. Any habitable residence or place of public assembly under separate ownership: 100 ii. Any private or public water supply source: 100 iii. Surface waters: 50 iv. Any well with exception of monitoring wells: 100 v. Any property line: 50 [I 5A NCAC 02T .0506(b)] 111. OPERATION AND MAINTENANCE REQUIREMENTS 1. The facilities shall be properly maintained and operated at all times. The facilities shall be effectively maintained and operated as a non -discharge system to prevent the discharge of any wastewater resulting from the operation of this facility. The Permittee shall maintain an Operation and Maintenance Plan, which at a minimum shall include operational functions, maintenance schedules, safety measures and a spill response plan. [15A NCAC 02T .0507] 2. Upon the Water Pollution Control System Operators Certification Commission's (WPCSOCC) classification of the subject non -discharge facilities, in accordance with 15A NCAC 08G .0200 the Permittee shall designate and employ a certified operator in responsible charge (ORC) and one or more certified operator(s) as back-up ORC(s). The ORC or their back-up shall visit the facilities in accordance with 15A NCAC 08G .0200, and shall comply with all other conditions specified in the previously cited rules. [15A NCAC 02T .0117] 3. A suitable year round vegetative cover shall be maintained at all times, such that crop health is optimized, allows for even distribution of effluent and allows inspection of the irrigation system. [ 15A NCAC 02T .0108(b)(1)] 4. Adequate measures shall be taken to prevent effluent ponding in or runoff from the irrigation sites listed in Attachment B. [15A NCAC 02T .0108(b)(1)] 5. Irrigation shall not be performed during inclement weather or when the ground is in a condition that will cause ponding or runoff. [15A NCAC 02T .0108(b)(1)] 6. All irrigation equipment shall be tested and calibrated at least once per permit cycle. Calibration records shall be maintained at the facility for a period of no less than five years, and shall be made available to the Division upon request. [15A NCAC 02T .0108(b)(1)] 7. Only effluent from Novozymes Franklin County Facility shall be irrigated on the sites listed in Attachment B. [G.S. 143-215.1] 8. No automobiles or machinery shall be allowed on the irrigation sites except during equipment installation or while maintenance is being performed. [15A NCAC 02T .0108(b)(1)] 9. Public access to the irrigation sites and wastewater treatment facilities shall be prohibited. [ 15A NCAC 02T .0505(q)] 10. The residuals generated from the wastewater treatment facilities shall be disposed or utilized in accordance with 15A NCAC 02T .1100. The Permittee shall maintain a residual management plan pursuant to 15A NCAC 02T .0508. [ 15A NCAC 02T .0508, 02T .1100] 11. Diversion or bypassing of untreated or partially treated wastewater from the treatment facilities is prohibited. [15A NCAC 02T .05050)] WQ0002806 Version 3.1 Shell Version 151201 Page 6 of 12 M4 12. Freeboard in the Lagoon Nos. 1, 2 and 3 shall not be less than one foot at any time. [15A NCAC 02T am .0505(d)] 13. Gauges to monitor waste levels in Lagoon Nos. 1, 2 and 3 shall be provided. This gauge shall have readily visible permanent markings, at inch or tenth of a foot increments, indicating the following elevations: maximum liquid level at the top of the temporary liquid storage volume; minimum liquid level at the bottom of the temporary liquid storage volume; and the lowest point on top of the dam. [15A NCAC 02T _0108(b)(1)] 14. A protective vegetative cover shall be established and maintained on all earthen embankments (i.e., outside toe of embankment to maximum allowable temporary storage elevation on the inside of the "M embankment), berms, pipe runs, erosion control areas, and surface water diversions. Trees, shrubs, and other woody vegetation shall not be allowed to grow on the earthen dikes or embankments. Earthen embankment areas shall be kept mowed or otherwise controlled and accessible. [15A NCAC 02T �.., .0 i08(bXl)] - 15. Wastewater irrigation fields with rock outcrops within the wetted area shall be properly buffered to avoid irrigation on these rock outcrops. [ 15A NCAC 02T .0108(b)(1)] 16. If animal waste is applied to any of the wastewater irrigation fields, adequate protection shall be taken to insure the animal waste is not washed off the site and the irrigation rate shall be reduced to an appropriate level to ensure that agronomic rates are not exceeded for that field. [15A NCAC 02T .0108(b)(1)] 17. Irrigation areas not under the Permittee's ownership (i.e., the 287.6 acres owned by R.J. Journigan, Charles Goswick, E.H. Journigan and William E. Pearce) shall not be used to provide additional wastewater treatment and disposal capacity, and shall only be used to provide better operation of the wastewater treatment and disposal system. [ 15A NCAC 02T .0108(b)(1)] 18. All water supply wells adjacent to the treatment or disposal areas shall be properly buffered or permanently abandoned in accordance with 15A NCAC 02C .0113. If any of these water supply wells are to be converted into monitoring wells in lieu of being abandoned, the wells must comply with the 15A NCAC 02C monitoring well requirements and be properly constructed to prevent the vertical migration of any groundwater contaminants that maybe released. [15A NCAC 02T .0108(b)(1)] IV. MONITORING AND REPORTING REQUIREYMNTS 1. Any Division required monitoring (including groundwater, plant tissue, soil and surface water analyses) necessary to ensure groundwater and surface water protection shall be established, and an acceptable sampling reporting schedule shall be followed. [15A NCAC 02T .0108(c)] mm' 2. A Division certified laboratory shall conduct all laboratory analyses for the required effluent, groundwater or surface water parameters. [15A NCAC 02H .0800] �► 3. Flow through the treatment facility shall be continuously monitored, and daily flow values shall be reported on Form NDMR. The Permittee shall install and maintain an appropriate flow measurement device to ensure the accuracy and reliability of flow measurement consistent with accepted engineering and scientific practices. Selected flow measurement devices shall be capable of measuring flows with a maximum deviation of less than ten percent from true flow; accurately calibrated at a minimum of once per year; and maintained to ensure the accuracy of measurements is consistent with the selected device's accepted capability. The Permittee shall maintain records of flow measurement device calibration on file for a period of at least five years. At a minimum, documentation shall include: a. Date of flow measurement device calibration, b. Name of person performing calibration, and c. Percent from true flow. WQ0002806 Version 3.1 Shell Version 151201 Page 7 of 12 r"' [15A NCAC 02T .0105(k)] 4. The Permittee shall monitor the effluent from the subject facilities at the frequencies and locations for the parameters specified in Attachment A. [15A NCAC 02T .0108(c)] 5. The Permittee shall maintain adequate records tracking the amount of effluent irrigated. At a minimum, these records shall include the following information for each irrigation site listed in Attachment B: a. Date of irrigation; b. Volume of effluent irrigated; c. Site irrigated; d. Length of time site is irrigated; e. Continuous weekly, monthly, and year-to-date hydraulic (inches/acre) loadings; f. Continuous monthly and year-to-date loadings for any non -hydraulic parameter specifically limited in Attachment B; g. Weather conditions; and .. h. Maintenance of cover crops. [I 5A NCAC 02T .0108(c)] .. 6. Freeboard (i.e., waste level to the lowest embankment elevation) in Lagoon Nos. 1, 2, and 3 shall be measured to the nearest inch or tenth of a foot, and recorded weekly. Weekly freeboard records shall be maintained at the facility for a period of no less than five years, and shall be made available to the Division upon request. (I5A NCAC 02T .0108(c)] 7. Three copies of all monitoring data (as specified in Conditions IV.3. and 1VA.) on Form NDMR for each PPI and three copies of all operation and disposal records (as specified in Conditions IV.5. and IV.6.) on Form NDAR-1 for every site in Attachment B shall be submitted on or before the last day of the following month. If no activities occurred during the monitoring month, monitoring reports are still required documenting the absence of the activity. All information shall be submitted to the following address: Division of Water Resources Information Processing Unit 1617 Mail Service Center Raleigh, North Carolina 27699- l 617 [15A NCAC 02T .0105(1)] 8. A record shall be maintained of all residuals removed from this facility. This record shall be maintained at the facility for a period of no less than five years, and shall be made available to the Division upon request. At a minimum, this record shall include: r, 0" a. Name of the residuals hauler; o. b. Non -Discharge permit number authorizing the residuals disposal, or a letter from a municipality agreeing to accept the residuals; c. Date the residuals were hauled; and d. Volume of residuals removed. [ 15A NCAC 02T .0108(b)(1)] 9. A maintenance log shall be maintained at this facility. This log shall be maintained at the facility for a .� period of no less than five years, and shall be made available to the Division upon request. At a minimum, this log shall include: a. Date of calibration of flow measurement device; b. Visual observations of the plant and plant site; and c. Record of preventative maintenance (e.g., changing of equipment, adjustments, testing, inspections and cleanings, etc.). !^ [I 5A NCAC 02T .0108(b)(1)] WQ0002806 Version 3.1 Shell Version 151201 Page 8 of 12 pn 10. Monitoring wells shall be sampled at the frequencies and for the parameters specified in Attachment C. All mapping, well construction forms, well abandonment forms and monitoring data shall refer to the permit number and the well nomenclature as provided in .Attachment C. [15A NCAC 02T .0105(m)] 11. Two copies of the monitoring well sampling and analysis results shall be submitted on a Compliance Monitoring Form (GW-59), along with attached copies of laboratory analyses, on or before the last �► working day of the month following the sampling month. The Compliance Monitoring Form (GW-59) shall include this permit number, the appropriate well identification number, and one GW-59a certification form shall be submitted with each set of sampling results. All information shall be submitted to the following address: Division of Water Resources Information Processing Unit 1617 Mail Service Center Raleigh, North Carolina 27699-1617 [15A NCAC 02T .0105 (m)] 12. An annual representative soils analysis (i.e., Standard Soil Fertility Analysis) shall be conducted on each irrigation site listed in Attachment B. These results shall be maintained at the facility for a period of no less than five years, and shall be made available to the Division upon request. At a minimum, the Standard Soil Fertility Analysis shall include the following parameters: a" Acidity Exchangeable Sodium Percentage Phosphorus Base Saturation (by calculation) 'Magnesium Potassium Calcium Manganese Sodium Cation Exchange Capacity Percent Humic Matter Zinc Copper pH fm� [15A NCAC 02T .0I08(c)] 13. Noncompliance Notification: The Permittee shall report by telephone to the Raleigh Regional Office, telephone number (919) 791- 4200, as soon as possible, but in no case more than 24 hours, or on the next working day following the occurrence or first knowledge of the occurrence of any of the following: ,., a. Treatment of wastes abnormal in quantity or characteristic, including the known passage of a hazardous substance. b. Any process unit failure (e.g., mechanical, electrical, etc.), due to known or unknown reasons, rendering the facility incapable of adequate wastewater treatment. c. Any facility failure resulting in a by-pass directly to receiving surface waters. d. Any time self -monitoring indicates the facility has gone out of compliance with its permit limitations. e. Ponding in or runoff' from the irrigation sites. Any emergency requiring immediate reporting (e.g., discharges to surface waters, imminent failure of a storage structure, etc.) outside normal business hours shall be reported to the Division's Emergency Response personnel at telephone number (800) 662-7956, (800) 858-0368, or (919) 733-3300. Persons reporting such occurrences by telephone shall also file a written report in letter form within five days following first knowledge of the occurrence. This report shall outline the actions taken or proposed to betaken to ensure the problem does not recur. [ 15A NCAC 02T .0105(l), 02T .0108(b)(1)] 0" WQ0002806 Version 3.1 Shell Version 151201 Page 9 of 12 M" V. 1. The Permittee shall provide adequate inspection and maintenance to ensure proper operation of the wastewater treatment and irrigation facilities. [ 15A NCAC 02T .0108(b)] 2. The Permittee or their designee shall inspect the wastewater treatment and irrigation facilities to prevent malfunctions, facility deterioration and operator errors resulting in discharges, which may cause the release of wastes to the environment, a threat to human health or a public nuisance. The Permittee shall maintain an inspection log that includes, at a minimum, the date and time of inspection, observations made, and any maintenance, repairs, or corrective actions taken. The Permittee shall maintain this inspection log for a period of five years from the date of the inspection, and this log shall be made available to the Division upon request. [15A NCAC 02T .0108(b)] 3. Any duly authorized Division representative may, upon presentation of credentials, enter and inspect any property, premises or place on or related to the wastewater treatment and irrigation facilities ^ permitted herein at any reasonable time for determining compliance with this permit; may inspect or copy any records required to be maintained under the terms and conditions of this permit, and may collect groundwater, surface water or leachate samples. [G.S. 143-21.5.3(a)(2)] PER V11. GENERAL CONDMONS 1. Failure to comply with the conditions and limitations contained herein may subject the Permittee to an enforcement action by the Division in accordance with North Carolina General Statutes 143-215.6A to 143-215.6C. [G.S. 143-215.6A to 143-215.6C] 2. This permit shall become voidable if the permitted facilities are not constructed in accordance with the conditions of this permit, the Division approved plans and specifications, and other supporting documentation. [ 15A NCAC 02T .0110] ^ 3. This permit is effective only with respect to the nature and volume of wastes described in the permit application, Division approved plans and specifications, and other supporting documentation. No �••� variances to applicable rules governing the construction or operation of the permitted facilities are granted, unless specifically requested and approved in this permit pursuant to 15A NCAC 02T .0105(n). [G.S. 143-21.5.1] 4. The issuance of this permit does not exempt the Permittee from complying with any and all statutes, rules, regulations, or ordinances, which may be imposed by other jurisdictional government agencies (e.g., local, state, and federal). Of particular concern to the Division are applicable river buffer rules in ^ 15A NCAC 02B .0200; erosion and sedimentation control requirements in 15A NCAC Chapter 4 and under General Permit NCG010000; any requirements pertaining to wetlands under 15A NCAC 02B .0200 and 02H .0500; and documentation of compliance with Article 21 Part 6 of Chapter 143 of the �.► General Statutes. [15A NCAC 02T .0105(c)(6)] 5. In the event the permitted facilities change ownership or the Permittee changes their name, a formal ^ permit modification request shall be submitted to the Division. This request shall be made on official Division forms, and shall include appropriate property ownership documentation and other supporting documentation as necessary. The Permittee of record shall remain fully responsible for maintaining and operating the facilities permitted herein until a permit is issued to the new owner. [15A NCAC 02T .0104] 6. The Permittee shall retain a set of Division approved plans and specifications for the life of the facilities ,M permitted herein. [15ANCAC 02T .0108(b)(1)] 7. The Permittee shall maintain this permit until all permitted facilities herein are properly closed or permitted under another permit issued by the appropriate permitting authority. [15A NCAC 02T .� .01050)] WQ0002806 Version 3.1 Shell Version 151201 Page 10 of 12 "�" 8. This permit is subject to revocation or unilateral modification upon 60-day notice from the Division Director, in whole or part for the requirements listed in 15A NCAC 02T .0110. [15A NCAC 02T .0110] 9. Unless the Division Director grants a variance, expansion of the permitted facilities contained herein .. shall not be granted if the Permittee exemplifies any of the criteria in I SA NCAC 02T .0120(b). [15A NCAC 02T .0120] 10. The Permittee shall pay the annual fee within 30 days after being billed by the Division. Failure to pay the annual fee accordingly shall be cause for the Division to revoke this permit. [15A NCAC 02T .0105(e)(3)] Permit issued this the 811 day of June 2017 NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION Jay Zimmerman, P.G., Director Division of Water Resources By Authority of the Environmental Management Commission Permit Number W00002806 .. W00002806 Version 3.1 Shell Version 151201 Page 11 of 12 om Permit No. WQ0002806 Wastewater Irrigation System Novozymes North America, Inc. .tune 8, 2017 hovozymes Franklin County Facility Franklin County ENGINEERING CERTIFICATION ❑ Partial ❑ Final In accordance with 15A NCAC 02T .0116, I, , as a duly registered Professional Engineer in the State of North Carolina, having the Permittee's authorization to ❑ periodically ❑ weekly ❑ fully observe the construction of the permitted facility, hereby state to the best of my abilities that due care and diligence was used in the observation of the construction, such that the facility was built within substantial compliance and intent of this permit, the Division -approved plans and specifications, and other supporting documentation. ❑ Any variation to this permit, the Division -approved plans and specifications, and other supporting documentation has been documented in the attached as -built drawings, and shall serve as the Permittee's minor modification request to amend the permit accordingly. Provide a brief narrative description of any variations: Professional Engineer's Name c Engineering Firm Mailing Address ' - -City... - State Zip i Telephone E-mail NC PE Seal, Signature & bate THE COMPLETED ENGINEERING CERTIFICATION, INCLUDING ALL SUPPORTING INFORMATION AND MATERIALS, SHALL BE SENT TO THE FOLLOWING ADDRESS: NORTH CAROLINA DEPARTMENT OF ENVIRONMENTAL QUALITY DIVISION OF WATER RESOURCES WATER QUALITY PERMITTING SECTION NON -DISCHARGE PERMITTING UNIT By U.S. Postal Service: By Courier/Special Delivery: 1617 MAIL SERVICE CENTER 512 N. SALISBURY ST. RALEIGH, NORTH CAROLINA 27699-1617 RAL,EIGH, NORTH CAROLINA 27604 WQ0002806 Version 3.1 Shell Version 151201 Page 12 of 12 on ., P" A 1 1 1 1 1 1 1 1 1 1 ATTACHMENT A — LIMITATIONS AND MONITORING REQUIREMENTS PPI 091 - W WTI' Effluent 1 1 1 1 1 1 Permit Number: WQ09027806 1 1 Srersio ut 3.1 EFFLUENT CHARACTERISTICS EFFLUENT LIMITS MONITORING REQUIREMENTS PCs Cade Parameter Description Units of Measure Monthly Average Monthly Geometric Mean Daily Minimum Daily Maximum Measurement Frequency Sample 'Type 00310 BOD, 5-Day (20 °C) mg/L 2 x Month 3 x Year Grab Grab 00916 Calcium, Total (as Ca) mg/L 50060 Chloride (as Cl) mg/L 700,0002 + 3 x Ycar' Continuous Grah Recorder 50050 Flow, in Conduit or thru Treatment Plant GPD 00610 Nitrogen, Ammonia Total (as N) mg/L 3 x Year Grab 00625 Nitrogen, Kjeldahl, Total (as N) mg/L 2. x Month 2 x Month 2 x Month 5 x Week Grab Grab 00620 Nitrogen, Nitrate Total (as N) mg/l. 00600 Nitrogen, Total (as N) mg/L Grab Grab 00400 pH so 00665 Phosphorus, Total (as P) mg/L 2 x Month Grab 00931 Sodium Adsorption Ratio ratio 3x Year Calculated 00929 Sodium, Total (as Na) mg/L 3 x Year' 3 x Year Grab — Grab 70300 Solids, Total Dissolved —180 °C mg(L 1. 3 x Year sampling shallbe conducted in March, July and November. 2. This flow value does not include the amount discharged to the Franklin County POTW. WQ0002306 Version 3.1 Attachment A Page 1 of 1 1 THIS PAGE BLANK ATTACHMENT B - APPROVED LAND APPLICATION SITES AND LEWTATIONS Permit Number: WQ0002806 Version: 3.1 Novozymes North America, Inc. - NovMmes Frsnklia County Facility IRRIGATION AREA INFORMATION APPLICATION LIMITATIONS Parameter Hourly Yearly Units RateMax 01284 - Non -Discharge Application Rate _ 30 inches Field Owner County Latitude 36.0844180 Longitude 78.3845640 Net Acreage 12.1 Dominant Soil Series E1 I Journigan, E H Franklin EJ2 Journigan, E H Franklin 36.079020 78.3844690 7.6 4.3 01284 - Non -Discharge Application Rate 01284 - Non-Dischargc Application Rate 30 inches F-M Journigan, E H Franklin 36.0765040 78.3843740 30 inches EJ4 Journigan, B 1-1 Franklin 36.0754660 78.3855630 4.3 01284 Nan -Discharge Application Rate 30 inches EJ5 Journigan, E H Franklin 36.0729300 78.3846360 8.8 01284 -- Non -Discharge Application Rate T 30 inches EJ6 Journigan, E H Franklin 36.0797120 78.3831380 7.7 01284 - Non -Discharge Application Rate 30 inches EJ7 Journigan, E H Franklin 36.0800000 78.381260 17 01284 -- Non -Discharge Application hate 30 inches F,J8 Journigan, E H Franklin 36.0759080 78.3819500 33.6 01284 - Non -Discharge Application Rate 30� inches E19 Journigan, E 1-1 Franklin 36.0727960 36.0838560 36.0791160 78.3968340 6.6 01284 - Non -Discharge Application Rate 0 inches GI Novozymes North America, Inc. Franklin 78.4007500 78.4011780 55.3 01284 - Non -Discharge Application Rate 30 inches G2 Novozymes North America, Inc. Franklin 40 01284 - Non -Discharge Application Rate 30 inches G4A Novozymes North America, Inc. Franklin 36.094053" 78.3897460 31.5 01284 - Non -Discharge Application Rate 30 inches Cr4B Novozymes North America, Inc. Franklin 36.0798460 78.3895550 36.9 01284 - Non -Discharge Application Rate 30 inches G4C Novozymes North America, Inc. Franklin 36.075620 36.0862230 78.3893890 26.6 01284 - Non -Discharge Application Rate 30 30 inches G5 Novozymes North America, Inc. Franklin 78.3898170 5.3 01284 -- Non -Discharge Application Rate inches G6A Novozymes North America, Inc. Franklin 36.087913" 78.3898410 7.5 01284 - Non -Discharge Application Rate 30 inches G613 Novozymes North America, Inc. Franklin 36.0881250 78.391148" 7.5 01284 - Non -Discharge Application Rate 30 inches G7 Novozymes North America, Inc. Franklin 36.078751° 78.398849° 7.9 01284 -Non-Discharge Application Rate 30 inches GF 1 Goswick, Charles Franklin 36.0630550 78.3912670 9.4 01284 - Non -Discharge Application Rate 0 30 30 inches GF2 Goswick, Charles Franklin 36.0664560 78.3938340 78.3921940 20.9 01284 --Non-Discharge Application Rate inches inches GF3 Goswick, Charles Franklin 36.067570 15.4 01284 - Nan -Discharge Application Rate GF4 Goswick, Charles Franklin 36.070913' 78.394666° 31.1 01284 - Non -Discharge Application Rate .30 30 inches J1 Journigan, RJ Franklin 36.0846480 78.3870120 12.9 01284 - Non -Discharge Application Rate inches 12 Journigan, RJ Franklin 36.0798080 78.387107° 28.8 01284 - Non -Discharge Application Rate 30 inches ` WQ0002806 Version 3.1 Attachwerit 13 Page 1 of 3 FieldF Owner County Latitude Lon itude I; Net Acreage Dominant Soil Series 'Parameter Hourly Rate Yearly Max Units J3 Journigan, RJ Franklin 36.0749670 78.3871550 12.7 7L 01284 - Non -Discharge Application Rate 01284-Non-Discharge Application Rate 01284 - Non -Discharge Application Rate 30 inches N1 Novozymes North America, Inc. Franklin 36.1048620 73.4062940 - 30 30 inches inches PF l Pearce, William E Franklin 36.0945210 78.3964840 - 4.2 PF2 _ Pearce, William E Franklin 36.0927150 36.0949240 78.3961390 13.3 01284 -- Non -Discharge Application Rate 30 inches PF3 Pearce, William E Franklin 78.3934530 11.6 01284 - Non -Discharge Application Rate 30 - inches PF4 Pearce, William E Franklin 36.09308" 78.3932160 78-3835180 78.381118* 11.2 01284 - Non -Discharge Application Rate 30 30 30 30 inches inches inches inches PF5 Pearce, William E Franklin 36.084514° 36-081306' 5.9 6.2 01284 -- Non -Discharge Application Rate 01284-Non-Discharge Application Rate 01284 - Non -Discharge Application Rate PF6 Pearce, William E Franklin Sl Novozymes North America, Inc. Franklin 36.096518° 78.3969230 20.9 S2 Novozymes North America, Inc. Franklin 36.0969021 78.393620 14.6 01284 - Non -Discharge Application Rate 30 inches inches S3 Novozymes North America, Inc. Franklin 36.0996680 78.3887000 26.5 01284 - Non -Discharge Application Rate 30 S4 Novozymes North America, Inc. Franklin 36.0999940 78.3955930 13.7 - 01284 - Non -Discharge Application Rate 30 30 inches inches T2 Novozymes North America, Inc. Franklin 36.1032011 78.411386" 6 01284 - Non -Discharge Application Rate VFl Novozymes North America, Inc. Franklin 36.0989950 78.4153910 _ 46.9 01284 - Non -Discharge Application Rate 30 inches VF2 Novozymes North America, Inc. Franklin 36.101050 78.419693° 48 01284 - Non -Discharge Application Rate 30 inches VF3 Novozymes North America, Inc. Franklin 36.1065420 78.418148" 16.6 ^- 01284 - Nor, -Discharge Application Rate 30 inches VF4 Novozymes North America, Inc. Franklin 36.1071180 78.420525" 7.5 01284 - Non -Discharge Application Rate 30 inches VF5 Novozymes North America, Inc. Franklin 36.1077710 78.4137750 5.5 01284 - Non -Discharge Application Rate 30 inches W 1 Novozymes North America, Inc. Franklin 36.0953850 78.4046240 8.7 5.9 7.4 01284 - Non -Discharge Application Rate 30 inches W2 Novozymes North America, Inc. Franklin Franklin 36.0952690 36.0949430 78.4028180 78.3992530 01284 -Non-Discharge Application Rate 01284 - Non -Discharge Application Rate 30 30 inches inches - W3 Novozymes North America, Inc. W4 Novozymes North America, Inc. Franklin 36.093138° 78.400299° 16 01284 - Non -Discharge Application Rate 30 inches WS Novozymes North America, Inc. Franklin 36.093810 78.4055750 5.3 10.5 01284 -Non-Discharge Application Rate 30 30 30 inches W6 Novorymes North America, Inc. Franklin 36.0949810 78.4082610 01284 -Non-Discharge Application Rate 01284 -Non-Discharge Application Rate inches inches W7 Novozymes North America, Inc. Franklin 36.0967680 78.4079040 9.6 W8 W9 Novozymes North America, Inc. Franklin 36.0974010 78.4031510 78.4049811 4.1 38.8 - 01284 - Non -Discharge Application Rate 30 30 30 _ inches inches inches Novozymes North America, Inc. Franklin. 36.098515° _ - 01284 - Non -Discharge Application Rate 01284 -Non-Discharge Application Rate W10 Novozymes North America, Inc. Franklin 36.09738211 78.399324" 16.1 _ 1+YQ0U0'Z806 -Version 3.1 Attachment R Pnpe 2 of 3 I Totals 404.30 WQ0002806 Vusion 3.1 Attachment P Page 3 of THIS PAGE BLANK ATTACHMENT C — GROUNDWATER MONITORING AND LIMI'IXjTIONS Permit Number: WQ00,02806 Vorslwa.' 3,1 Monitoring wells: MW-1, MW-2, Mid-3, MW-119 MW-129 MW-139 MCI-14, MW-15, IV-16, Phi-47,MWA8., MW-19, MW-20, I`Y VVb 2l,1' fVV-22, MW 23, MW-24 and Mitt/-25 --' GROUNDWATER CHARACTERISTICS -- PCS Code Parameter Description GROUNDWATER STANDARDS -- (Daily Maximum � - - - - MONITORING REQUIREMENTS Frequency Measurement Sample Type Footnotes 00680 Carbon, Tot Organic (TUC) 250 mg/L mgfL 3 x Year Grab 1,4 00940 Chloride (as Cl) 3 x Year Grab Grab --_ _ Grab 1 -- __ 1 — 1 01055 Manganese, Total (as Mn) 0.05 mg/L — 3 x Year ---_ 00610 Nitrogen, Ammonia "Total (as N) 1.5 mg/L 3 x Year 00620 Nitrogen, Nitrate Total (as N) 10 mg/L 3 x Year - Grab Grab - -- Grab i-- --- Ty 1 1,2 r 1 T-- _ 1 1 1, 2, 3 - 00400 pl-I 6.5-8.5 su 3 x Year 3 x Year - 00665 Phosphorus, 'Total (as P) --- mg/L 70300 Solids, Total Dissolved - 180 °C 500 mg/i, mg/l, 3 x Year 3 x Year Grab Grab- 009,15 82546 Sulfate, Total (as SO4) 250 _ Water level, distance from measuring point R 3 x Year Calculated^ !. s x Year monitonng shall he conducted in March, July & November; annual monitoring shall be conducted every November. 2. The measurement of water levels shall be made prior to purging the wells. The depth to water in each well shall be measured from the surveyed point on the top of the casing. The measurement of pH shall be made after purging and prior to sampling for the remaining parameters. 3. The measuring points (top of well casing) of all monitoring wells shall be surveyed to provide the relative elevation of the measuring point for each monitoring well. The measuring points (top of casing) of all monitoring wells shall be surveyed relative to a common datum. 4. If TOC concentrations greater than 10 rng/L are detected in any downgradient monitoring well, additional sampling and analysis must be conducted to identify the individual constituents comprising this TOC concentration. If the TOC concentration as measured in the background monitor well exceeds 10 mgjL, this concentration will be Uiken to represent the naturally occurring TOC concentration. Any exceedances of this naturally occurring TOC concentration in the downgradient wells shall be subject to the additional sampling and analysis as described above. 5. Monitoring wells shall be reported consistent with the nomenclature and location information provided in this attachment. 6. A Corrective Action Plan was conditionally accepted by the Division on January 31, 2017. See Condition I.3. WQ0002806 Version 3.1 Attachment C Page I of I 3 q Farm Field Farm 3 Field G7 1�4 -Ed 3 d G6A I'm Journigan Ad EA Pearce Farm Field PF5 Pearce Farm Field PF6 n "mo5 n l Fieldd EJEJ5 E. Journigri Field EJ31a�. is &dIL_ ' r tiatulule, c�u::�w: r-:-;t �rkt�iutu:.;� E - W 4 Farm 6 Farm 6 Field VF3 Field VF5 6 VF4 Farm Field TO Farm 6 Field V t-, 0 kl%6 G18 Lloa R Appendix B: Industrial User Pretreatment Permit (Permit # 0112) www.dewberry.com Franklin County Public Utilities Control Authority and/or Municipality PERMIT Industrial User Pretreatment Permit (IUP) ` To Discharge Wastewater Under the Industrial Pretreatment Program 0112 N/A IUP Number 40 CFR Category(if Applicable) r In compliance with the provisions of North Carolina General Statute 143-215.1, any applicable federal categorical pretreatment regulations, all other lawful standards and regulations promulgated and adopted by the North Carolina Environmental Management Commission, and the Control Authority and/or Municipality Sewer Use Ordinance. The followine Industry hereafter referred to by name or as the permittee: Indumry name. permix : Novoz mes NA, Inc. (NZNA) Fao ity LmaW al Street A Fm 77 Perry Chapel Church Road - P. O. Box 576 01Y Franklinton stme. zip North Carolina 27525 is hereby authorized to discharge wastewater from the facility located at the above listed address into the sanitary sewer collection system and the wastewater treatment facility of the Control Authority and/or Municipality also known as the POTW listed below: IUP warm Aepwdtya Cvw mvm pawyW pname: Franklin County Public Utilities NPDES Number: NC0069311 W WTP Address: 1099 Lane Store Road ory. Slate. zip Franklinton, NC 27525 in accordance with effluent limitations, monitoring requirements, and all other conditions set forth in Parts I, 11, and III of this Industrial User Pretreatment Permit (IUP). Effective date. this permit and the authorization to discharge shall become effective at midnight m this date: 11/9/2018 Expiration date. this permit and the authorization to discharge shall expire at midnight on this date. 9/22/2023 GIM Sig lure Date signed Chris Dohe Director Public Utilities hidugtrial User Pretreatment Permit (1UP) PART I Specific Conditions iup., PARTA, OUTLINE A) TURBasid. Infofthation B.) 1UP-Modiflogtion Ristory C.) Authorization Statement Dz) Description of Discharges E.) Schematic.and Monitoring Lo,60i ' ons ' F.) Efflumil Li-liji(S & Mbititoriq, Rdquilvaients G.:) Winitions.-and Limit Page(s) dotes A. tUP BasicJnformation: Redeiving-C ontm.1 Autfiorlly & wmap-mitid-, POTW, JNFDd .Fr-an,klin.'QO.u,jty Public Utilities &pifal*liri Cmmty.,WWTP NCO069311 [UP Nanic: Novozymcs,.NA, Inc. 0.112 ]UP-Effr;r-fiviidate ,- Pipa INAIT&I,4jist-all regulated pilms: 001 lUP Expiiatidildate : kUP 466FR #.(if appt'icable.), or*N/A: oft 0/ - W,-02S N/A .)B.. lup. History: am pm am im Effective- Date. 1110hoi-8 819/2016 IV23/2014 -8/08/2014 3/17121014 MR Industrial User Pretre'affiient Permit (!.UP) FART I Renewal -or NI-odifteation R�de*A[ Modifidd Modified Modified Modil.-W fle Gotiditi Description of changes over previous -IU- V - -z nitm go: -.004A. Tit$ • match hAKc tip stir a Pi fidticfft. .2.fgr,.tfqge mt i tigeriie • Added. mass limits -'for total nitrogqn discharge to the Po,rw*. • Changed phosphorous- from a concentration'based . lirni,t to gmass based limit. • Added penalty clau.se.givtng the POTW diteqtor.authqdt�y to. cevoke or cvrtail permission to discharge in the event limits are. violated. o- Modifted deibitions.page. • Strettifiliried, *references td-POTW -and thd. SUO throughciut permit • Deduce ammonia lifiliL (tom 40 mo/L to -seasonal limits. Wirifer: Weeikly average 29.4 mgAL, Wnifily average 10.0 mg/L 0 : Summer: *W,&e.kl} average 15-0 mg/L,.Monthly average 5mg/L. • Change ammonia PREQU04CY-1o, Weekly • Remo ve.-teiting.rquireme.nt for acrolein, acrylonitrile; 2,4 clinitrophenoi and 2..methy.1 44 dinitrophenol. • FLOW limit ine.reAselfrorn*Q.400'to 0.525 OPD- • Sodium limit iifdease from-20.294-lbs. 00-rhorith icy 50,608 IN, per month' • C , opper limit increa�.e 'frdm.0'.03. rng/l to':0.05'mg/I- Potassium limit stays at-65,956 lbs'..* per -month • Montblyavera* limit on.Pplass'Whi 65,956 lbst per month 9P 00, . 000'GPD. • Monthly average limit on 8odium 202, .94--lbs. per month =200.nis/l at 400;0.Ob GOD. • Sdas.6nal. liKit feoni. October 31 to. APOI I forlurbidity, monitor Weekly with Kohtlily average lihfluif 1.5 NTU's. 3 P" bdu'strial User Pretreatment Permit (1-UP) PART I Specific Condiffons 9/221203 Renew4l -Removed Turbidity, 'Chlorinie and Daily Maximiim firnia. fti6reased Copper -to 0.03 mg/L Changed freque'pcy ofTenipeirat&6 to Quarterly, TSS and Aj WciWty, to Morithly. Now prameters--acroldin and gcryioni.6-i.le at 2Q.Q* ug/I., 44--dinfiropfienol, ind. 2 methyl 4.6 -din.itropfiekiol. it 500 ug/l. .-and antimony at I mg;1L. as per NPI)ES Permit NC4060.3.1 *1 Part: III* Other.RequiremenLs S&fion C. a.- Ty*pftraphida1ly.difor*Dri. limiL� pages corrected Modified ! o lncreniefftal FLOW ificeeas6: 0.3.25 MGD starting 1/1/7 . ,011, increase t 0.400 MGD starting 12/1/20121. Redu6 CU(cadmium) limit -from 0.01:2 to 0.008 mg/l... Reduci,- CU (copper) limit. from 0.04-1 to 0.03�0'mg/l. Re.dtift ZN (zhic) limit from 0.480 to 0.4 nigll Redqge, tnonftorisfg frequency to. quarterly fot the fbi'lowing parameters: AG (silver-), CK '(cyanide), BODS. NH3 (ammonia); CL (chlorine), and AL (-aluminum). I I/ U10 12 Modified Replace limit for AG. and.CL wift h MONITOR ONLY; :6/2712011 Modified Incremental FL. OW increas e: .0.200 MGD starfing -V 1 j/Z0 12 ijictease to 025- MGD stopting-7/U20IZ .Increase Copper (Cu) daily litnit to 4.045. Mgt[, monthly -average 0.036 mg/1. Iniffreasp Zinq (ZnY� aily. limit to OA Mgt[, monthly a'Vqage. 0.39 mg/l, 519/20.1 1. Modified Chloflnq-ihould be -listed as h grab 06t Wr6posite and Chlorine limit -change to.2.0.mg/L 10/5/09 Modified TL__ t4l aosphorus limit Monthly Avemgeof'1.5 mpfi.., DECREASING to 6.mg1, beginuft, L 1/9120"11 then DECREASING to .5 rng/L. beginning. 1'1/9420 11 -Daily. N14x. 18 /'I*Z 1 6 respectively: Fi'equeftcy —Weekly by I'UP M,0A - Opily, m4xinium-Ar .10.4 gpm Alki3lihity --Mdh116r Only Frequency Weekly by IL 8xpiration Date-,— from 013 W_b I I .to '0/22P20 1.3 -09/22/08 Modified P* Limits page relax 'parameters xm. c6pper, -'Wd, -nickel, Aly&, chtdrinb. and TSS4.als*u changgW sampling to "(Wjce'a month," Pant III Special Cot1diflbn.*2:i:hahgedt6 'Weter-shall tiave..aoptt)otiate.prdveilti.ve maintima6ce performed.at'least -every lZmbnths." Permit. Issite'd C. Authodzatio.n Statement:. LY The. Permi ttee is -.hereby .authorized to discharge wastewater -in - accordance. with the- effluent linfitaticins. monitoring toring rtqU'ire-inentsj and .all other cotiditioti8 set' forth it! Phis Industrial [.User Pretreatment Permii (1UP) into the.sewer collection. 5:stern- and wastewater. treatment tmelt facilityof the POTW. '2:.) The. Permittee is hereby- authQrized to. continue oper;ition of -and dikhakgp: -wastewatep from the following* treatment orr pretreatment facilities. Th-e8d fitellifies. must correspond to the treatment unitilis.tO -9r; both the appkicatibn -and inspection Wm . 4 as am A* a" am om a" am me ow am ow low Ift PM fam dm oft Industrial User Pretreatment Permit (1UP) PART I .80-effic ConditiOns :It Tin6Atme fit Units - List allTmAnimL Udits,I? cripfibds: - W T W ,aera yj s C"Pe Pretreatment - -.q i WUI" R&-,-.60men aqOT"igppmary. qp 01.. 4 ag 0 6a i F-f6i't qcin-,,Mtl asbirated`heriicA a m 66 moral 4 "S. -and". 1JUS .0%, -removig ­­* :.. � - - - - - -', - -- - -:ai m .6 ampeti k niC V-Xjj&� 'd rqn i'mg The.'Permitfee it hereby -aJuthbriz6d to,. if required by the.. - POTW and after. receiving Authorization. to Construct (AAo C) from the POTW., constmetand ,q . puate, ad4itiqna't ppetreatiftefit units as: needed to meet- final. efflaemt linfitations. D,) Description of [UP Nscharge(g)from- all regulated pibeg: S) SO =*abc- and Mwiftbring Locations: OnS: The 'facility schematic and description of monitoring location(s) given on following pages- must shoo* enough. detail such 'that someone udamiltdr With the f9dility could. readily ly fin. d and identify the mohitoHng.1mation(s.) and connection Ao.- the. sewer, It must. include.-and identify All. regulated -pipes. Representative sampling for Pipe 00 1 may - bd - taken from 2 'sample -point;. Sample -point A and/or sample point B as shown* on PART I Specific Conditiot1s;— Pjapt site Layout Plan (page-6). 5 t I `1 l 1 1 I l I 1 1 I 1 1 t t t i ! lu.l Q a d u"a1 INDUSTRIAL USER WASTEWATER SURVEY AND DISCHARGE PERMIT APPLICATIgI b T Q IUPAppkaflor Mank_aW_2012 pap sd2$ S 0.lr\ i V i 4 3 I I l . l' l; 1 I i 1' l' 1' I DAF unit s a a' m`, u x .T •fir .•�� Arw WON ,• r. Y .I All tit -.,.... SANITARY• SEWER SYS'i' At W ,AiA i�IAI MA! S'1J%01'• b� E =UFA .4 WAIM'" V47 VIVA T Ia. .R Wtrw FEAcv O nm' co 1'fir P1�:.....•n.. AF11 41/'HOW O L R ��' W. WOUMAL USER WASMVATM SUW& Alid tk$CfiARdF PMdXTAPPUCAMOM WASTEWATER L'itETRFATmr:NTSYSTEM f:LOWDIAGRAM (IFApp AMA:). LIC -PrOdbiS How diagram- MY — AA u d 4; bi .An ro S. AN lqu 04 t 404"'Rcku3v, A6nMwo Raga ro LOP c -W Ur, ZIP .9 IUPAPPIICSfiM-blv3*Lavr-2012 Page 0026 U) i W 51 I - I- I , I I I I "I - I i I I I I C S 1 Receiving PGTW.narh&=> Franklin County IU name => "N6v6zvines N A Inc. Public; iftitities. Receiving. POTW NPDES ## >yC00093:1.1 W..P # => I)12 Ef*tive•date fQr the$e:Limits =>9f22.2a .8 Pipe # => I1U1 .Expiration date fot these Limits >. 9l22/2023 40 CFR N/A if nit applicable put N/A THE LIMITS 4N' THIS' PAGE ARE, (Check one below): LIMITS for ENIME.permh period => INTERIM Limits.for•pg.iod #"1 => iNTEkIM Liinits fo*r period*#.2 => FINAL Limits. Pa 6 =5 X Monitoring Frequency Monthly" Avers. to Weeklytabomtoty Avers "e Unity By Indusa• . $ POTW SampleM. ethod ('Cum sosite ur'"Glab1 RecluiW 13e!tcrion Level 1 'Flow 0.525 Mob DOly Daily C 2 BOD TOU ingIL QuanerlyI-/6 months C* 3 TSS I50 m Monthly 1/G months" C 4' Tem "erature 40.0 CC Quart6rly :I/6 inonths. fi 5 PH 6 to lA S "ed-Units: ice er month 1/6 inoriths G 6 Turbidit 15 NTU Seasonal 10/31-4-11 Weekly 1/0 months G T Aluminum Moriitor m' haderl 1/6.rhonths C 8 Alkalinity monitor* ni L Mo6thly 116 months Ami ioriia 1.0.0 25.4 ' k 'vaeekl " 1./6`m6--thse C 10 ..Antimony 1.0 m Quarter) 1/6.months .0 1.1 Arsenic. Monitor- ni r . 9 uarterl y 116 -months C. 12 Ctidmium 0.008 m L • uarterl 116-moths C 13 Chramium 0.020 rn ' •• uaiterl 1/6:xnonths C 14 Conductivit 'Monitor` uhmos/cin Twice r month •1/6 months G. 15 Copper. 0.05 m L Monihl" 1 /6 -months, C 16 Cyanide. 0.010 mg... • .uarterl V6 -months G 17 Lead 0.01:25 rn uarterf 116.rnonths C 18 Mercury IVloiii tot m " •Quarterly 1 /6 months C` 19 Molybdenum Monitor Q'uartefly 116 months C ,20 moll. Quarteily1 6monihs C 21 T'otal:Nltr�•=:O ] $2 420 Lbs. i e7c1:'; 11.6 months C .22 Total •PhoS chorus 295 67 8 Lbs. Veekl . 1J6•mobths C .23 Potassium: -65;956: Lbs. er.month Weekly 1/6•m6nths C .14 Selenium- Monitor m-/L Quarterly •11b:months C 25 Sodium SU,fQ8. tbs, per month Week{ 1/6'months Q: 26 Silver Moriitor• m /L guarterly1l6.,:months C 2�. Zinc 0.39U ntg Monthly 116 months i C V fm am .Industrial User Pretreatment Perm -it (IUP..) PART I Specific Conditions G. Definitions and Limit Pages aotes.- in 10 the .:addition' ib the definitions in th Franklin County -Sdwer Uga* Ordinance-.(SUO), the .following: defiR'ition.%.--and requirements. apply: 1. Perin'tt issuing'authority Means Franklin County Public UtIl it tie' 9 2. Division or DWR means the Divigion of Water R-Mutc-es.,patt. of* -the sw Department of Environment and :Natural Rqwwm. 3. EMC means the North Carolina'Erivirotimental Management Commission. 4. POTW (Publicly. Owned Treattnent Works] .means. Franklin County Public Utilities 5, Ad of`th&-A-cV"the, Feder -at Water Pollution Cotmtirot Act, alga kn0 wil. as the Cle*aa Water -Act,. as amended. 33 USC 1251, PI 86 q. 6. Continuous, for.the pp�-pose of flow.monitoring, is a measure of c4schgge flow fropi the facility which occur.-t vithout interruption throughout the operating hout.4 of the facility. Ftbw-shall be monitored continually except for the infrequent diTles. when there may be no flow or for iffrequeiit thaitit hance activities6n the, qn flow device. 7.. Grab sample for the monitoring reqdirejbnts -of this. IUP, is defined hs'.-d.-single "VIO and take'-samplc.-collected at a representative point in the..dis-charge sn' eam. .9. Acompros.im-samp le, for- monitoring -requirements of this. IUP, is defiped as a -stfios- of grab. samOles'dollceted. at equal. iffid intervals durirrb.Ihe entire disch-argf, on the sampling. day .24 hours-.+/- hours). The .time interval -shall beat .: -( period Cr least:..ey. 45 minutes, approximately 100 nits of sample and greater than .60 p.ry samples per -day. The 'sampling -day shall be typical production* And di.qchafge. ;day.. 9. Daily- M-orfitoritig FreclutnCy, as specified .in this IUP shall mean each. day of discharge... 10.t/6.*montiqM*onitort.nzFrequency as, spePif,�edintkTIqIUP is deNinedas. sampling to be condbded- during the. monthsofMarch -and September. I L Quarte.rly.M.6nitoring, frequqacy- as.s.pecified hi this [UP- is d6fined -as.sAix1pli4g to � be -c6nductedquarterly -ag one-24-hour composite sampling period durihg. the months of January, Ap6l, July and Octobqr. Ow 1 *1 oft Industristl User Pretreatment Permit (IU.P) PART I Specific Conditions 12. Monthly Monitoring Frequency as.specified in this IUP- is d6rine'd as sompling.to be doncluded * ondily'as Otie: 24.:.hOti.r'compo.9ite sainp ling- period during all twelve calendar: months.. pnftqfirik at. Iei;:`oric:yveek:{defuied as Sundayo .. hy A Iv. - po c th ute *-ax.-one- ou .. 14. Andngtantancou$ specified -ia this IUP is defined as a single . m�asuremetit as spep reading, Qbsdrva'fion., OTmeasatenief)t. AM Om #wk Om Im am OW PM 12 hidiistrial User Pretreatment Pprmitliulp) PART II General Cmdifions Outline. of. FART 11, I Re re�ehtaffve Sampling . P - 0 16, Federal arid/or 8tdteLaws. 2:. Reporting 17. Penalties 3. Test Procedures 18, Need to KAU or Reduce .4. Additional Monitoring -by 19. 'Transferability' Pemittee 5. Duty to comply 20. Propetty-RitrIlts- -.6. Duty. tq, Mitigate 21.. Severabilit y 7. Faciiiiies-0 e.r ation, Bypass. -22. Modification,, Revoc6tion, Termination 8. Rem&&d substances 23.. keapplication 9. Upset .Conditions 24. D'Hutiori Prohibition I . 10. Right of' -Entry 25*. Reports. of Chiaged Corididofts I.L. Availability of kecords4 2.6. Construction of preircaitment facilities, 1. 2. Duty - fo 0rQvide information' 27. R-topenia 13. $ighati)ry R6qu*L'rdt'n&ftt& 28*. Categorical ftopdner 14. Toxic. P61.1pta0k 29.. GOneral Prohibitive Slandhr& 15'. Civil -and Criminal -Li.ability 30. Reports 'of PoUmtial Noble ms. I., Representative Safnpting Samples and measurements tAken ag required her.eih shall be represeriftitiVe of the -volume and.natute-of the moftitore d-distharge. All gamples-shall betaken, at the monitoring points s ceffled in this -pprinit -and Junjess otherwise specified, b0bre the efflu�ht joins or is 1 .p. - . .1 diluted by any other waste stream, -body of water; or substance. Wnitoring points shall -not. be changed without notific4ion,io -and -approval. by, the permit issuin&-authority. 2. Repad-ng tO Monitdring fesults obtained by th&-peribittee shall be reported on forms: specified by the POTW, postmarked' no -later than. the twentieth .(20). 04y- O'f the triobth fbtlowi n*g the month in which the samples were taken. If no discharge occurs. during a. PM feportihg period.(hofeift d6tified.-as- each calendar month) in which gsarnplingvvent was to have occurred:,. a form with *fhephr.as�e "no -discharge" -shall. be'-subti-afteO.. C-.ppi6§dfthes6- and all other reports required hereijn -shall be submitted. to the-0.01V and- shall ])&-sent to.. thefdllovving address:. Pretreatment Coordinator Frahkiiii County Public* Utilities t630 US Hwy, 1. Y.QungsvWe,:NC.27596 am 13. on WIPS.MW U*ger Pretreatment Permit (j'UP) 'PART 11 General Conditions If the. sampling; performed by the pen-nittee indicates a violation, the Permittee. shall nPO fy. the PUM within 24.hours of becoming aware of -the violation. latibr, The* Octni ittee .§hal I also. reipdat:fhe sampling and atialysils. and submit -the -resLilts-of the repeat analysis to the POTW . wit . hin-30 . days after beQomtn*gaware 6 f 'the Violaition, . 1; Test Proce.dures Test. procedures for the analysis Q.f. pollutants shall b pro a e performed- in accordance with- the. .prol. techniquesprescribed in.40 CFR part 136 and amendments thereto unless specified otherwise in the monitoring conditions of thispermit. 4. Ad&tion-at. Monitoringby-Permitiee If f the -permi ttee -monitors any:pollutant at the -locatibri(s.) designated hbreinmorb.fTequently .04'n. required by -this permit, using approved analytical -methods as specified .above, the results*of.such monitoring shall -be. stibmilted to thePo'rw. The POTW-mayreq . uire more . e . -frequent.-monitoring. or the. monitoring. of -other pollutants not, required in this periTIit by Wfitten notification. 5. Duty to.Comply Ttie permittee: must- eomply with A I conditions ofthis--perijijt: Any permit noncompliance qqnsiituteg- a vidlatt"On of the SUO and is grounds rounds -for-possible :enforcement action. -;ti' - 6. Duty -to-.Mi gate. r Ptevetitio*n of Adverse Impact am The permitted. shall Lake all reasonable steps 'to minimize or prevent any discharge in OW violation of this Permit which has a reasonable .likelihood of adversely affecting human health,, (he POTWi -thd waters'teceivi rig the POTWs discharge, .or the envirorunent.. IM 7. Facilities Operation, Bypass The peribittee gh-alf-at.-all times maintain iti good working otder and aperatia:as. efficiently .as possible, all control facilities or systems installed or used. by the piermittee to aeffir"eve. am carqpliance With the terms And conditions -of this permit. Bypass of treatment facilities is: .prohibited -except when approved in advance by the POTW. Bypass -.approval.. shall be, -given only' -when .such bypas's -is in.cpm.plianck! with 40 CFR 403.17. 188� S. .-Rethoved.*.S.pbstanc'es $61ids... sludges, -filter backwash, or other pollutants removed in the course of treatment or OW -control of -wastewaters shall be disposed of in, a mapticr such. asjo prevent any pQllutants- frdrn such ffiatefial§ from entering the. sewer systejn. The permitted -is responsibl'd for -assuring its compliance--withany requirements regardiing the.generation, treatment, storage, am and/or disposal of "Nazardous-waste"as defined under the Zdd'eral Resource C' bosefvation :arid Recovery Act.. 9. Upset Conditions '0" MW 14. PM PM Industrial 'User Pretreatment Permit(luj?) TART V General -Conditiofis - An "upset" means an exceptional incident in which thefe ig*,aa unintentional and temporary aonc6mplihrtci,- with the categorical pretreatmen.L.siandards because- of fiactors boy..6 nio the reasonable control -of the pennittpe.- An upset does, not include a6ndomplilafiCe to the extent ccaused by operational error. i jmptopprly designedor hiadequate treatment6cilhies, -lack of preventative -modritenatice, or carless or. improper operation An­up�set may constitute an affirmative defense for action .brought for the noncompliance. The permittee has -the burden of proo f to prOide. evidehce and d6m6osteate thit none. of the factors specifically listed above w0e -responsible for .the.-noricompfiancP. 10. R-.�ghvof Entry The- �pertnitre& shall allow the staff of the. State of 'North Carolina D .i.vis'I on :of Water Re. sjources,:the- -Regional -Admihistrator of .the Environmental ProiectiQt! Agency, t4e staff ofthe POTW, ArrcVor their authorized- representatives, upon the. present6tiopresentationof credentials: 1. To -enter upon the..perrpittee's premises. where a rP41 or -potential discharge - 'in terms and conditions is located or:' -which records. ate, required io, be. k�pt. u.der the. jern of this permit; acid - 2.. At reAsdriable.-fimes to- haveacdess to -and copy records.required to be kept -under the terms and conditions -of this perrnit> to inspect any monitoring equipment or monitoring.. method required hi- this permit, and to - sample-' any dischatge of an pollutants. I L. Avai-teibitity of Records and Reports The permittee shall retain records of all njonitoring.. information, including ill calibration and maintenance rdcot&.*as Well as copies of reports- and information used to. tornglet'd the. applicatioti for this Peniiiit for at least three years. AU records tfiat -pertain -to matters. ilia! are . subject to any type of enfbrc-dn!ei!ifiction shall bo retained and preserVed by the. permittee untlLall enforcement aiDtivities. have.c. wiciuded :and dIf.Perio& orlimit'Ition with - respect to any and all appeals have expired. Except for data determined to be coafiden.ttiail tinder the SU;O, 411 reports. prepared in. :accordance ..with .tenus -qfthin per' it shall be-availableFor pub] is inspection at the Control M A-Lithority. and/or Municipality. As required by the.. SUO; :effluent data shall. not be: -considered- confidential. a" MM 11. Duty to'Provide 106nnafi4jn. MONA The permittee §hal.1 furnish to. the Dirdotor of Ptibtio- W.Oeks*br'-his/her d6sighees, within. a - time, any. information which the Director, his/her .deslignee; or thr,:.Divigion of 15 WR Industrial User Pretreatment Permit (IUP) PART 11. General Conditions Water Resources -may request to determine whether cause exists f0i modifying-, -revoking and reissuing, or terffiipating this. permit -erto determine -compliance with, this permit. The. permittee shall ialso furnish; upon recLmst, copies of repards required. to lze kepi by this .perrriiL 13. Signatory kequtrements. All reports or: iff6rmatiQn.-suhmitted pursuat*W the requirement's -of this permit: must be, signed* and certified by -the- Mthbetzdd Reoresentative% as defiried'under the-.SOO' ' If the. designation of an Authorized Representative is poJonger.. accurate because a different .individual or position has.-reispdnsibiljt-y for the overAll, operation of the fk6lity, -or over-al.1, responsibility f6r brivironmbntAl matters for the company; -a new authorization -satisfying - Y authorization -the requirements of'this seciion must- be submitted. to the POW. Dif6dor prior to or. togdther. with any repbfts to be signed by ad' authorir/Wd represefttafiivd- 14. Toxic PoIlLitants 00 -if 4 -toxic. efilgent standard. or prohibition (including Efhy schedule of -compliance s*eeified -in--sueh-efhttt;nt Standard -i)r prohibition) :is established. under Secflon-"307(g).of.the-Federal. 'Clean Water Act. for a-loxic. Polluiant, which is p0s6nt in: the dischafge, a such standard su h 0 '" :or pr6hibitkQn is more strifiggent -than any litnitatioin tot such pollutant'in this per MIt, this permit nay be revised or modified --in -acordwe with the toxic effluent. standard or. prohibition and. the- perrnittee s6.. no.ti ftied. IS. Civil and Crimiiial Liability Nothing in this pemift 4.hall be c.qin§Iriidd Ib 'relieve the peftnitfe e*- from civil br `orimil.idl. penalties for noncompliance: 0. Federal - and/or` State :Laws Nothing in this .permit shall be -construed to'preclude th& institution of any.ltg4t action of relieve the- pemnittee from any responsibilities, liabilities, or penalties, establiMied pursuant to any -applicable federaLihdlor`state law or regulation. IT Penalties The 8-U.Q. County provide,s that any -person -who violates a permit -condi.flon is subj*ect.tp a Q'Ivil penalty not* to ekce6d $251000 dollars per day bf 'sddh violation'.. on In. addition, The -POTW Direictor mAy fpr go.64.caiise revoke a wastewater disch4rge permit am or perinisgion :to discharge for any -of the.fol[k)wing reasons: (1) Faiturd'to 'accuriitely(epdrttlTe-WastdWateecoiistituerits-6ndchcir-adtefistic.s' 'ot­ ihe discharge; (2)- Failure. 'to -report .significant changes in operations,, or wastewater. slewater constituents and characteristics; (3)* Refusal of reasonable 4ccess:tQ the use'e's PTOM'i8es for the purpose qf inspection 'or- monitoring; -or, (4) Violation- of onditions offfie pen -nit or permission to discharge, cond4ioins of the SUO, or any applicable state and federal teguladom 07 IndustrigI User Pretreatment Permit (1UP) PART'll General Conditions Noncompliant pliant industrial userswill be notified- of the. proposed -termination of their- am wastewater- permit -and will be.-o-ffered -an oppQqunify io 06.mqqstrat&-why- the. proposed action -should. not be tdkdri. it is the responsibility of the holder of this hermit to deliver pretreated wastewater within the eM uerit lithits prescribed in The POTW is not-requirod to. accept any wastewater tivhich-.contains--e.foueiit.l*imits in.excess-of such limits prescribed imthis p1prMiL Up -on notice to the -perthit-holder, the POW has the right and option, ion, to OWW'Lacceptainco- a r sewer now rrom.* the permit whenever There has been a violation of "the effluent limits of this permit, incl.tiding delivery of floW-by the permit holder that causes or contributes to the POTW violating or potentially violating: the.. loading j i6mits: imposed on the POW fc!r..itsdischarge at-its..approyed.(Qeat!Qn. Any curfid1meni shall be for. adur-Ation -and'in a yokirno or-Arriount,. in the-.soledisefetion of the POTW; deemed sufholent -for- it- to rernaln incompliance with. any -laws-i'mpQsed on it.Qr with agreements -to whicih it is party. Should the POTW exercise it. - right and (50flon to iMpose.-Curtailnielit on th-6 h6lde'r*aFthis permit, the POTW* may thereafter grmdubilly or all at once resume acceprafteo. of Row OM provided. -the pi5mift holder has.satisfied the POTW that the holder is:abLe to discharge within the efftutint limits prescribed herein. Under stak--:'Iaw, -(N . C G-S 143-215.6B), under certain cite-umstaftees it.-i Sia crime to violaw am terms..Conditionsix requiremen.6,of pretrogtoient,perni-its. It is a crimp to knowingly make Any false statement,repkesentatio'n, 'x')'r -certification in record or other document submitted. or required. to he. maintained' under --this permit, inctudi ng monitoring -reports or reports of compliance or -noncompliance. These crimes are enforced 'at the prosedutQrial digerei(i.oh.-6f the.. local "District Attorney: 19. Need to. Halt or -Reduce not a Defense It shall not be-A&fense for -a..permitte e. in: arL-e.nfQrcement.aqtjon that.. it wpv[d have necessary to. halt or reduce the permitted. Activity tQ maintain compliance with the Onditions:of the-petinit. M Trans ferabi 11t-Y A I . This permit. shall not be re Or t' fisf6ftdd or -�bld to a new goed now- user, - different premises, or a new or changed operation' -without approwil of the POTW. '20. Property Rights This -permit does --not convey any 'property rights in either real or personal property; or any explusive privileges; fior does. it authbri*?:e-any injury to private pro p*'eitt' or d ij� invasion of .y personal. rights, nor any infringement of F edoral, - State -or local laws or regulations. amZ L Severability The. provisions..of this -permit are severable and, if any prQvi0qn of this pennit- or the applieatio.4 of any provision of this' permit to Any' circiarrig%nde is- held invalid, the 4pplication Of -such. provision to other.circumstances and. the remainder of this permit shall nett he affected thereby; 0 ml� PMR P-1 Industrial User Pretreatment Permit (IM, low PART 11 general Conditions 22. Nrm'it Modification, Revocation, Terint-nation This -permit.may be modified'. revoked mid reissued or-te miindted'With.cause i*ti acicordanc6 t4 the rNuirdifierits of the SUO'afid North Carolina. Cjenera! Statup4 or- implementing regulations.. .23., Fie-Applickion for Permit Renewal The per M."Itteels responsible for. tiling an application fdr reis_suanoe ofthis permit-at.least 810.diaiys prior to its expiration date. 24. 'Diju- tiob Prohibition 0" P" M 'Yhe permittee shall not increase .the ,use of potable or process water :or in, any other way. :attempt to dilute theditcharge as -a partial or complete--subsCktute fbr adqqu4tdJreAfrfieftti to achieve -com 'I iance with the limitAtions contained in. this permit,; OW P 2-5. Reports of Changed Conditions. `The p.egmittee shall give notice -.-to the POTW or any planned .significant change,5 to -the WR pdn-nittee'§ operationsa volume- of its ot system which might alter flie nature, quality; wastewater at least 18 .O'dqg before -the Ogngp- The perMIttee, shall .not be * gin the changes until tweliving. written 4ppfoval fimrri the Control Authority and/,or.M(inicipalilty. AIS-0 sci-.. OR Part 11, 30. below 'for additional reporting itqAire'rnents 6dr spiU/slugt issues. No 25. Reports o-f Changed Conditions Continued OW SigniCid"Ant changes rnay include:but:are.not limited to (a) increases or decreases- to PrOudtion-, (b) increases in discharge -of previdusly reported pollutants; (c) disthargp of pollutants not previously report ed to,: he. Control Authority and/.or Municipality; (d) neO or changed product thics; (e) new or ohanged -manufa-etming processes and/or chemicals;. or (J) new or.changed- customers. :2*6. Construction 19'0 cQn5truction of pr.e�treatmem facifli*- or -additions thereto- shalt be begun until Final Plans and Sp9clificadofts- have been -sub M*itted to the POTW and. Wriit6n ­hpptcival aild: an .Authorization to Construct (A to C-) have: been issued. 27, Reo'p en-er The. permit Shall be rhodified or, Alt6rhadvely, rev oked and reissued to comply with any .appficablb effluent -siandard or 11mitation for the control of any pollutant -shQwn -tq: contribute to tokicity of the. WWTP efflueot or -any pollutant :that "is otherwise limited by PM4 Indus tria[­Mer Pir etr-eatment Permifj PART 11 General Conditions tha-POTWdischarge permit. The permit as- modified or reissued under this paragraph may. also :contain any other requirementt or state br federal gretmeltme.nt regulations then fool applicable.. a" 28'. Categorical Reqpefier This p `ermit.ghall be -modified, or-edt6tnativ6ly, revoked and reissued, to comply with 'any . applic"'Able -effluent. stAridard or limitation -issued .9r. approved. under- Sections 302(b)(2)(C) and. (1)), 304(b)(2), And 307(i)(2) of the Clean Water Act., if the effluent .standard or, limitatioft so isgutd or approved: L) tontains diff-emit conditions: or is otherwise more stringent than any effluent.* I imitation.in this ppribit; pr 2.) controls any pollutant not limited in this* permit. The. *pdrmft as moditied or -reissued under this paragraph. shall also contain any other requirements. of -the.. Act then applicable. 29. Gen&­al.Prohibifive Standatds, The pernlitt,66 shall comply with the-gbiietal - prohiVitive discharge. standards. -in 4o 1C1{R 4015 (�) and (b) of the Pedeml pretreatment regulations. 30. P6teftfiaI'Probferns "rhe permittee shall' provide protection 6c..)m accidental and slug discharges- cif -prohihi -prohibited. qiateriaU-and:-o(her. substances regulated by this pertnit. The pemiittees.hall. also notify the PUrW immediately of -any cfiandes.aLfL%* facility affecting the potential for spills and other I? accidental discharge, discharge of a non -:.routine, episodic. nature, a -non-customary bath discharge, or a 41ug load 4§ defined. in the, SUO_ Additionally, the permluO6 -shatt notify by telephone (lie POT-W Iminddiately of all discharges thm-could cause. ptoblietus to the POTWi-inctuding any -slag loadings -as defined in: the-.$-U'O.- If the petrnittee *experiences strqli-:a di�qharge. they shall inthe-POTW immi�digt6ly upon the -first awareness 6P-th.6 commeincemient of the ditehaege. Notification on shad include location of t1wdischarge, type of waste,, concentration and volume -if kliovAi and co'rrective actions- taken by the p6rnifttee; Awrittetifo.lt()w:-up.report ther6of'shallbe -filed by -the p6niiittee within five.-.(5) days, unless waived by the POW. no am MR 19 MR hidustrial User Pretreatment Permit (1U.P) Part III Special Conditions 1. Slug/S .pill Qontrol Measures The permittee shall piOWtd protection ft6snaccIdental and slug discharges of prbh-ibited. materials 'arid other substances -regulated by this.-perm.it. The plan. shall include, but is -.not limited to: description of dis6har.,gre practices, inotudino- hat non- -routine batch discharges; . . . gi*, description of stored c*hernicals,. procedures for.irnm6diate�ty notify [Kia, the POTW of slug. discharges. that -wouldcause a.*vibldtition of 40 CFR 403.5 (b)., with procedures. -for -f011OW Lip notification- within S. days, and if necessary, procedures, and :if necessary, procedures io prevfit 'adverge, impact froth accidental spills, including.. inspection -and aftamitehatice: of* storage .-areas, handling and -of materials., loading. -and .unloading oper4tions, com.rol. -of plant. site runoff; worker training building of containindfit. 's:ft*4ctu.re,. or' eqtdpment , tnegsdres, for -cdntdimng .- `toxic' ic' OW organic. pciflutahts (including solvents)*. and /or measures -and. equipment for .emergency response.. th addition. to the requirements in -.Part 11, jO, the Permiftec shall maintain, update and subh1it current revisions --and versi6ns.of the Novozytnd-s'SAfety,dbdumdnt. named "Spill -On-S ite" to- the PO-1r*W. W" The, ;brihittee shall P pfbvide.-Lipdates to'Ranklift County as -required by Part 11, 30, .of this* 1-UP. Modifications to the measures shall be.- approved' .y b t OW Franklin County prior to. instdilationlioole'ni6jit-Ati6q. If -a ineasitrd- tails, the Control Authority shall be. notified: -Within 24 hours. udgewllariagemertP: -3. Flow MeAsur'eMq,,1at R-eqLkir6m6nts, 0" ... ­1 .. - - - - ..... OMR F—M am The permitieeAall maintain -appropriate djsr.*hEtrgeT1oW i-neasuremerit n devi6es and *hods.- consistent with approved scientific practices- to ensure the arcutao-y-and reliability of -p measurements of the volume of monitored. discharges. Devices installed shall be a on .. continuous red&ding flow meter -capabld of measuring flows. with a itaximum, deviation* of less than 109/b from true discharge rates throughout the range. of expected discharge volumes. The devices ices shall be.installed, calibrated, -and mAintaifted to-.enSuri_--:accufacy. At IN" the time bfissuzaice-.of the permit -,.-'this method consists of MAGNETIC FLOW METER. The meter shal.l*ha.ve, appropridtc-preveilldtiv.e.niaintenance perforrridd -at-least ovcry twelve PM (12) months, 'Modifications to the flow metering elqtlipin. etit S'ha-11 *be, approved by- the am 20' OM a" - Industrial User Pretreatment Permit -(RJP.) p9ift III Spe..e al C4nMtions an POTW prior to installation. 16tion. If a required flow. measurement.. device 'fails; die- CQ1100,1 Aui 'hority shall be riotifie d within 24 ho&s.. am 4. Certified Laboratory Analysis Pollutant. analysis. shall be: performedbya. North Carolina Division of Water- Resources Certified Laboratory thatlis cerfifted- in the.'an-al . Y.s.is-of'thepollut-apt-inwasteWgtti,. mew5. Laboratory Fees and Administrative: Charges /.Su*r-chargds-- The pertnittee -shall be -billed for ;all. Laboratory fees associated with FrajR**kl.in CountY's cpmpliamce- monitoring, of the periiiittee-. The. pet.mittee- will be. bitted a monthly Administrative 'fre of -$100-00. The. permittele . . . will be surcharged .for any overage o.. .4LIowahle limits pet the S.TJO. -6. Certified Operator an Pursubint to: Chapter 00A-44.,of North Carolina General Statutes, and. upon -class iricatimi of the, facility by ihe.'Certification Commissloin, th6 * eradmm shall employ a certified waste p - OY , water pietteathidiit- plb:nt operator in te9pOnsibility. charge, (ORC) :of tho wastewater- „„ treatment facilities. Such operator - must. .hold a. certification of the ty-p'' e and grade equiValent U), or areattr that jhe. bltssifidatiori- assigned to. the.- wastewater ttcatrAent- zgtion Cbmm'ission. The. pprinitt by the Cetiifii. pe must also employ . -a certified :backup..op6rator of the appropriate' typt: and'arde to comply with the conditions of Tide 15A, Chapter 8-A .0202. The OkC of the facility must Visii. the wastewater facility as.. required; must properlymanage -and docunii0t, daily operatib.ii anti. maintenlinco of the facility; and must:comply with all other. conditions, of Title 15-A, Chapter.8A .0200. The. permittoe shall sub.mit a letter .designating the: operator in responsible.. charge to the. Re ' m-M*rication. Cerfirtc6fidn Commission or their d6sig it� withixi'thir(y days after facility cl 1. Attachment from NPDES N C00693 1. 1. Part H I — Other Reqyi'reirhdrits, -Sdetibn. 'C." 'Municipal Control Of Polttita.hts from, 1ndu§tt-ial Users-." MR 014 0" am 20 ow Industrial User Pretreat ' P me'hf ernitt (TUP) -Part. Special Conditions 7 2b nsn Industrial user Ptetreatment Permit (IUP) Part III _ Special Conditions NPbES PetmitStandardConditiOh$. Pcgc 'I_S of I$ Section H. Nhliclv'Q%Mned Treainient Works (POTWs1 am All p01'Ws Must provide $drgttatc notice 16 fire Director of the folloniing 14. CFR:122.42(b)j: 1. Any new introduction Of pollutants into the POTW front art itidiieei:discliacgef, regardless ofdie. means oi' transport, Which would be.subjeci:`tb secildn AI or 306.OfCWA:if it were.directly,.dischargingfhose ppliytQu�s; and 1. Ar y iubstaritial chinge in the•voldmic br character•oFpoltutatits;being•tntroduced by an.indinct:discharbcr as: influant to titat.POTKr at the ttmt: of issuance of the pennit. 3. For 0ur09ses.of this'paragrziplt, adg4uate notice shall Include information on (•1 j the quality and quantity o(efiluent. introduced into the POTW, and (2) any anticipated impact that may result. from the dtAnge of the quantity or quality.of c#iluent to bc:discharged f nt.the FOTW. Sec{tan C. Maildnal tonWol or Foll4tants-from indtastrial ilsit-s.' 1. 'Effluent limitations ara listed7it Parr I tifthis;peratit: Othdr'pollutana attributable fa inputs from Industrial Users• Moo discharging•tb•the POTW* May be.presetit in the Permittee's dischargi Ai such time as sufrcienain6tmation becdmrs availablc.lo: establish limitattions for such pollutants,.this permit may be reyised.lo'spt cify bmuenl dimiwtibns for any ar all.bf such other, polhitan s itt accortlaitee with best prat:tit:able technology or water quality. standards.. . 21 Prohibited Discharges. a. Thi-Pixmiftee ihilldevelop s ld enforce their Pretreatment:Program to im Ardent the proliffi tiott aguibst the introduction otpolfutants or discharges�into the waste treatment systimorw"te eolledioKsystetti Aich . -cause or contribute to Pass" r1#ouglt:dr Interference as lief -tried. in *l6A t:AC 61H AM--and-40 COP. 463.. 40 b. The Pi r ttittgeshall develop and txi('orce their -Pretreatment Program to implement the.prohibitlons against the intritductiott of the €allowittg•aastcs in the waste gninient or waste eblledtidn.sgsteit} [40 CFR4il3.5(b)j: 0) Pollutants whichAreate a fire or explosion hazard in the POTW. iricludirig; but not liriiited.to. wastesweems with. a closed gup Gashpoint oriess *an. L40 degrees Fahren6it or 60 degrees Centigrade• using the test.me:ihodsspecifid'd•iii 40-dik 261?•1, (2) PoUutants:whibh cause•conrosive structural damn& fo ahc POTW,.but in no case discharges'wlth pH lotvet than d.6, unless•,the wo& is•speclftcally designed to acccmma41e•5uch'disciiarges; (1) Solid ar viscous polhttants in amounts which causcobstructidn to'thc flow ilt:thc FOTWji:sulting:ia lnterferennc;. (4) Any pollutant, indlud'atg oxygen demanding pclluiditls (BOD, etc.) released,in'a Disclwge at •a flow rate and/or pallutant concei tratiod which will cause interf6rence with the POTW; e� (5) Heat in.amounts %thich:will:inhibii biological activitY•in.tlie l'OTW resultingin ltuerference, but in'ao case'hcai iti'such•,quantities'that the temperature at the P&W 'Cre9tatent•P.lan4 �reeeds 44°t:.(104°F) unless the. Division, upon request of the POTWapproyes alternate tempe�attire.liibits; .(6)' Petroleum oil, non -biodegradable cutting oil, Or praducts,,ofmfneral oil origin•in•ainounis thai will cause fnterrerencd or Pass Through; 'JM (7). P¢tlatatitst wttich.restilt in.the. .pre*ettce,orsoxic; gases; •vapors;. or fumes within the POTW in a quantity that titay cause acute. worker hearth and safety problems-, or (8) Any lr6cked.or Hauled pol lutants, except at discharge points designated by the POT%%,; Q. The -Permit tee-shalf i0estigaie•the.source of all discharges into the POTW, including 'slug toms and other am unusual discharges, hich have tfte potential to•adverse7y impat:t.the Pcirtiittee's:Prctrcatment Program and/or. the operation•dTthe PUTW. The Pet>iiittec shall icpbrt•sueh.dischargts into the F01 W•to the Director or the appropriatc.Reg1 hal'Otlibd.. Any•informatidn shall be provided orally within 2d hours from the tirite'lhe Perniittcc besra;ttn: aware cif the am circumstances. A wriuen submission Shallalso 6n: pro' yided 1hithiii.5 days. of the tune die. Permittec becomes am am Vers`twi ?0! 1 Old 2a 0" 01111111 Industrial User Pretreatment Permit (IU1'j Part III •• .� S.peial Conditions _. am NPOES. Permit Stpdhrd Conditions Page 16 iif 18•: aware or tlic•circumstance3.11tc wrigen submission shall contain s dcscriptlon.orthc discliargg: the am investigation •hito possiblasources; die. period oftlte dischargc,•includlag exact datesand tildes; ifthe, disc�hafgr lid nof-ccased, tht: anticipated time it is:erliectcd to continue; and sups taken or'pldntted toxedacet elictiinate,.ati. prevent ieoceuitenee of thanonrrotnpliat' 3. iuith regard tp.thl:•efftuent•requiremcnU li$tcd in Part I oft his pcintikit may bznecessiiy*for the POTOittee to supplement cite requRenienis ofthe Feddal Wetreatmeni Standards (40rCFP,, •Part403) to ensure -compliance by the perrnincc -with ail applicable afiluent.limitations; Such actions 4y the'Perinittrc may be necasbry tngarditig somot or all of the indusir;e_e discharging.to the municipal sysiem. 4.. The Petmtlteeshal) require _pny Industrtal.User(I'U) discharging to iltc. P.OTW'.lo meet rederal'Pretreatment Standards,developi;d.urider 5ecticn'307(b)•of the -Act asamended (which includestdiegorical standards and. t� specific -local limits, best'ntanagerltentpeactices and nairalit++e requirements}, PtQF to arccpung wuge+vatar ffgm any 5igeifiddnt Indus&ial••Vso (SRA th&rPerrriiuce•sltalf'dititct:.aevelop and submit to the Drvisian.a,new Pretreatment Program or.as necessary; a.lmodifcadim of an'existing Pretreatment Program, for approral ss- rrquired under sdbdoa D b#lov�as *ell as 13ANCAC-.02H.0907@)•and (b).140 CFR 122.44OX2}j S. This permit shall1K modifpdj or altemativily, revoked and•rdliiued, to iticarporrile at modify an approved POW Pttreatment Program or W.include a cornpliance.schedule for the development oft POTW Pretreatment Program =.required underSection 402 (b)(8) of`tlie C•Wkand implementing rquiations.or-by the requirements of the approved State•pretreatment prodran)"M a' proprliie, 01111111 Section D_ Pretroa(ntent Programs Under authbrily, of scotions 367 (b) and tc)'and• 402(X) of the-CA'A attd implementing regulations 40 CFR•403, North Carolina Ocneral Statute 143-215.3()4) and.implertteittipg regulations. I SE'1 Nook .02H ,09¢0,and in'aFccrdetice. with,theapproved pretreatment pmgram,•all pravWd ts.and regulations.contlifned and ref4ranccd in the pre4tatntenl one piograw.suhmittai are an etifbrcesble part df diis perm$. (all CFR Ii144Gkj)] The Permiuee:shall operate its approved pretreatment; program•ih aecordartea With Section 402(b)(8)•of the.CWA, 40. CFR'403,1 SA NCAC 02H.0900, and the legal authorities, polieies,pi4cedures. and finano:lQ pjvvisions -coiifairied in its pretreatment program •submission acid Div'(siori approved modificatlotis thereof .Such operation shall include but -is t^ not 1im11ed to the implementation ot~the•fallo%ain$ conditions and requirements. Tarns udt:defined•ia Part It or P;�rl iv ofthis petmrt areas defined in 13A NCAC 02H .0903;an('40 CFR 403.3. 1. S45lgr_Use Ordinance fSUO) Tht9 Permittee shalt mdintain.aiiequate 4al.authority to implement;ts approved pretreatment program: ('I SA .� NCAC 02H•.0963(6)(32),•.0905 and .09W(6)(I');-40'CFR403.5(W) a6d•4b3.9(b)(1) and (2)j. 2: Tndltstri-a� W.aSse'SurvevilVNS') ., The Permittee-shall •implement air IWS• consisting•of the survey of users of�the POTW collection• s3stem or tieatrnent plant, as required by40 CM* 463.8(f}(2)(141H) and I $A NCAC 02H .p905 [also 46 CFR'l.' 2),440)(1)], including identificat;on of all Industrial. Users dtai may hav*van'impact•on tlte'POTW and the 6harectca aiiO. Wt uhr. �"'► 6f-061lutanti conidbuted io.the PO'T:'W,by these Industrial. Users and idcnliCcatibn of thosc. industrial Users meeting iftc de(utition at: SIU. Where the Pcnnittee accepts ►vastewatcr lions one or more satellite POTWs, the IW$ for the permitter shall address all satellite POTW services areas,. unless the pretrtatment program in those satellite service area 4adittinistered b�a separate Perminei: with an approved P.tetmatment Program. Tlte. � Permittee. shall submit o.summaO: of its •IWS activities to the Division ai [cut once every rive -years; and -as required by the. Division. the IWS subnitsston shall include a stintmary-.of any investig�liom condt4c(ed under paragraph C.2.c, of this.Pait. (1.5A NCAC 62H .0903(b.(i1),,p905.and .0906(b)(2), 4.0 r.FR 4031(f)(2) aitd 403.9)- 3� Mbnitbrine Plag The Perminec shall implement a Division -approved Monitoring Planlor.the collection of facility specific'data to ...� be used -in a•wastewater treatment:pjatil l)eadworks Analysis(HWA).for'lhe•davetopmeni af.sgEc(fic•pretrcatmarit; local limits. Eftluent.data from the Plan shall be reported on the DMRs (•s�• nquired*6y Pans*-II.D and NCAC 02H .0963(4}(16)..0906(b)(J) and .05A) End of ,Permit Version 10112811• .20 11111111 41111111 L----= Appendix C: Approved Corrective Action Plan Correspondence www.dewberry.com - Water Resources ENVIRONMENTAL QUALITY CERTIFIED MAIL Steve Stadelman, PhD Groundwater Manager/Specialist Novozymes North America, Inc. 77 Perry Chapel Church Road PO Box 576 Franklinton, NC 27525-0576 January 31, 2017 RE: Conditional Corrective Action Plan (CAP) Final Approval Novozymes North America, Inc. (NZNA) r Permit No. W00002806 and WQ0003487 77 Perry Chapel Church Road Franklinton, NC Franklin County ROY COOPER Governor MICHAEL S. REGAN Secretory S. JAY ZIMMERMAN Director Dear Dr. Stadelman: - On July 16, 2015, the Raleigh Regional Office, Water Quality Regional Operations Section received your proposed Corrective Action Plan (CAP) for the above -referenced site. Review and conditional approval for this CAP was delayed in anticipation of legislation (HB 765), which contains provisions to allow for monitored natural attenuation of groundwater at certain permitted facilities. - As described in Title 15A North Carolina Administrative Code, Subchapter 2L, Classifications and Water Quality Standards Applicable to the Gi•oundwaters of North Carolina (15A NCAC 2L), the Division's final approval of a CAP is contingent upon consideration of public input received following notification in accordance with 15A NCAC 2L .0114. Certified mail receipts were provided, showing proof of notification to the property owners and occupants potentially affected by the approval of the proposed CAP submitted pursuant to 15A NCAC 2L .0106(1), "using natural attenuation processes." Based upon a review of the information submitted in the CAP and after considering any public comments and the Raleigh Regional Office recommendations, I am hereby granting conditional approval to implement the CAP. The Division's decision is based on the information submitted in the proposed CAP and supporting documents, and is contingent upon the following conditions: 1. The NZNA-recommended approach is for selected area active remediation via groundwater extraction associated with Farms 1 and 2 and monitored natural attenuation State of North Carolina I Environmental Quality I Water Resources 512NSallshury5treet 11611 Mail Service Center I Raleigh NC27699-1611 919.7079000 (MNA) of the impacted groundwater found in association with Farms 3 and the Smith, .. Pickrel, and Alston properties and adjoining NZNA properties. The details of the CAP Phase I and Phase 11 are found in Sections 6.3-7.2 of the CAP on pages 36-44. a. Focused ground water extraction includes the continued extraction of groundwater via six (6) existing groundwater recovery wells located north of Farm 1, six (6) proposed recovery wells on the east side of Farm 2, and eight (8) proposed groundwater recovery wells on the north side of Farm 2. Further details on this are available in the CAP Section 7.1.1.2 on page 40. b. As discussed in Section 6.1.1, natural attenuation of impacted groundwater at points beyond the compliance boundary will require a reduction in irrigation rates ,. primarily to reduce total dissolved solids (TDS) loading. Reduced irrigation rates require an off -setting increase in direct discharge of treated wastewater. 2. The Monitoring Plan is discussed in Section 8.0. beginning on page 45 of the CAP. Tables .. 21 and 22 summarize the monitoring wells to be included in the groundwater monitoring program by farm. a. On Farm 1, Farm 2, and the Smith/Pickrel/Alston/NZNA Properties, all of the trend .. monitoring wells and the background monitoring wells will be sampled for Nitrate - Nitrogen and TDS annually. All of the new and existing compliance monitoring wells will be sampled for Nitrate -Nitrogen and TDS semi-annually in the first year, and ,a, annually after the first year. b. On the Joumigan and Goswick Farms where MNA is proposed as the remedial strategy, NZNA proposes to monitor groundwater for 5 years, examine data collected, r and report the findings to DWR. The existing and new trend and background monitoring wells on these properties will be sampled for Nitrate -Nitrogen and TDS three times per year. _ c. New monitoring wells will be installed on the following properties, as mapped in Figures 2, 3, 4A, 4B, and 5: i. Farm 1: 9 new monitoring wells ii. Farm 2: 6 new monitoring wells iii. Farm 3: 4 new monitoring wells iv. Smith, Pickrel, Alston, and NZNA Properties: 2 new monitoring wells v. Joumigan Property: 3 new monitoring wells vi. Goswick Property: 1 new monitoring well d. Known or potential water supply wells in the NZNA vicinity are included in Table 12, aaa and Figures 7 and 8. NZNA proposes to conduct monitoring upgradient of the Bowers, Burt, McNeil, and Goswick water supply wells as outlined in the CAP Section 8.1. DWR may recommend including the sampling of these water supply wells if any of MaN the upgradient monitoring wells show increases in nitrates or TDS over two or more sampling events. 3. The surface water assessment plan is outlined in Section 6.2 of the CAP. A surface water .. monitoring plan will be prepared and issued upon completion of pilot testing and the selection ofthe final remedial options. This CAP Phase 3 includes the development of full- scale design, costs, and permitting of the corrective actions. Approval of this CAP is •+ conditional upon receipt of an NPDES permit to allow for the treatment and disposal of contaminated groundwater, which is required to comply with conditions of 15A NCAC 02L .0106(e), and .0106(1)(1). .. WaS state of North Carollna I Environmental Quality I Water Resources 512 N. Salisbury Street 11611 Mail Service Center I Ralelgl% NC 27699-1611 919.707.9000 MaN 4. Approval of this CAP is conditional upon successful demonstration that NZNA can demonstrate compliance with 15A NCAC .0106(1)(6) upon completion of the surface water assessment plan outlined in Section 6.2 of the CAP. Upon receipt of additional information by our office, you may be required to perform additional monitoring, conduct additional site assessment activities, assess the performance of the ongoing corrective action, and/or evaluate the technological and economic feasibility of implementing a new technology at the subject site. If NZNA cannot meet any of the conditions described in Conditions 1 — 4 above, a new Corrective Action Plan may be required to meet the requirements of 15A NCAC 02L .0106. You are required by 15A NCAC 2L .0114(c) to notify all interested parties, as specified in paragraph (b) of that rule, that approval of the CAP was granted by the Director. Notification is required by certified mail and must be made within 30 days of receipt of the Director's decision. The above referenced restrictions have been determined to be applicable to the site and NZNA is hereby approved in conjunction with the CAP. A survey plat delineating the areas of contamination at the site and containing the information required in § 143B - 279.10. A report detailing the findings of the monitoring effort must be submitted to this office on or before the last day of March, July, and November of each calendar year. Failure to adhere to the requirements of the CAP and this approval letter may be considered to be a violation of the rules, subject to possible .. enforcement action by the Division. If you have any questions, please call Laura Robertson of the Raleigh Regional Office at 919-791- 4200. Sincerely, l . Jay erman, P.G., Director Division of Water Resources cc: Franklin County Health Department WQROS Central Files +► Water Quality Permitting, Non -Discharge Unit RRO files Edmund Henriques, S&ME, Inc. 8646 W. Market St. Ste. 105, Greensboro, NC 2740 State or North Carolina I Environmental Quality I Water Resources 512N. SalisbwyStreet I ]bit Mail Service Center I Raleigh. NC27699-1611 919.707.9000 Appendix D: DEQ December 14, 2016 BAT Correspondence Letter www.dewberry.com r IIIIIIIII PAT MCCRORY q,drmor DONALD R. VAN DER VAART S. JAY ZIMMERMAN Water Resources ENVIRONMENTAL QUALITY December 14, 2016 Ms. Angela Walsh, Environmental and Utilities Operations Manager Novozymes North America PO Box 756 Franklinton, NC 27525 Subject: Second Request for Additional Information NPDES Application NCO089621 Novozymes North America Franklin County Dear Ms. Walsh: The Division received your additional information in response to our letter from August 9, 2016. The additional information document referenced the Tar Pamlico Phase III Agreement as the basis for justifying the proposed total nitrogen (TN) limit of 6 mg/l and total phosphorus (TP) limit of 1 mg/l. Page 15 of the agreement stated that new discharges of any kind receive 1 mg/1 TP effluent concentration limits if they exceed 0.05 MGD permitted flow and additionally 6 mg/l TN effluent concentration if they exceed 0.5 MGD permitted effluent flow. However, the Phase III agreement referenced in your letter is no longer in effect and the Phase IV agreement approved in July 2015 no longer includes the referenced statement. In addition, 15A NCAC 02B. 0229 states that TN and TP limits for new industrial discharges that have permitted flows greater than 0.05 MGD which are not members of the Tar Pamlico Basin Association are to be established based on BAT. TN and TP limits of 6 mg/l and 1 mg/I apply to domestic POTWs. The application does not demonstrate or support that 6 mg/l TN and 1 mg/1 TP are BAT for the proposed Novozymes industrial discharge. The permit application must be revised to include a complete BAT analysis. The development of limits based on BAT is a case -by -case determination which is dependent upon the characteristics and treatability of the specific industrial wastewater. The BAT analysis should include evaluation and discussion of the industrial process involved, wastewater characteristics and treatability, wastewater treatment technologies evaluated, proposed treatment and expected reductions, and a comparison of the cost of treatment alternatives considered. Treatability tests must be conducted unless sufficient data from treatment of similar wastes are available. For industrial wastewaters it is important to consider the complexity and the nature of nitrogen compounds (i.e. refractory or non -refractory nitrogen components) and clearly demonstrate that the industrial wastewater is amenable to treatment under the selected treatment technology. Sate of North Carolina I En iro memal Quality l Water Resources 1617 Mad Service Center I Raleigh, North Carolina 27699-1617 919 807 6300 Oft Page 12 Please reply within 60 days of receipt of this letter. If you have any questions or require more time to complete the BAT analysis, please contact me at 919-807-6387 or email at teresa.rodriggezQmcdenngay. am Sincerely, am Teresa Rodriguez NPDES Complex Permitting Unit Division of Water Resources/NCDEQ cc: NPDES Files Katie Jones, P.E., Dewberry Engineers Inc. Appendix E: Novozymes September 75 2018 Correspondence to the m Division www.dewberry.com In" am novozymes- Rethink Tomorrow September 7, 2018 Via U.S. Mail and E-Mail Jeffrey Poupart �., Water Quality Permitting Section Chief NCDEQ - Division of Water Resources - 1611 Mail Service Center Raleigh, North Carolina 27699-1611 jeff.poupart@ncdenr.gov Julie Grzyb �. Supervisor, Complex Permitting Unit NCDEQ - Division of Water Resources 1611 Mail Service Center Raleigh, North Carolina 27699-1611 Julie.Grzyb@ncdenr.gov Teresa Rodriguez a.►. Complex Permitting Unit NCDEQ - Division of Water Resources 1611 Mail Service Center Raleigh, North Carolina 27699-1611 teresa.rodriguez@ncdenr.gov Mike Templeton .. Water Quality Permitting Section NCDEQ - Division of Water Resources - 1611 Mail Service Center Raleigh, North Carolina 27699-1611 mike.templeton@ncdenr.gov so RE: NPDES Permit Application NCO089621 Novozymes North America, Inc. Franklin County 400 Dear Mr. Poupart, Ms. Grzyb, Ms. Rodriguez, and Mr. Templeton: This letter follows up on our meeting that was held on Friday, August 24, 2018 and my letter to you dated August 30, 2018 that memorialized the meeting. As forecast in my August 30 letter, on September 5, 2018, representatives of Novozymes North America, Inc. ("Novozymes") and Dewberry Engineering, Inc. ("Dewberry") met with Teresa Rodriguez, Mike Templeton, and Bing 302473101 v1 so novozymes Rethink Tomorrow "4 Bai of the Division of Water Resources (the "Division") to discuss the analysis of best available technology economically achievable ("BAT") for nutrients related to NPDES Permit Application NCO089621 (the "Permit Application"). Specifically, the objective of the September 5 meeting was to fully and finally agree upon the protocol and parameters for the BAT analysis and to clarify the information requested by the Division in its letter dated June 19, 2018. Accordingly, with regard to the BAT analysis, the Division, Novozymes, and Dewberry agreed as follows: am 1. Novozymes will prepare and submit to the Division an updated, revised, and compiled BAT analysis document ("Revised BAT Analysis") that incorporates and replaces the previously submitted Best Available Technology Analysis dated .. February 28, 2017 and Addendum to Best Available Technology Analysis dated February 26, 2018. 2. The Revised BAT Analysis will focus on three different food -to -mass ratios (F:M) that o" represent the typical operation of three different treatment technologies; extended aeration (F:M = 0.1), conventional aeration (F:M = 0.5), and high -rate aeration (F:M = 0.7). .. 3. The Revised BAT Analysis will include: a. a clarification of the interpretation of treatability study data L Novozymes will calculate and present effluent total nitrogen limits based on both maximum and 95th percentile data analysis for the .. three technologies. ii. After review of the data set, the Division agreed that data from treatability study reactors M6-M11 should be eliminated from the data .m set used to evaluate a BAT total nitrogen limit. For completeness, data from reactors M6-M11 will be included in the raw data appendix. r. b. a description of (i) the current wastewater treatment system at the Novozymes facility; and (ii) the proposed new wastewater treatment system to be installed in conjunction with the NPDES permit, and a discussion of the performance of the current system and its inability to achieve enhanced nitrogen removal; c. updated effluent data for the purpose of describing current system performance; d. a discussion of treatability testing results with regards to effluent ammonia (NH3) concentrations given that the permit limit for NH3is expected to be 1.0 OM mglL; e. a discussion of the food -to -mass ratios as the design basis for treatability No scale up for each of the three technologies; 2 ..► 302473101 vi cue novozymes- Rethink Tomorrow f. spreadsheet model outputs for each of the three technologies; and g. Proposal of a BAT Total Nitrogen (TN) limit based on the technology represented by F: M of 0.5. 4. The comparative cost analysis in the Revised BAT Analysis will compare the costs of the three technologies and will include graphical analysis. 5. The reduction of the proposed BAT permit limit for TN by 1.0 mg/L would be appropriate if reverse osmosis (RO) treatment is determined to be feasible by Novozymes and proposed for the NPDES permit. 6. Novozymes will submit the Revised BAT Analysis to the Division on an expedited basis. Thank you again for your time and efforts regarding review and processing of the Permit Application. Please let us know if there is anything you would like to add or clarify regarding the contents of this summary of the meeting from September 5, 2018. We look forward to working with the Division toward issuance of a draft NPDES permit. Sincerely, Angela . Walsh �► Novozymes North America, Inc. cc: Bill Lane, DEQ General Counsel Linda Culpepper, Division of Water Resources Director Mary Penny Kelley, Special Advisor, Office of the Governor Andrew Hargrove, DEQ Assistant General Counsel Jeff Manning, Classifications, Standards & Rules Review Branch Connie Brower, Classifications, Standards & Rules Review Branch Chris Ventaloro, Classifications, Standards & Rules Review Branch Bing Bai, Complex Permitting Unit Rick Bolich, DWR - Raleigh Regional Office Steve Tedder, Tedderfarm Consulting (all via e-mail only) 3 302473101 v1 Appendix F: Novozymes' WWTP Existing Site Layout www.dewberry.com EFFLUENT IRRIGATION STORAGE LAGOON ;i ei PFE ,. „..,�G Y,: y,", • ' Pal .,.. �' 1`-F �. _qr A BIOLAC LAGOON r Appendix G: Novozymes' 2010 — 2014 Historical Wastewater Effluent Data www.dewberry.com so 41M am ON low Appendix G January 2010 - December 2014 Historical Effluent Data Novozymes, Franklinton, NC Month -Year COD �.z Total phosphorus' Calculated Total Nitrogen (TN) Ammonla-N 3 Total Kjeldahl Nitrogen (TKN)3 Nitrate/Nitrite-N 3 m/I m/I m I m/I m/i m/I Jan-2010 90.0 Feb-2010 120 Mar-2010 180 61 24 34 27 A r-2010 130 48 0.9 7.7 40 Ma -2010 240 Jun-2010 120 38 0.3 4.2 34 Jul-2010 150 21 0.2 6.3 14 Au -2010 180 9.7 0.2 9.3 0.36 Se -2010 180 17 0.5 12 5.2 Oct-2010 140 8.4 0.1 8.4 0.03 Nov-2010 130 8.1 0.7 7.1 1.0 Dec-2010 110 7.4 1.0 5.4 2.0 Jan-2011 28 0.1 5.5 22 Feb-2011 23 0.1 8.4 15 Mar-2011 58.3 1.5 13 1.5 11 1.6 r-2011 63.5 0.8 19 0.1 7.4 11 Ma -2011 0.2 15 0.1 6.3 8.5 Jun-2011 1.0 15 0.2 6.8 8.2 Jul-2011 Au -2011 80.3 0.9 Se -2011 87.5 0.6 Oct-2011 0.2 Nov-2011 70.5 0.7 Dec-2011 55.0 0.8 Jan-2012 60.0 2.7 5.6 1.1 5.6 0.02 Feb-2012 76.0 3.6 9.3 0.1 7.7 1.6 Mar-2012 82.0 3.0 7.8 0.1 7.0 0.8 A r-2012 80.0 3.2 14 0.2 4.7 9.3 Ma -2012 74.0 3.6 18 0.1 5.6 12 Jun-2012 57.0 2.4 6.7 0.0 4.2 2.5 Jul-2012 63.5 3.1 4.7 0.1 4.7 0.01 Au -2012 72.0 2.5 7.8 1.1 6.5 1.3 Se -2012 61.0 2.7 6.9 0.1 4.3 2.6 Oct-2012 2.3 4.3 0.1 3.6 0.7 Nov-2012 59.0 2.5 9.7 0.0 4.7 5.0 Dec-2012 76.0 2.4 11 0.3 10 1.5 Jan-2013 63.0 2.5 Feb-2013 74.0 2.8 15 0.1 5.8 8.7 Mar-2013 2.1 A r-2013 59.0 2.9 7.6 0.2 4.4 3.2 Ma -2013 67.0 2.7 5.4 0.5 3.8 1.6 Jun-2013 74.0 2.1 Jul-2013 89.0 2.6 6.0 0.2 4.1 1.9 Au -2013 66.0 3.2 13 0.1 4.5 8.6 Se -2013 115 2.8 73 50 70 3.2 Oct-2013 100 3.5 15 0.1 6.6 8.3 Nov-2013 97.0 2.3 6.5 0.1 5.2 1.3 Dec-20131 110 2.9 14 3.5 12 1.5 Jan-20141 140 2.9 18 8.5 17 1 1.4 Feb-20141 140 3.3 14 2.4 11 3.0 ew 11/14/2018 v Dewberry Appendix G January 2010 - December 2014 Historical Effluent Data Novozymes, Franklinton, NC Month -Year COD' Total phosphorus' Calculated TotalTN� gen ( Ammonia-N3 Total Kjeldahl Nitrogen (TKN)3 Nitrate/Nitrite-N 3 m/I m/I m/l m/I m/I m/I Mar-2014 2.6 11 0.3 8.7 2.1 A r-2014 95.0 1.7 7.8 0.1 7.1 0.7 Ma -2014 110 2.6 8.3 2.3 8.1 0.2 Jun-2014 95.0 2.3 9.2 1.4 7.0 2.2 Jul-2014 100 2.1 6.8 0.3 6.7 0.1 Au -2014 82.0 1.7 11 3.8 11 0.2 Se -2014 86.0 2.0 4.7 0.1 4.7 0.02 Oct-2014 94.0 2.4 6.8 1.1 6.8 0.04 Nov-2014 98.0 1.7 9.8 0.1 6.4 3.4 Dec-2014 190 1.9 39 18 39 0.04 11/14/2018 Dewberry -- en Appendix G January 2010 - December 2014 Historical Effluent Data Novozymes, Frankiinton, NC 1.2 COD Total Calculated Total gen 3 Ammonla-N Total Kjeldahl 3 Nitrate/Nitrite-N Month -Year Phosphorus' Nitrogen (TKN)3 (Nitro mill m /I m /I m /I mill m /i 2010 - 2014 Average 100 2.2 15 2.6 9.5 5.8 95th Percentile 180 3.5 45 15 28 25 MAX 240 3.6 73 50 70 40 Data presented in this table were analyzed by a certified lab or calculated if noted. 'Data was taken from post tertiary (DAF) effluent 2COD data from 2010 was taken from Lagoon 3 3Data was taken from Lagoon 3 am FM !m 11/14/2018 Dewberry Appendix H: Novozymes' 2015 — 2018 Historical Wastewater Effluent Data www.dewberry.com SW am mklrt ow fen am ,m a" MR duo Appendix H January 2015 - October 2018 Historical Effluent Data Novozymes, Franklinton NC Month -Year COD' Total Phosphorus Total Nitrogen (TN) Ammonia-N Total Kjehldahl Nitrogen' NitratelNitrite-N 4 m /l m /I m /I m /I m /l mg/l Jan-2015 100 0.9 19 2.1 7.3 12 Feb-2015 120 2.4 14 0.1 6.1 7.4 Mar-2015 110 2.2 16 1.7 16 0.0 Apr-2015 100 2.9 18 6.0 12 5.7 May-2015 98.0 2.3 14 3.5 8.4 5.9 Jun-2015 48.0 1.7 7.3 0.1 4.7 2.5 Jul-2015 110 1.9 8.5 1.0 6.3 2.2 Aug-2015 130 1.3 15 2.5 7.7 7.3 Sep-2015 85.0 1.6 15 1.0 4.9 11 Oct-2015 77.0 1.2 13 2.2 6.7 6.1 Nov-2015 86.5 1.9 26 2.2 7.6 19 Dec-2015 71.0 2.1 48 0.3 4.0 44 Jan-2016 191 3.7 67 7.7 47 20 Feb-2016 253 2.2 67 5.4 48 19 Mar-2016 165 1.8 50 0.4 33 17 Apr-2016 50.5 1.6 49 0.1 35 14 May-2016 37.6 0.7 31 0.1 20 11 Jun-2016 49.7 0.6 17 0.3 9.4 7.2 Jul-2016 57.6 0.5 7.9 0.6 1.8 6.1 Aug-2016 67.3 0.6 9.1 2.5 2.9 6.2 Se -2016 67.9 1.0 7.3 1.4 0.3 7.1 Oct-2016 57.7 2.2 14 2.4 7.2 6.4 Nov-2016 41.0 0.9 7 0.0 1.6 4.9 Dec-2016 46.5 1.2 9 0.2 -0.1 9 Jan-2017 65.1 1.4 9 0.2 -5.0 14 Feb-2017 60.3 1.2 8 0.5 -1.5 10 Mar-2017 48.2 1.1 15 0.6 2.6 12 Apr-2017 48.7 1.5 19 0.5 5.4 13 May-2017 36.7 1.3 13 0.1 1.2 12 Jun-2017 28.6 0.6 9.1 0.1 4.2 4.9 Jul-2017 34.1 0.8 6.0 0.1 3.4 2.6 Aug-2017 36.7 1.1 7.9 0.1 3.4 4.5 Sep-2017 61.6 1.2 8.1 0.05 3.7 4.4 Oct-2017 73.3 1.6 14 3.2 8.7 4.9 Nov-20171 82.1 1.3 12 1.9 7.5 4.6 Dec-2017 91.2 1.7 15 0.1 5.1 10 Jan-2018 118 0.7 15 2.8 8.6 6.4 Feb-2018 116 0.8 34 23 29 5.2 Mar-2018 90.1 0.9 14 5.7 11 3.0 Apr-20181 78.5 1.1 11 0.7 4.3 6.8 May-2018 239 0.5 18 0.2 5.6 12 Jun-2018 59.7 0.4 19 0.2 3.8 15 Jul-2018 66.5 0.2 19 1.5 4.4 14 Aug-2018 85.6 0.3 10 0.7 -0.8 11 Sep-20181 81.9 0.5 12 0.4 0.8 12 Oct 2018 85.8 1 -- -- - -- 12 Im .r 11/14/2018 Dewberry Appendix H January 2015 - October 2018 Historical Effluent Data Novozymes, Franklinton NC COD Total Total Nitrogen Ammonia-N Total Kjehldahl NitratelNitrite-N 4 Month -Year phosphorus (TN) Nitrogen m/I m/I m/I mll m/I j m/l 201 S - 2018 Average 1 85.0 1.3 1 19 1 1.9 9.0 1 10 Max 1 253 1 3.7 1 67 1 23 48 1 44 Notes: All data presented is from certified lab analysis, unless noted otherwise All data presented was collected from post tertiary (DAF) tretament 'Data collected via internal lab samples or online instrumentation 2Dashed lines indicate data was not collected for that parameter or for that sampling event. 3Indicates values are calculated 4Nitrate/nitrite data for 2017 is from Novozymes internal analysis go go 4W 11/14/2018 lu Dewberry � Appendix I: Certified Lab Data www.dewberry.com I l i Reactor 1(Food-to-Mass = M15, M16 Reactor 2 ... i MENNEN No Reactor 3 (Food -to -Mass = 0.7) Batches Compositedz's Nitrate/ Nitrite Ammonia Soluble Total Kjeldahl Nitrogen Soluble Organic Nitrogen 1 (Calculated) Soluble Total Nitrogen Soluble Chemical Oxygen Demands Soluble Biochemical Oxygen Demands Total Suspended Solids Total Volatile Solids M1, M2 0.87 < 0.10 5.6 5.5 6.5 232 38:6 20.0 148 M3, M4, M5 0.19 1.4 6.8 5.4 7.0 97.0 10.6 23.2 150 M6, M7, Me 0.28 12.2 23.4 11.2 23.7 226 85.2 121 588 M9, M10, Mli° 0.36 20.5 33.7 13.2 34.1 714 14.3 74.7 478 M12 0.23 0.35 1 13.0 12.7 1 13.3 115 - - - M13, M14, M15 0.04 0.4 1 4.8 4.4 1 4.9 110 11.8 25.7 764 Notes 1. Results above are in mg/L 2. The M in the batch number denotes the batch was operated with the modified protocol initiated on July 21, 2017. 3. Certified lab samples are composite samples of multiple cycles in order to provide laboratory with adequate volume 4. Effluent results for Reactor 3 batches M6 through M11 will be excluded from the BAT limit analysis. These results are not consistent with the analysis performed by and are not consistent with the performance of other Reactor 3 batches. 5. Reactors were not operated in a manner to optimize for chemical oxygen demand or biochemical oxygen demand removal. 2/26/2018 19 Dewberry Appendix J: Dewberry Treatability Reactor Logs www.dewberry.com I m m oma,mW wa1wXW6M u.muen N o-w.. I/IIRI6:Wvm WWI 1.1 0.16 610 >RE/1>fIDM 1 0.16 0.10 IRNI)>.W VN m) ] 0.1O IRUI>I bvm wW} D% 0.1D >1'Y)w) WNIM5 0.]] > 1]R31.Wms 1 616 D% M} 1 0.W 010 71WW3Wpm I/Al]Il'AVM ms qp 0.1 0.10 )AIl])bWVM ] D.16 UV1)TI).1M WHS MI1 D 1 V>/1>fiW vm WM 4V)>]1W u/ wM mli ql) VNIILW VM YM6 MY PIO B/WI>111vM WN'6 PID >tl}M WNy �oa���omom©oegun ■rim mao�0��m®m©©���� os� oaa�m�mmomoo���� 0 oa0���mmmmmm���� • D`mba r �®®oom• ©omao ©moo ©®o0m m�©mmam moo®o0m. moo®moo moo®mom. pp �a.,.� ©®�m0��mommmmmmmmm moa��mmvmvmvmmmm oom��m©mmmmmmmmm o MOM=oa��mmmmmmmmmmm �0m0�mommmmmmmmm �am��mmmmmmmmmmm ou MEMEMMM mom© �ao��mmmmmvmmmmv �000m•mmm0mmmmmmm ®o®��mmm®mmmmmmm WOM �.©®moo m� MFASMM� m,m0�mm©mmmmmmmmm ��mmomvmmmmmv m•omm•�mmmmmmmmmmm m®®��mmmmmmmmmmm o,� � �� ®®��®�m•mam®mmmmmmm moan®mmmmmmmmmmm �0m��mmmmmmmmmmm �amm�mmmmmmmmmmm mmm��mmmmm®mmmmm o �©®maa�0moommmommmv �� ■ram �mmt��mmmommmmmmm �m®®�mmmmmmmmmmm ma0��mm®mmmmmmmm Eras �� oao��mm®mmo®mmmm mmm•��mmmmmmmmmmm �� �� v.^� mam.0�mmmmmmmmmmm oao�smmmmmmmmmmm oo0��mommmmmmmm® Er's� � o-o��m�mmvo®mmmm moa��mmmmommmmmm m0m��mmmvmmmmmmm m� m� mom0�mmmmmm��mmm oam�0mmmmmmmmmmm ooa��m®mmmmmmmmm ©©�om��m®mm�m®mmmm rumaa��mmmmmmmmmmm oME�©�m0®�mmmmommmmmmm m� �omm�mmmmmmmmmmm oo®��mommmmmmmmm c,�©®moa��mm m� mom mm mvv ®®®��mmmommmmmmm �o®®�mmmmmmmmmmm m� m� oa®��mmmmmmmmmmm oom��mmmmmmmmmmm r�� IWuM� ooa��mvmmmmmmm�m �am�mmmmmmmmmmmm IWM� mlrjar� mlEnmMM mom®�mmmmmmmmmmm mam��mmmmmmmmmmm mam�mmommmmmmmmm ®®ma���mo® mm�mmmm OUBHEEIZO �� v��®�mm,��mmmmvmmmmmm m0m.��mmmmommmmmm mo®��mmmmmmmmmmm �*� oo®��mmommm®mmmm u § Devd rr Ems®®0®m ��®ammo �®®ammo ■r��®am.mmo v�®ao0m, ��©oomm !r��©oommo Imo®m.�m. im�m��m.mmm. m+�®©m�mm�mm®mmmmmmmmmm m� �ao�mmmmo0�ommms �oo�mm®mmmmmmmmm Ems ®� �ao�mmmom m m m•mmmm m INEXISmm®mmmm �a0m�mmmmmm�mmmmm vv� �aom�mmmomo0ommmm �mamm•mmmmmmm®mmmm �a®�mmmmmm�mmmmm � !mom ©��mmmm�mm®mmmmtmmmmm �oo�mmmom®®mmmmm �o®mmmmmmm�mmmmm �mam�mmmmmm�mmmmm Etat�®®oao�mm om� m� ommmm �mm®�mmmmm m INEN®ommmm �mmm�mmmmmm�mmmmm p� 'irv� ammo®mmmmmm�mmmmm �mmm�mmm®mmmtmmmmm '�+� oaoomma��oomoommmo �0a�mmmmmo�mmmmm I one m� �a©m�mmmmom�mmmmm �om�mmmmmmmmmmmm MINION ��mm•mmmmmm�mmmmm �mmo�mmmmmm�mmmmm �mo�mmmmmm�mmmmm m,mo�mmmmmmmamm®m vu� ��� INVIENERSE31 m� 000�mm�_ammmommmmm �mmm.m�mmmmmm�mmmmm yam®mmmmmm�mmmmm mam�mmmmmm�mmmmm mamm�mm®mmmmmmmmmm vZEOZ� m�©�m�mm®�mmmmmm�mmmmm mao�mmmmmo�mmmmm m�om,m•mmmmmm�mmmmm mmmmm®m�mmommm�mmmmm A� �ao�mmmmmm�mmmmm �©©tea®mmmmm®m®®mmmmm ram a+u� �oo�mmmmmm�mmmmm �mm®�mmmmmm�mmmmm mmmmm®ommmmmm�mmmmm 01)10=20 mmm®mmmmm®mmm©mmmmm �c� mm©® moo®mammom�mmmmm 110000201010 �mmmmmm mmmmm rc� �® m� o�mmmmm®mmmmm ®ma om�mmmmm ammo®mmmmmm�mmmmm 00300 �am�mmmmmm®mmmmm w� oaam�mmmmmo�mmmmm �mso�mmmmmm�mmmmm ��omm•mmmmmm�mmmmmi �e� �a®�mmommm®mmmmm rMOHIZIS IN*a�©®� mmom�mmmmm®�mmmmm� �mm®m�mmmmmm�mmmmm NUa� m� m®m.�mmmmam�mmmmm �mmm.m•mmmmmm�mmmmm �+v� ©� ram m0m�mmmmmm�mmmmm �a®m•mmmmmm�mmmmm ®am�mmmmmmommmmm r�zr-r:� ©oa®mmmmmo�mmmmm �mm®mmmmm®mmmmm �� �� m� �mmm,m�mmmmmm�mmmmm m�omtm•mmmmmm�mmmmm ®0m.�mmmmmmmtmmmmm �*,� ���®�mm®m�mmmmmm�mmmmm oaom�mmmmm®mmmmm �� m� �om.m•mmmmmm�mmmmm ®m©m.m�mm®mmmmmmmmm s uzwm,a wwb. Appendix K: Proposed Novozymes Wastewater Treatment Plant Upgrades Block Flow Diagram www.dewberry.com I 1 1 { 1 1 1 1 1 1 1 I I I i 1 1 1 1 Existing Lets Application D oebage to Fiankin County I New CarbonAdditbnChemical FeedReactor PO W (O.S MGD) Cladhrary ------ DiacMgeroPamade j .—__ CedrtCn.t Vftr osorPutts 9E 7 9E U� ft0 Ramvalsritem \ I Pre 9E O 9f Aerobic —`[ Arottk ReeNas UFwkv Pymem �m__--ll qmy OTook an ReaGar (T01/f021 V .le _ — — — SYetionbClarifier PMary PAT TMkRest_ — ; Pump Pump I I Chemical Feetl Station 1 New �' — — — Eahauat to Atmosphere I y Prinany Clanfe Annotate Realtor Clarifier i I I r I Rermwl 3yGem EVaptxator 1. I— — — — —) Eeap«ator Bogmm �— Aeamn syMem Leaenti ONato Station BlWge to OHsite Disposal SE Sludge to O8f8e D'spoaal SIWge/UF Reject d OBeRe DiWomi O — — — New EquipmaM NO. Altivated SIWpe RAS Pump Station WAS Pump Station Exiatin0 Equipment -t �IMtakdl Pmoeva Wh4ewadrindueM BaNs of Design ` Bkropkal Treadant Uppdtle hRmeter (Pwnwate a N. Pemeate Flow 2 MGG Ib/d al Biochemical 0 en Demand 9,082 See MemicaiD en Demand 89.889 5,389 Ammonia-N 1,045 63 Total K)eld8hl Nitcoll.n 31283 197 Nltete-N as 29 Total Nitintitten 3.463 2W Total Phos homs L503 % Sulfate 1963 118 Poalsslum 8,0)!1 508 Rimsry Cled6er.M Plosplams Remove) Future Non -Permeate No. L74 MGD New Pdmary ❑arifier Diameter d6 Ik ExiaNng Tel/re2 Rea Gor Volume 48Q000 19.1W.Wital Rea Gorr < I $win Diffused Alr System Wattled U'olde Extended AerationTednmlogy Required Aerobic Process Vol ume 19.8 MG Quantity SO Volume per Res Gor 1 lA IRS ( emiaal Aemtlon Tedawlotly Re, ul red Aemblc Ponces Volume 1 4.0 IRIS Du ntiry 1 3 Volume per Realtor 1 1.3 MG Hig"m ANatlon Ted raIm Raoul red Aembl c Pmcem Vol ume 1 2.0 1MG Cuantlly 2 Vol ume pe r Rea ctor 1 1.4 JMG MRoMrT,R I Aemblc lFine Bubble Diffusion '-5_ Twany PhowW. R.' Exbd Tmortam wid'a SNNm Opening Gpadry 0.5 Imo .. RMpbOno T... Flow Up-11 7 MGO Quantity sudace Ala 350 it' 1 16 UltraMnlbn, Reverie Oemonie,aM Evapcetor <) EllhrenlLMb Flow Gpadry 2 MGD Resene Osmosis Permeate Recovery TOD Ultakltrad.n T8D Evaporator Capad no Parameter Effluman Buis of Dell, Flow 2 MGD BlocbemiolOften Demand 5m L Ammonia-N Ion L Total Nlmllon 8.8 m /L TOM Phos homs Ion L Tod l Suspended Solids 30m L Notes. d�i Semrdary Chanter e4rdpe, ppintlgoe w1.Froe a)GmvraRxl uirdngWivmneMrehfaand pMM,,a sl6Wonpa. emNtsrtcarnto rya. andro oe tlGermined dtvi, detailed deign. Eris Ong Oanf er Diameter 8) ft New Oanfler Diameter 115 ift DATE L— Dewberry TITLE PROPOSED NOVOZYMES WWTP UPGRADES DEmenyaontannm' 1113QI2018 BLOCK FLOW DIAGRAM atne"o PRoao PanEa+p PROJ. NO. PROJECT NOVOZYMES NORTH AMERICA arse 4reee� wz NPDES PERMIT APPLICATION NCO089621 tn�neaal. SD107104 BEST AVAILBALE TECHNOLOGY ANALYSIS SHEET NO. 1 Appendix L: Preliminary Equipment Specification Table www.dewberry.com • M M 4€P Dewberry DATE: 11 /1412018 Preliminary Equipment Specification Table Best Available Technology Analysis Novozymes North America, Inc. Franklinton, North Carolina EXTENDED CONVENTIONAL AERATION: EQUIPMENTi r 1. BIOREACTOR Quantity: 14 3 2 Size: 19.75 MG, 107' DIA, 4.0 MG, 107' DIA, 2.82 MG, 107' DIA, 20' SWD 20' SWD 20' SWD Materials of Construction: Bolted 304 SS Bolted 304 SS Bolted 304 SS Notes: Provide minimum of 2' freeboard Provide access stairs and platform. No cover Volume listed is required process volume. 2. BIOREACTOR Quantity: 14 3 2 Type: Direct Drive Surface Direct Drive Surface Direct Drive Surface Mixer Mixer Mixer Materials of Construction: 304 SS 304 SS 304 SS Notes: Assume TSS concentration of 5,500 mg/L 3. PRIMARY CLARIFIER Quantity: 1 1 1 Size: 1.74 MG, 47' DIA, 15' 1.74 MG, 47' DIA, 15' 1.74 MG, 47' DIA, 15' SWD SWD SWD Materials of Construction: 304 Stainless Steel 304 Stainless Steel 304 Stainless Steel Mechanism in Mechanism in Mechanism in Concrete Tank Concrete Tank Concrete Tank Notes: Provide minimum of 2' freeboard Provide pier mounted H-type conventional scraper blade, energy dissipating inlet, effluent launders, density current baffles, and scum skimmer. Preliminary Equipment Specification Table Rev. 0.0 MY, Dewberry DATE: 11114/2018 EXTENDED CONVENTIONAL AERATION:•AERATION: EQUIPMENT1 0 - 4. PRIMARY CLARIFIER PUMPS Quantity: 1 duty/ 1 standby 1 duty/ 1 standby 1 duty/ 1 standby Size: 1,210 GPM at 30 FT 1,210 GPM at 30 FT 1,210 GPM at 30 FT TDH TDH TDH Notes: Sized for non -permeate flow 5. BIOREACTOR DIFFUSED AERATION EQUIPMENT Quantity: 14 3 3 Type: Fine Bubble Diffusion Fine Bubble Diffusion Fine Bubble Diffusion Grid Grid Grid Design Condition: 2,550 scfm/tank 10,000 scfm/tank 15,000 scfm/tank (2.0% SOTE per (2.0% SOTE per (2.0% SOTE per ft SWD.) ft SWD.) ft SWD.) Diffuser Density: Provide 15% with Provide 15% with Provide 15% with 10% installed 10% installed 10% installed Notes: 9" Disc Diffuser with PVC manifolds and headers. 6. BIOREACTOR BLOWERS Quantity: 28 duty/1 standby 3 duty/1 standby 3 duty/1 standby Type: Positive Centrifugal Centrifugal Displacement Max Condition 1,275 scfm 10,000 scfm 15,000 scfm 11 PSI 11 PSI 11 PSI Design Condition 915 scfm 8,000 scfm 11,300 scfm 10 PSI 10 PSI 10 PSI 7. SECONDARY CLARIFIERS Quantity: 1 1 1 Size: 115' DIA, 15 SWD 115' DIA, 15 SWD 115' DIA, 15 SWD Materials of Construction: Epoxy Coated Steel Epoxy Coated Steel Epoxy Coated Steel Mechanism in Mechanism in Mechanism in Concrete Tank Concrete Tank Concrete Tank Notes: Provide pier mounted H-type conventional scraper blade, energy dissipating inlet, effluent launders, density current baffles, and scum skimmer. ..r Oft M Preliminary Equipment specification Table Rev. 0.0 Dewberry M DATE: 1111412018 Quantity: 2 Duty / 1 Standby 2 Duty / 1 Standby ' 2 Duty / 1 Standby Size: Max — 2,084 GPM at Max — 2,084 GPM at Max — 2,084 GPM at 31 FT TDH 31 FT TDH 31 FT TDH Design -1,390 GPM Design - 1,390 GPM Design - 1,390 GPM at 28 FT TDH at 28 FT TDH at 28 FT TDH Min. — 700 GPM at Min. — 700 GPM at Min. — 700 GPM at 26 FT TDH 26 FT TDH 26 FT TDH Notes: Sized 50-150% of Design Flow r9. WAS PUMP STATION Quantity: 1 duty/1 standby 1 duty/1 standby 1 duty/1 standby Size: 76 GPM at 47 FT 111 GPM at 36 FT 125 GPM at 38 FT r� TDH TDH TDH • DISSOLVED • • •• �+ Quantity: 2 duty1 2 duty 12 duty 250 sq.ft. 250 sq.ft. 250 sgft .n 11. ••(LAGOON Quantity: 11 duty, 1 standby 1 duty, 1 standby 1 duty, 1 standby .� Size: 1,400 GPM at 28 FT 1,400 GPM at 28 FT 1,400 GPM at 28 FT TDH TDH TDH Notes: Assumes 25 FT static Assumes 25 FT static Assumes 25 FT static head head head • Quantity: 1 duty/1 standby 1 duty/1 standby 1 duty/1 standby TDS: 2,000 mg/L (average) 2,000 mg/L (average) 2,000 mg/L (average) Size: 1,400 GPM 1,400 GPM 1,400 GPM Permeate Recovery: 90% with reject recycle loop 90% with reject recycle loop 90% with reject recycle loop .n Notes: System shall include ultrafiltration step, RO Feed Pumps, RO filtration, chemical feed systems, necessary pumps, and Evaporator sized for 10% reject stream Preliminary Equipment Specification Table Rev. 0.0 Dewberry DATE: 11 /14/2018 Notes: 1. Multiple (dual at a minimum) components such as pumps, chemical feed systems, and aeration equipment are provided where necessary. 2. Pumping total dynamic head assumes 1,000 L.F. of force main, 25 FT static head, and design velocities between 2-5 fps. Unless otherwise noted. 3. Diffused Aeration Equipment assumes design operating level of 0.5 mg/I dissolved oxygen (DO), with _ maximum design of 2.0 mg/I DO. c� Preliminary Equipment Specification Table Rev. 0.0 Appendix M: Biowin© Model Inputs and Outputs www.dewberry.com NZNA Biowin Model Results Novozymes North America Franklinton, NC NZNA Influent Conditions Extended Conventional High -Rate Aeration Aeration Aeration 0.1 F/M 0.5 F/M 0.7 F/M Flow MGD 2 2 2 COD mg/I 3,950 3,950 3,950 TKN mg/I 197 197 197 TP mg/I 90 90 90 Nitrate mg/I 29 29 29 Recalcitrant Soluble Organic Nitrogen mg/I 1.3 7.6 11.6 Microbial Kinetics Heterotrophic Yield g VSS/g COD 0.4 0.4 0.4 Nitrifier Yield gVSS/g COD 0.12 0.12 0.12 .� Nitrogen Content in Cells % 0.12 0.12 0.12 TSSNSS ratio 0.8 0.8 0.8 Aerobic Target MLSS mg/L 4,000-4,500 4,000-4,500 4,000-4,500 Calculated Volume MG 19.75 4 2.82 Target F/M 0.1 0.5 0.7 .. Model MLSS mg/L 4,122 4,249 4,215 Actual F/M 0.10 0.46 0.66 Dissolved Oxygen mg/L 0.3 0.4 0.5 i r Volume MG 0.48 0.48 0.48 Dissolved Oxygen mg/L 0.5 0.2 0.5 Number of Clarifiers # 2 2 2 .� Diameter ft 87 87 87 Depth ft 15 15 15 Model SOR gal/ft2*d 158.46 159.33 155.2 Model SLR Ib/ftZ*d 11.0 11.55 11.2 Retention Time SRT days 84 15 10 Flow MGD 1.39 1.36 1.34 Recycle Ratio 0.695 0.68 0.67 TSS mg/L 10,533 11,048 10,725 VSS mg/L 9,280 9,511 9,177 Flow MGD 0.11 0.14 0.16 TSS mg/L 10,533 11,048 10,725 VSS mg/L 9,280 9,511 9,177 11/13/2018 DRAFT r Dewberry NZNA Biowin Model Results Novozymes North America Franklinton, NC Extended Aeration 0.1 F/M Conventional Aeration 0.5 F/M Ammonia mg/L 0.23 Nitrate mg/L 0.55 Nitrite mg/L 0.1 TKN mg/L 2.4 TN mg/L 4.49 TSS mg/L 16.5 cBODs mg/L 1.52 PH S.U. 7.66 Notes: 1) All scenarios were modeled at a liquid temperature of 2(° C 2) 1 M of calcium carbonate was added at a flow of 50,000 gallons per day for alkalinity 3) NZNA influent wastestream data used from 2/28/2017 BAT Analysis submittal after accounting for 24,000 lbs/d removal from anaerobic reactor 4) Effluent data is water quality after secondary clarification. It does not include tertiary tretament. SOR - Surface Overflow Rate SLR - Surface Loading Rate COD - Chemical Oxygen Demand TKN -Total Kjehldahl Nitrogen TP-Total Phosphorus MLSS - Mixed Liquor Suspended Solids F/M - Food -to -Mass ratio RAS - Return Activated Sludge WAS - Waste Activated Sludge TSS - Total Suspended Solids VSS - Volatile Suspended Solids cBOD, - Carbonaceous Biological Oxygen Demand 0.25 0.01 0.03 8.33 10.06 17.4 4.62 7.65 High -Rate Aeration 0.7 F/M 0.31 0.05 0.12 12.49 14.4 17.2 5.46 7.65 11/13/2018 DRAFT 40 Dewberry Appendix N: Capital and Recurring Cost Estimates www.dewberry.com i I r r r r r r r r r r r r r r I Table M.I. Summary of Equivalent Annual Costs (EAC) BAT Analysis Novozymes North America - Franklinton, NC Alternative 1 Extended Aeration 0.1 F:M Alternative 2 Conventional Aeration 0.5 F:M Alternative 3 High -Rate Aeration 0.7 F:M Capital Costs Equipment, Installation, Engineering & Construction $25,507,000 $7,969,000 $6,199,000 40%Contingency $10,200,000 $3,188,000 $2,480,000 Engineering and Construction Management $3,570,000 $1,116,000 $868,000 Total Capital Requirement $39,277,000 $12,273,000 $9,547,000 Recurring Costs O&M, including chemicals, labor and maintenance $473,000 $313,000 $303,000 Laboratory costs $42,000 $42,000 $42,000 Residuals disposal costs $3,035,000 $3,550,000 $3,893,000 User Fees $365,000 $365,000 $365,000 Tar-Pamplico Nutrient Offset Fees $173,000 $173,000 $173,000 Utility costs $4,019,000 $892,000 $746,000 Total Annual Reoccurring Costs $8,107,000 $5,335,000 $5,522,000 Equivalent Annual Costs (EAC) $17,700,000 $8,300,000 $7,900,000 Notes and Assumptions 1. Allocation for land acquisition/easements are not included because NZNA will own the forcemain and construct it on their property. 2. Nutrient offset fee calculated assuming $865,332 for a permit cycle (5 years). Fee has been annualized but is required to be paid at the beginning of each NPDES permit cycle. Assumes offsets purchased for discharge of 8.8 mg/I TN and 1 mg/I TP . 3. EAC calculated assuming life of 5 years. 4. EAC calculated assuming provided Novozymes North America discount rate of 7%. 5. Annual equipment maintenance costs are assumed to be 5%of equipment cost. Dewberry 11/29/2018 Table L.I. Summary of Equivalent Annual Costs (EAC) film Table M.2. Alternative 1. Extended Aeration Capital and Recurring Costs BAT Analysis Novozymes North America - Franklinton, NC rlon M am dfiff Cos< EASa+3! Capital Equipment Costs 1 Positive Displacement Blower, 350 HP 1,275 sdfm 1S 29 $ 81,000 $ 2,349,OW 2 Mixers EA 14 $ 26,000 $ 364,000 3 Fine Bubble Aeration Systems IS 1 $ 2,100,000 $ 2,10D,000 4 Waste Sludge Pumps, 3 HP each, l duty,1 standyby EA 2 S 12.000 $ 24,000 5 Return Sludge Pumps, 25 HP each, 2 duty,1 standby EA 3 S 32,000 $ 96,000 6 Primary Clarifier Pumps, 20 HP each, I duty, I standby EA 2 $ 24,000 $ 48.000 9 Effluent Pump Station, 50 HP each,1 duty,1 standby EA 2 S 25,000 $ 50,000 Capital Equipment Subtotal $ 5,031,0m Installed Equipment Cost 10 Biological Reactor Tank; above ground, 304 bolted SS with foundotioi EA 14 $ 820.000 $ 21,480,000 11 Miscellaneous Concrete CY 350 $ 2,000 S 700,000 installed Equipment Subtotal $ 12,190,000 CAPITAL EQUIPMENT SUBTOTAL $ 5,031,000 Equipment installation Cost (% of Capital): 30% $ 1,509,000 Sub -Total S 6,540,000 Civil Site Improvements (% of Capital): 10% $ 503,000 Electrical Equipment, Controls, and Instrumentation (% of Capital): 20% $ 1,006,OW Electrical Installation(% of Capital): 1S% $ 755,000 Piping Allowance (% of Capital): 12% $ 604,000 FOS Allowance (%of Capital): 4% $ 201.000 Sub -Total $ 916091000 Installed Equipment Subtotal $ 12,180.000 Sub -Total $ 21,789,000 Overhead and Profit. 15% $ 3,268,000 Contractor General Conditions: MONTH IB $ 25,000 $ 450,000 Sub -Total $ 25,507,000 Contingency: 40% S 10,200,000 Sub•Tatal $ 35,707,000 Engineering Design Fees: 10% $ 3,570,000 Sub -Total: S 39,277,000 TOTAL ESTIMATEDPROIECTCOST• $ 35i277,000 Notes: 1. Cost opinion Is based on concept design assumptions shown and stated in Figure 1 Block Flaw Diagram. 2. Assumes that an existing power source may be utilized without new primary transformer and power can be distributed to local control panels. 3. Assumes flat, clear site; no significant grading, clearing and grubbing required. 4. Assumes no rock excavation, deep foundations, or dewatering. S. Assumes 2.000 PSF soil bearing capacity so allowances assume conventional concrete foundations. 6. Assumes exiling SCAOA has capacity to accommodate 1/0 from new Instrumentation. 7. Indicates cost was scoled from Conventional Aeration treatment alternative 8. Listed tank volumes are process volumes and costs account for freeboard 9. Assumes primary feed is located within 100It of electrical room 10. Assumes primary transformer provided by utility 11. Assumes no Impact to wetlands 12. Assumes Novozymes will handle construction phase of W WTP upgrades 13. Costs items presented In this table are a subset of the items included In the EAA cost estimate 14. Costs presented in table are rounded to the nearest thousand. 9619. OAM Costs (SX of Capital Equipment Subtotal) $ 2S2,O00 Lob Fees $ 4Z000 Maw Costs Est. Cos unm• Acetic Acid Needed 17 gpd Unit Cost $ 2.42 $/gal Acetic Add Annual Acetic Acid Cost $ 15.000 Total Chemical Costs S 151000 M Cos Mixers, Pumps, Blowers 59,277,475 kW-hr Unit Cost $ 0.068 SAW-hr Total utility costs $ 4,019,000 9~ 2keem oats Chemical Phosphorus Sludge Generation 2S3 cubic meters/day Biological Waste Activated Sludge Generation` 416 cubicmeters/day Sludge Disposal Unit Costs $ 12.43 $/cubic meter Total Disposal Costs $ 3,03S OW Lei Additional Full -Time Employee 3 employees Labor Rate $ 33 /hr AnnualAddidonal Labor Costs $ 2061C00 Immuse Fees Franklin County Hydrautic Surcharge $ 7.70 /1,000 gatlans Discharge to Franklin County° 130,000 gpd Annual Sewer use Fee $ 365,000 u affaLft Flow 2.00 MGO Total Nitrogen 8.8 mg/l Total Phosphorus 1 m0 TN BMPc 29.00 $/kg Nutrient Offset fee' S 855,000 per 5 yr permit cycle ual Fee $ 123AW r ar I Est. CostsualRecaMngCosts $ 81107,000 No am 4141 am am am 00101 f» Notes: 1. Requited 94% acetic add volume calculated based on polishing 10 mg/1 of nitrate -nitrogen. 2. Electrical costs are calculated based on demand of future electrical equipment. 3. Phosphorus sludge generation rate estimated from historical NZNA sludge data. 4. Biological waste activated sludge generation rate estimated from historical NZNA sludge data. am S. Sludge disposal unit cost based on historical NZNA sludge disposal cost data. 6. Value represents the minimum flow Novorymes projectes to send to Franklin County. 7. Nutrient offset fee calculated per the requirements in 1SA NCAC 028.0229(c) and 1SA NCAC 028.0237. 8. Costs presented In table are rounded to the nearest thousand. fR li/29/2018 Table L2. Extended Aeration Capital and Recurring Costs ® Dewben y fIA 1=1 f-`T4 lR oft Table M.3. Alternative 2. Conventional Aeration Capital and Recurring Costs BAT Analysis Novozymes North America - Franklinton, NC nit am llattCos Ef�Caft: Capital Equipment Costs 1 Blower, 600 KP,10,000 scfm LS 4 $ 161,000 $ 644,000 2 Mixers EA 3 $ 26.OW $ 78,000 3 Fine Bubble Aeration Systems LS I $ 895,ODO $ 895,000 4 Waste Sludge Pumps, 3 HP each, I duty, l standyby EA 2 $ 12,0W $ 24,OW 5 Return Sludge Pumps, 25 HP each, 2 duty, I standby EA 3 $ 32,000 $ 96,000 6 Primary Clarifier Pumps, 20 HP each, 2 duty, i standby EA 2 $ 24,000 $ 48,W0 9 Effluent Pump Station, 50 HP each, I duty. I standby EA 2 $ 25,000 $ SO,0f10 Capital Equipment Subtotal S 1,835,0W installed Equipment Cost 10 Biological Reactor Tanks above ground, 304 bolted SS with foundation EA 3 $ 820,000 S 2,460,OW 11 Miscellaneous Concrete CY 3W $ 2.000 S 6W.W0 Installed Equipment Subtotal $ 3,060,WO CAPITAL EQUIPMENT SUBTOTAL $ 1,840.WO Equipment Installation Cost {% of Capital): 30% $ 552,000 Sub -Total $ 2,392,000 Civil Site Improvements of Capital): 10% $ 194,000 Electrical Equipment, Controls, and Instrumentation of Capital): 20% $ 368,000 Electrical Installation(% of Capital): 15% $ 276.000 Piping Allowance (% of Capital): 10% $ 284,000 FOB Allowance (%of Capital): 4% $ 74,0W Sub -Total S 3,478,000 Installed Equipment Subtotal $ 3.060.000 Sub -Total $ 6.538.000 Overhead and Profit: IS% $ 981,000 Contractor General Conditions: MONTH 28 $ 25.000 $ 450,000 Sub -Total $ 7,969,000 Contingency: 40% $ 3,188,000 Sub -Total $ 11,157,000 Engineering Design Fees: 10% $ 1.116,000 Sub -Total: S 12.273,000 TOTAL 6f"MATEDPWIECTC0STt $ =73,000 Notes: 1. Cost opinion is based on concept design assumptions shown and stated In Figure 1 Block Flow Diagram. I. Assumes that an existing power source may be utilized without new primary transformer and power an be distributed to loaf control panels. 3. Assumes flat, dear site; no significant grading, clearing and grubbing required. ON 4. Assumes no rock excavation, deep foundations, or dewatering. 5. Assumes 2.000 PSF soil bearing capacity so allowances assume conventional concrete foundations. 6. Assumes exising SCADA has capacity to accommodate 1/O from new instrumentation. 7. Listed tank volumes are operating volumes and costs account for freeboard S. Assumes primary feed Is located within 100 ft of electrical room 9. Assumes primary transformer provided by utility tAM 10. Assumes no impact to wetlands 11. Assumes Novozymes will handle construction phase of W WTP upgrades 12. Costs items presented in this table are a subset of the items included in the EAA cost estimate 13. Costs presented in table are rounded to the nearest thousand. AnCOATlurr rner eer,ueTea. no f0l0 OUR am f9p an sin 08M Costs (SX of Capital Equipment Subtotal) $ 9�000 WA 19 cam ll1du Lab Fes 42,000 flalft Acetic Add Needed' 17 gpd Unit Cost $ 2.42 $/gal Acetic Add Annual Acetic Add Cost $ 15,016 Total Chemical Costs $ 15,0W is Mixers, Pumps, Blowers 13,156,819 kW-hr Unit cost S 0.060 $/kw-hr Total utility Costs $ 892,000 Chemical Phosphorus Sludge Generation5 2S3 cubic meters/day Biological Waste Activated Sludge Generation 530 cubic meters/day Sludge Disposal Unit Costs $ 12.43 $/cubic meter Total Disposal costs $ 3,SS0,000 �BQJtC Additional Full -Time Employee 3 employees tabor Rate $ 33 Ar Annual Additional Labor Costs $ 20ti M Franklin County Hydraulic Surcharge $ 7.70 A,000 gallons Discharge to Franklin County, 130,000 go Annual Sewer Use Fee $ 365,000 Ae t OItsK Fee _ Flow 2.00 MGO Total Nitrogen B.8 mg/I Total Phosphorus I mg/I TN BMPc 29.00 $AS Nutrient Offset Fee r $ 865,000 per 5 yr permit cycle Annual Offset Fee $ 173,OW per year Annual Recurring Crib $ SIUS 000 Notes: 1. Required 84%acetic add volume calculated based on polishing 10 mg/I of nitrate -nitrogen. 2. Electrical costs are calculated based on demand of future electrical equipment. 3. Phosphorus sludge generation rate estimated from historical NZNA sludge data. 4. Biological waste activated sludge generation rate estimated from historical NZNA sludge data. 011111 S. Sludge disposal unit cost based on historical NZNA sludge disposal cost data. 6. Value represents the minimum flow Novozymes projectes to send to Franklin County. 7. Nutrient offset fee calculated per the requirements in 15A NCAC 028.0229(c) and 1SA NCAC 028.0237. 8. Costs presented in table are rounded to the nearest thousand. om 11012018 Table L3. Conventional Aeration Capital and Recurring Costs ® DewbelrY- - Table MA. Alternative 3. High -Rate Aeration Capital and Recurring Costs BAT Analysis Novorymes North America - Franklinton, NC Ra-graft llBtiCos Capital Equipment Costs 2 Blower, 800HP, is, 0OOscfm LS 3 $ 125,0W $ 575,000 2 Mixers EA 2 S 26,000 $ 52,OOO 3 Fine Bubble Aeration Systems LS 2 $ 702,000 $ 7OZOOD 4 Waste Sludge Pumps, 3 HP each, l duty, I standyby EA 2 $ 12.000 $ 24,000 5 Return Sludge Pumps, 25 HP each, 2 duty, I standby EA 3 $ 32,000 $ 96,000 6 Primary Clarifier Pumps, 20 HP each, l duty, I standby EA 2 $ 24AW $ 48,000 9 Effluent Pump Station, 50 HP east% I duty,1 standby EA 2 $ 25,000 $ 50,000 Capital Equipment Subtotal $ 1,647,000 Installed Equipment Cosa 20 Biological Reactor Tanks, above ground, 304 bolted SS with foundation EA 2 $ 643,000 $ 1,286,000 1t Miscellaneous Concrete CY 300 $ 2,000 $ 600.000 Installed Equipment Subtotal $ 11886,000 CAPITAL EQUIPMENT SUBTOTAL $ 1,647.000 Equipment Installation Cost (%of Capital): 30% $ 494,000 Sub -Total $ 2,141,000 Civil Site Improvements of Capital): 10% $ 165,000 Electrical Equipment, Controls, and Instrumentation of Capital): 20% $ 329,000 Electrical Installation(%of Capital): IS% $ 247.000 Piping Allowance (%of Capital): 20% $ 165,000 F0B Allowance (%of Capital): 4% $ 66,000 Sub -Total $ 3,113,000 installed Equipment Subtotal $ 1,886.000 Sub -Total S 4,999,000 Overhead and Profit: 25% $ 750,000 Contractor General Conditions: MONTH 18 S 25,000 $ 450,000 Sub -Total S 61199,000 Contingency: 40% $ 2,490,000 Sub -Total S 8,679,000 Engineering Design Fees: 10% $ 868,000 Sub -Total: $ 9,547,000 TOTAL E=A4ATEO PROJECT COST. 9,50,,000 Notes: 1. Cost opinion is based on concept design assumptions shown and stated in Figure I Block Flow Diagram. 2. Assumes that an existing power source may be utilized without new primary transformer and power can be distributed to local control panets. 3. Assumes Bat, dear site, no significant grading, clearing and grubbing required. 4. Assumes no rock excavation, deep foundations, or dewatering. S. Assumes 2,000 PSF soil bearing capacity so allowances assume conventional concrete foundations. 6. Assumes exising SCADA has capacity to accommodate 1/O from new instrumentation. 7. indicates cast was scaled from Conventional Aeration treatment alternative. 8. listed tank volumes are process volumes and costs account for heeboard 9. Assumes primary feed is located within 100 ft of electrical room 10. Assumes primary transformer provided by utility 11. Assumes no impact to wetlands 12. Assumes Novolymes will handle construction phase of W WTP upgrades 13. Costs items presented in this table are a subset of the Items included in the EAA cost estimate 14. Costs presented in table are rounded to the nearest thousand. noeosrIrur_ ener ernueTae. mim 004 (SM of Capital Equipment Subtotal) 8zow M&COX Rau Lob Fees 4;,a80 E9Costs Units: Acetic Add Needed 17 gpd Unit Cost $ 2.42 $/gal Acetic Add Annual Acetic Acid Cost $ 15,016 Total Chemical Costs $ 151000 IJfilUv Posh . Mixers, Pumps, Blowers 11,005.073 kW-hr Unit Cost $ 0.068 SAW-hr Total Utility Costs $ 745,080 Chemical Phosphorus Sludge Generation 253 cubic meters/day Biological Wage Activated Sludge Generation` 606 cubic meters/day Sludge Disposal Unit Costs $ 12.43 $/cubic meter Total Disposal Costs $ 3,893,000 i� Additional Fuil-Time Employee 3 employees Labor Rate $ 33 At Annua/Addidana/LaborCash $ 206,000 Sewer Use Fees Franklin County Hydraulic Surcharge $ 7.70 /1,000 gallons Discharge to Franklin County' 130,000 gpd Annual Sewer Liu Fee $ 365,000 Flow 2.00 MGD Total Nitrogen 8.8 1719/1 Total Phosphorus 1 mg/I TN BMPc 29.W $/kg Nutrient Offset fees $ 865,000 per 5 yr permit cycle Annual Offset Fee $ 174OW per r Itzte� llLdti Annual Recurring Costs $ S,SA000 on ti P,911111 am on �t am low ram am am On" fti Notes: 1. Required 84%acetic add volume calculated based on polishing 10 mg/1 of nitrate -nitrogen. 2. Electrical costs are calculated based on demand of future electrical equipment, 3. Phosphorus sludge generation rate estimated from historical NZNA sludge data. 4. Biological waste activated sludge generation rate estimated from historical NZNA sludge data. no S. Sludge disposal unit cost based on historical NZNA sludge disposal cost data. 6. Value represents the minimum flow Nowrymes projectes to send to Franklin County. 7. Nutrient offset fee calculated per the requirements In 1SA NCAC 028.0229(c) and ISA NCAC 020.0237. 8. Costs presented In table are rounded to the nearest thousand. Jai 11/29/2018 Table L.A. High, -Rate Aeration Capital and Recurring Costs ® Dewbewr Appendix O: Vendor Quotes www.dewberry.com Appendix O Contents: 1. Blowers 2. Mixers 3. Fine Bubble Aeration System _ 4. Pumps 5. Bioreactor Tanks fj Dewberry° Novorymes North America, Inc. I Engineering Alternatives Analysis I APP M 1. Blowers a) Positive Displacement Blowers b) Centrifugal Blowers 11A Dewberry Novorymes North America, Inc. I Engineering Alternatives Analysis I APP M Lawrence, Jordan From: Poulios, Michael Sent: Monday, November 12, 2018 3:42 PM To: Lawrence, Jordan ., Subject: FW: Franklinton Bio Pharma project - Dewberry - Robuschi PD Blowers From: Jim Cooper [mailto:JCooper@heyward.net] Sent: Monday, October 22, 2018 4:02 PM To: Poulios, Michael <mpoulios@Dewberry.com> Subject: Franklinton Bio Pharma project - Dewberry - Robuschi PD Blowers This message originated from outside your organization Mike: Read below from my PD Blower guy. The new flow rate (well actually, the flow rate you originally asked for) really take the blower type away from PD. I cannot imagine the quantity of PD's being practical for this application when compared to multistage centrifugal or turbo blowers. We shall see. In order to do 1275 SCFM @ 11 prig with a PD or screw blower you would need 3 blowers per tank to meet the load. That would mean they would need 10 blowers (9 to meet the load and a spare). It would still be the exact same blowers I gave you info on but they would need 10 total blowers not 4. This may be an application for Centrifugal or _ Turbo blowers. They can use those for the base load and still look at using a screw or PD for turndown. Let me know what they say. (10) ES 145/5C 350 HP Robsuchi ROBOX Lobe $80,500.00 BUDGET net each $805,000.00 BUDGET net for (10) (10) W5145/SP-1F 300 HP Robsuchi ROBOX Screw $143,673.00 BUDGET net each $1,436,730.00 BUDGET net for (10) We still have to add for freight, start-up and possibly for controls beyond the standard control package. Sincerely, Jim Cooper Heyward Incorporated 704-583-2305 - office _ 704-591-1270 - cell icooper@heyward.net 0 E Continental Blower., LLa . 23 Corporate Circle East Syracuse, NY 13057 Date: 11/8/18 To: Heyward Inc. Attn: Jim Cooper Phone No: (704) 583-2305 Email: jcooaer@hevward.net No. Pages: 1 Subject: Dewberry -- bio Pharma Project Dear Jim, From: Phone No. Fax No: Email: CC: Patti Waring (315) 451-5410 (315) 451-5950 pattiw@continentalblower.com I have reviewed your revised application and am pleased to offer the following budget proposal. For this lower flow, I would go with this selection as it is more efficient at the new design condition. The blower model remains the same but with a different impeller mix and smaller motor. Have included a standard accessory and blower protection package. Job Conditions: 10,000 SUM Air Flow per Blower 11.0 PSIG Discharge Pressure 360' Elevation 105OF Inlet Temperature 80% RH Equipment List: 4 — Model 600.04 Multistage Centrifugal Blower 4 — Base Assembly with Baseplate, Coupling, Coupling Guard & Base Pads 4 -- 650 HP 3/60/460-volt 3,550-rpm TEFC Motor 4 — 24" Inlet Filter Silencer, Panel Style 4 — 24" Inlet Butterfly Valve, Wafer, Manually Operated 4 -- 24" Inlet Expansion Joint 4 -- 20" Discharge Check Valve, Wafer 4 — 20" Discharge Expansion Joint 4 -- Surge/Overload/Vibration Protection Panel, NEMA 12 Budget price for the above equipment is $642,000,00 FOB Syracuse, NY. Freight to the jobsite, start-up service and training are not included in this price. Due to the size of the project, payment terms will need to be discussed prior to order placement. Drawings can be supplied in 3 to 4 weeks from receipt of an order. Estimated shipping time is 22 to 26 weeks from release for fabrication. Please let me know if you have any questions or require any additional information. Regards, Pa ru 1Nowal , ON oft .. PM .. .• no .. .. am r. fm on a� am �I a* oft fm ram, 0% aft ,a. po MR Continental Blower LLC - Blower / Exhauster Selection - design data Customer Dewberry Project -No : blo Pharma Project Application Date 22-10-2018 Notes Heyward Air blower 600A.04 - 590.8 HP - 3570 RPM impeller 3x9202 + 1x9201 Drive arrang. direct drive, 2-poles motor 60 Hz Suggested motor 650.0 HP Prepared by PLW Printed 13 November 2018 14:59 ---- PERFORMANCE CURVE ---- 600A.04 - 3x9202 + 1x9201 3570 RPM 3670 RPM 541 600 623 550 IL = O IL. . - 500 i�VL a 450 O 1400 350 4000 5000 6000 7000 8000 9000 10000 11600 12000 13000 14000 15000 16600 17000 13 11.0 11.0 12 • 11 :.... .... 10 :. .. .... ..... 8 _......................... .... 6 a 4 3 .......... 3 2 -1 0 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 15000 16000 17000 Flow rate - scfm (Std:14.696 psla, 68°F, 36% RH) ♦ = a�scciv PaNr Dsgn : AIR : t1 =105.0 °F pBar = 14.496 psia RH / inlet = 80 % Alt-1 : AIR: 11 = 105.0 OF pBar = 14.496 Asia RH / inlet = 80 % CURVE DEWBERRY-SIO PHARMA-REV1A - WINSELECT 6.65-59e 08. October 2018 - CONTINENTAL INDUS1111312018 14:59 — page 1 of 5 — 4M Continental Blower LLC - Blower I Exhauster Selection - design data Customer Dewberry Project -No bio Pharma Project Application Date 22-10-2018 Notes Heyward Air blower 600A.04 - 590.8 HP - 3570 RPM impeller 3x9202 + 1 x9201 Drive arrang. direct drive, 2-poles motor 60 Hz Suggested motor 650.0 HP Prepared by PLW Printed 13 November 2018 15:01 --•- OPERATING CONDITIONS ---- Operation : Air blower Barometric pressure 360 ft asl --> 14.496 psia Gauge pressure I inlet 14.496 PSIA -> 0.000 psig Variable losses / inlet 0 inchH2O ••> 0.000 psig Gauge pressure I outlet 11 PSIG -•> 11.000 psig Variable losses / outlet 0 inchH2O --> 0.000 psig Design temperature / inlet 105 F --> 105.0 °F Relative Humidity / inlet 80 % --> 80 % Design flow rate 10000 scfm --> 11455.2 lcfm ---- THERMODYNAMICAL DATA -- pi - 14.496 psi a p2 - 25.532 psi a p2/01 - 1.7613 tl - 105.0 °F t2 = 233.0 OF Ri 293,7533 J/(kg K) Q1 -- 11455.2 icfm 02 - 7978.5 cfrrt Pad = 444.9 HP rhol - 0,068 Ib/ft3 rho2 - 0.0972 Ib/113 PGas - 581.9 HP kappal -- 1.3939 Cp1 1039.56 JI(kg K) MW - 6.76Ibllbmol mTotal - 775.8lb/min mAir - 745.7lb/min mWV - 30.0lb/min Val.% Total = 100.0 lb/min Vol.% Air = 93.9 % Vol.% WV --- DESIGN POINT - UNTHROTTLED ---- Flow rate (00) : 10000.0 scfm (Std: 14.696 psis, 68°F, 36°% RH) Gauge pressure Pressure 11.04 psig (deviation: + 0.3 %) Driver (PDr) / Machine (P) shaft power: 590.8 HP (at 105.0 °F, 80 % rel. humidity) Adiabatic efficiency (eta ad) 76.5 % Polytropic efficiency (eta poly) 78.3 °% Blower mech. efficiency 98.5 % Transmission mech. efficiency 100.0 % --- SURGE / DESIGN POINT DATA -- Q1 icfm QO scfm Q2 cfm Pressure psiq P HP PDr HP eta ad % eta pol % t2 OF SP DP 5198.9 11455.2 4638.49 10000.00 3677.76 7978.50 12.34 11.04 365.70 590.79 365.70 590.79 61.42 76.52 64.54 78.29 233.0 turn down 6256.3 icfm (54.6 °%) (for 01) pressure rise DP--->SP 1.3 psig (11.8 %) power rise SP-->DP 61.5 % REPORT DEWBERRY-BIO PHARMA-REV1A - WINSELECT 6.65-59e 0 8. October 2018 - CONTINENTAL INDUn 1/1312o1a 15:01 - page 1 of 4 - so ow ON or PM am am oft r No am am .► a" ow am fm no r� M fm me an dw aiw Continental Blower LLC - Blower / Exhauster Selection - design data ---- MACHINE SPECIFICATIONS ---- model 600A.04 impellers U9202 + 14201 drive arrangement direct drive, 2-poles motor 60 Hz REPORT DEWBERRY -BID PHARMA-REViA - WINSELECT 6.65-58e ®8. October 2018 - CONTINENTAL. INDUy1r131201s 15:01 — page 2of4-- aa Continental Blower LLC - Blower ! Exhauster Selection - alternate 1 ---- OPERATING CONDITIONS - ALT1 Operation: Air blower Barometric pressure 360 It asl --> 14.496 psia Gauge pressure / inlet 14.496 PSIA --> 0.000 psig Variable losses / inlet 01nchH20 --> 0.000 + 0.476 psig (throttled) Gauge pressure / outlet 11 PSIG --> 11.000 psig Variable losses I outlet 0 inchH2O --> 0.000 psig Design temperature / inlet 105 F --> 105.0 OF Relative Humidity / inlet 80 % -> 80 % Design Row rate 8000 scfm 9164.1 icfm ---- THERMODYNAMICAL DATA - ALT1 »-- p1 - 14.020 psi a p2 - 25.497 psi a p2/pl - 1.8187 t1 s 105.0 OF t2 - 246.9 OF Ri = 293.7533 J/(kg K) 01 - 9475.6 icfm 02 - 6514.7 cfm Pad = 377.8 HP rhol - 0.065 Ib/ft3 rho2 = 0.0952 Ib/ft3 Peas - 515.6 HP kappal -- 1.3939 Cp1 -- 1039.5E J/(kg K) MW 6.76 Ib/ibmol mTotal - 620.1 lb/min mAir - 595.3 lb/min mWV - 24.8 ib/min Vol .% Total = 100.0 lb/min Vol.% Air = 93.9 % Vol.°% WV = 6.1 % ---- DESIGN POINT - ALT1 - THROTTLED ---- Flow rate (QO) : 8000.0 scfm (Std: 14.696 psia, 68°F, 36°% RH) Gauge pressure Pressure 11.00 pslg 0.0 °%) Driver (PDr) / Machine (P) shaft power: 523.5 HP (at 105.0 OF, 80 °% rel. humidity) Adiabatic efficiency (eta ad) 73.3 % Polytropic efficiency (eta poly) 75.4 % Blower mech. efficiency 98.5 °% Transmission mech. efficiency 100.0 °% ---- SURGE / DESIGN POINT DATA - ALT1 ---- Q1 icfm QO scfm 02 cfm Pressure psis P HP PDr HP eta ad % eta pot % �.w t2 OF SP DP 5198.9 9475.E 1 4493.58 8000.00 3676.69 6514.72 12.07 11.00 362.00 523.50 362.00 523.50 61.43 73.27 64.55 75.39 x�79'i►a=v 246.9 -»-- MACHINE SPECIFICATIONS - ALT1 ---- model 600A.04 Impellers 3x9202 + 1 x9201 drive arrangement direct drive, 2-poles motor 60 Hz REPORT DEWBERRY-BIO PHARMA-REV1A - WINSELECT 6.65-59e 08. October 2018 - CONTINENTAL INDUA 1/13l2018 15:01 - page 3 of 4 -- a. a OR am oft so om .r 1M am so am an TECHNICAL DATA Number of stage : 1 t ru 6 Inlet connection : 24" (612 mm) flange, matches 125# AN! Outlet connection : 20" (511 mm) flange, matches 125# AN; or 18" (460 mm) flange, matches 125# AN: Operating speed: 3550 rpm in direct drive (601-1z) Lubrication : Oil type with constant level Impeller diameter: From 34" (864 mm) to 36" (915 mm) Impeller tip speed : 443 (ps (135 m/sec) ^ Drive : Direct drive or gear box Vibration tolerance: 1.25 mils peak -to -peak (4.5 mm /s) Balance piston : From 3 to 6 stages with pipes connection Shaft end : 3" 3/4 (95 mm), inlet end drive standard MATERIALS OF CONSTRUCTION ~ Heads, Sections, Bearing housings: Casri=AS7MA-48Class 35B Tie rods : 7/8" (22 mm) diameter cold drawn steel A60 Joint sealing compound : RN IS502 Silicone Seals (air) : Two graphit rings each end Seals (,gas) : Four carbon rings each end with inert gas injection Bearings: Ball bearings 6320 C3 P92AFBMAB10SfA1`440 Shaft: AISI 1038 Carbon steel or equivalent Impellers : Fabricated aluminium ASTM 6061 Baffle rings: Stainless steel Motor pedestal : Structural steel. Base pods: Anchor bolts NoisakW: In co nplionee with OSHA standards when machine is Cully, piped (certified tests available). BLOWZR ZIZZ rrA' B "Crr WEIGHT LZ6 11 RO ROTORWR' (Ib. IF) 60001 26.77 (680) 126.0 (3200) 144.0 (3658) too no4 76.W 60009 36.85 (936) IM.0 (3505) 156.0 (3962) 149M woo 12855 60000 46.93 (1192) 162.0 (4115) 180.0 (4572) 19w 58M 181.07 60006 57.W(1448) 162.0(4115) 1BO.0(4572) 14720 6709 9 A9 60005 67.08 (1704) 186.0 (4724) 204.0 (5182) 16970 110 M.11 60006 77.16 (1960) 186.0(4724) 204.0(5182)1ws0 wro 808.11 DIMENSIONS ARE IN INCHES AND IMMI ACTUAL DIMENSIONS MAY VARY SLIGHTLY TO SUIT APPLICATION "600" SERIES ) I / AIR & GAS , -- it. it 143 ?F� .�J�_y^��IIIIJt,I> i--F Ili IIIIII+. IPl!lil'Isl"'/1 B= li uni � l.i�,iiliil')�_� s_ 0 MEN 1 Q EN; 6 6 Working area z 1 � `all 1 a= e. � 1 `2- z Mirx ed V 1 B II O •� f O u 000 15 000 20 000 25 000 SON10 30 000 INLET FLOW IN SCFM ■■■ITV■■■■ ,,• . i,■-� MODEL 600 I ■■■�ttltllltla/■■I ® Values, dimensions and reterenw in dsis brochure are approximate and imended a: a golds only, not I« wns6o41ien and are svbjva to change without notice. CONTINENTAL BLOWER LLC .CONTINENTAL BLOWER LLC. CONTINENTAL BLOWER LLC. CONTINENTAL BLOWER LLC. 2. Mixers Dewberry Novorymes North America, Inc. I Engineering Alternatives Analysis I APP M TO: Franklinton Biopharma Project Franklinton, NC USA ATN: CC: Heyward Incorporated,Jim Cooper A PROPOSAL DATE: November 8, 2018 Proposal # 51268 If billing and/or shipping address is different, please advise. Qty Description Unit Price Total Price We are pleased to quote, for acceptance within (30) days of this date, prices and terms on equipment listed below. Equipment readiness is expected to be (8-10) weeks* after receipt of purchase order with mutually acceptable terms and conditions, subject to credit approval. *Notes: Aqua -Aerobic Systems' proposal is based upon supply of equipment models as noted. Actual shipment is dependent on equipment availability at the time of receipt of order. Note: Aqua Aerobic Systems, Inc. will be closed November 22-23 & December 24 - January 1. Equipment will be furnished by Aqua -Aerobic Systems, Inc. with civil work and installation by the purchaser. 3 40 HP Model SS Endura® Series AquaDDM® Mixer. Motor base $25,585.81 $76,757.43 and intake volute assemblies will be of 304 stainless steel. Float is 14 gauge 304 stainless steel skin, filled with closed cell polyurethane foam. Propeller is cast stainless steel. Motor will be premium efficient, TEFC, 460 volt, 3 phase, 60 hertz, 900 RPM with 1.15 service factor and Class F nonhygroscopic insulation. Motor shaft is one-piece 17-4 PH stainless steel. WARNING: The AquaDDM9) Mixer has a high velocity downflow discharge directly below the unit. This flow pattern may, in some instances, cause damage to basin bottoms, creating leaking potential. In earthen or lined basins, Aqua Aerobic Systems recommends the use of a concrete pad on the basin bottom directly below the mixer. If concrete is known to be nonresistant to the waste, other materials should be investigated. If basin contains toxic wastes, user is advised to obtain engineering advice as to basin design and construction necessary to prevent possible erosion and leakage. Aqua Aerobic Systems assumes no liability or responsibility for any damage to basin bottoms or walls, or for any injuries or damages resulting therefrom. COMMERCIAL NOTES: .. Freight charges are NOT included in this proposal. Freight charges will be prepaid with actual charges to be added to invoice. Startup supervision is NOT included. Payable net 30 days from date of shipment subject to credit review; no retainage allowed. - Unless specifically stated herein, no taxes were included in Aqua -Aerobic Systems' price. State and/or local taxes will be charged unless we receive a valid resala/exemption certificate. 6306 N. Alpine Rd. Loves Park, IL 61111-7655 p 815.654.2501 f 815.654.2508 wwwaqua-aerobic.com Copyright 2018, Aqua -Aerobic Systems, Inc Printed: November 8, 2018 Page 1 of 5 AQUA -AEROBIC Proposal Date: November 8, 2018 Proposal # 61268 Ar SYSTEMS. INC. ,,,,....,.� SCOPE / EQUIPMENT NOTES: - Only the aerator and/or mixer unit is provided. Electrical and mooring accessories, control panels, junction boxes, anchors and eyebolts are not included in Aqua's scope of supply and shall be supplied by others. Pricing is provided below for reference. - Based on the current instability in stainless steel pricing, Aqua -Aerobic Systems, Inc. reserves the right to re-evaluate the pricing quoted prior to order acceptance. - Aqua -Aerobic Systems' offer is based upon the supply of Aqua -Aerobic Systems' standard equipment as described within this proposal, including the warranty as included within Terms and Conditions of Aqua -Aerobic Systems, Inc., and Aqua -Aerobic Systems' standard factory test(s) prior to shipment. Aqua -Aerobic Systems' scope of supply does not include any process or performance guarantees or warranties or process or performance testing unless specifically detailed within this proposal. - TRADEMARKS: Aqua -Aerobic, Aqua -Jet, Aqua -Jet II, AquaDDM, ThermoFlo, Endura Series, OxyMix, Fold -a -Float, Aqua MixAir, AquaCAM-D, AquaSBR, Aqua MSBR, AquaPASS, Aqua BioMax, AquaEnsure, Aqua EnduraTube, Aqua EnduraDisc, Aqua CB-24, AquaDisk, AquaDiamond, AquaDrum, Aqua MiniDisk, Aqua MegaDisk, AquaPrime, OptiFiber, OptiFiber PES-13, OptiFiber PA2-13, OptiFiber ACR-13, OptiFiber PES-14, OptiFiber PF-14, Trust the Tag, AquaABF, Turbilite, AquaMB Process, Aqua -Aerobic MBR, Aqua UltraFiltration, Aqua MultiBore, Aqua MultiBore Series C, Aqua ElectrOzone, SpareCare, IntelliPro, Aqua Financing Solutions, and the Aqua -Aerobic logo are registered trademarks or pending trademarks of Aqua -Aerobic Systems, Inc. All other products and services mentioned are trademarks of their respective owners. Nereda@ is a registered U.S. trademark of Royal HaskoningDHV. SHIPPING NOTES: To expedite your order, please provide the shipping instructions below: Earliest acceptable equipment on site date: Ship to address (including zip code): Driver to provide 24 or 48 or HOURS pre -delivery notice to: Jobsite contact name: @ telephone number: Deliveries are accepted on the following days of the week: Monday Tuesday Wednesday Thursday Friday Saturday Sunday Acceptable hours of delivery — _ AM to — PM Special instructions to relay to the carrier and/or the driver: 6306 N. Alpine Rd. Loves Park, IL 61111-7655 p 815.654.2501 IF 815.654.2508 wwwaqua-aerobic.com Copyright 2018, Aqua -Aerobic Systems, Inc Printed: November 8, 2018 nr Page 2 of 6 AQUA -AEROBIC Proposal Date: November 8, 2018 Proposal # 51268 SYSTEMS, INC. Pricing Summary Equipment and/or Accessories: $76,757.43 Total Job Price: $76,757.43 Material and/or services not specifically listed in this proposal are not included in the quoted TOTAL JOB PRICE and are to be supplied by others. Goods quoted above will be sold subject to the terms and conditions of sale set forth on the face hereof and the following pages entitled "Terms and Conditions of Aqua -Aerobic Systems, Inc. (A MetaWater Company)": Any different or additional .. terms are hereby objected to. Available Options 1 Feet, 7 X 19 X 1/4" high flex 304 stainless steel mooring cable. $1.10 $1.10 1 Cable clip(s) 1/4" U-bolt. $4.09 $4.09 1 3/16" - 1/4" 316 stainless steel wire rope thimble. $4.05 $4.05 1 Feet, #4 AWG flexible service cable for 460 V, 40 HP operation. $13.18 $13.18 Cable has three power conductors and an insulated ground conductor assembled together with a nonhygroscopic filler materia in a hard usage outerjacket. 1 1" - 1-1/4", 2 eye, wire mesh strain relief cord grip assembly. $45A5 $45.15 1 3/4" spiral wrap abrasion protection for power supply cable. $43.39 $43.39 1 5' x 9" plastic electricaVmooring cable float complete with 2 nylon $14.83 $14.83 ties. 6306 N. Alpine Rd. Loves Park, It 61111-7655 p 815.654.2501 If 815.654.2508 wwwzqua-aerobic.com �" Copyright 2018, Aqua -Aerobic Systems. Inc Printed: November 8, 2018 Page 3 of 6 Proposal Date: November 8, 2018 Proposal # 51268 AQUA -AEROBIC p P SYSTEMS, INC. TERMS AND CONDITIONS OF AQUA-AEROBICSYSTEMS, INC. (AMetawater Company) Page I of 2 This offer and all of the goods and sales of Aqua -Aerobic Systems, Inc. are subject only to the following terms and conditions. The acceptance ofany order resulting from this proposal is based m the expresscondition that the Buyer agrees to all the terms and conditions herein contained. Anyterns and conditions in any order, which are in addition to or inconsistent with the following, shall not be binding upon Aqua -Aerobic System, Inc. This proposal and any contract resulting therefrom, she] I be governed by and construed in accordance with the laws of the State of Illinois, without regard to conflicts of laws principles. �. PAYMENT Unless specifically stated otherwise, quoted terms are Net 30 Days from shipping date. Past -due charges are 1.5%per month and will apply only on artypast-due balance. AquaAerobic Systems, Im. does mt allow retainage ofany n%vice amount, mlessauthorized in writing by an authorized representative ofour Loves Park, Illinoisoffnce. DURATION OF QUOTATION This proposal of Aqua -Aerobic Systems, Inc shall in no event be effective more than 30days from date thereof, unless specifically stated otherwise, and is subject tochange at arty time prior to acceptance. SHIPMENT Shipping dates are rota guarantee of a particular day of shipment and are apprmimate, being based upon present production information, and are subject to change per the production schedules existingat torte of receipt ofpurchase, order. Aqua -Aerobic Systems, Inc. shall not be responsible for any delay in shipment for causes beyond is control including, but net limited to, war, riots, strikes, labor trouble causing interruption ofwork, fires, other casualties, transportation delays, modification oforder,any act of governmental authoritiesoracts of God Quoted shipment datesin this proposal are approximate dates goods will be shipped arid, unless agreed to in writing by Aqua,Aerobic Systems, Im., Buyer may not postpone or delay the dazes ofshipnentofgoods from ourplant orfrom our suppliers plants beyondthe datessetforth inthis proposal. .. TITLE AND RISK OF LOSS All pricesand all shipmentsofgoods are F.O.B. Aqua -Aerobic Systens,lnc.'splmt at Loves Park, Illinoisunless specifically stated otherwise Delivery ofthe goedssold hereunder to thecarriershall bedeemed deliveryto the Buyer,and upon suchdelivery,title to such goodsandrisk oflom or damage shall be upon Buyer. TAXES Pricesqueted do not include arty taxes, arstomsduties,or import fees, Buyershallpay any and all use, sales, privilege or other tax or customs duties or import Jima levied by any governmental authority with respect to the sale or transportation of arty goods covered hereby. If Aqua -Aerobic Systems, Inc isrequiredby any taxmgauthority tocollector to payany such tax, duty or fee, the Buyer shall be separately billed at such time for the amounts Aqua -Aerobic System%Inc isrequiredto pay. INSURANCE �. Unless the goods are sold on a CIF basis, the Buyer shall provide marine insumme for all risks, including war and general coverage. SECURITY Ifat any time the 9remcial responsibility of the Buyer becomes unsatisfactory to Aqua -Aerobic Systems, Im., or Aqua -Aerobic Systems, Inc. otherwise deems iself insecure as to receipt of full payment of the purchase price from Buyer hereunder, Aqua -Aerobic Systems, Inc. reserves the right to require payment in advance or security or guarantee satisfactory to Aqua -Aerobic Systems, Inc. of payment in full of the purchase price. LIMITATION OF ACTION No action shall be brought against Aqua -Aerobic SystemsSysteni% Inc. for any breach of its contract of sale more than two years after the accrual of the cause of action thereof, arid, in no event, unless the Buyer shall fast have given written notice to Aqua -Aerobic Systems, Inc., of my claim of breach of contract within 30 days after the discovery thereof. CANCELLATION CLAUSE No acceptance of this proposal, by purchase order or otherwise, maybe modified except by written consent of Aqua -Aerobic Systems, Inc. tar may it be cancelled except by prior payment to Aqua -Aerobic Systems, Inc. the following sums as liquidated damages therefore: 1) If cancellation is prior to commencement of production and prior to the assumption of my obligations by Aqua -Aerobic Systems, Irafor any materials or component parts, a sum equal to l 5°/u of the total purchase prim; 2) If cancellation is after the commencement of production or after the assumption of any obligations by Aqua -Aerobic Systems, Inc for any materials or component parts, a sum equal to theta al of the direct, out-ofpocketexpenses incurred to the date of camel lation for Iabor, machine time, materials and arty charges made to us by suppliers fix cancellation, plus 30"/o of the total purchase price. Al I charges and expenses shall be in determined by Aqua -Aerobic Systems, Inc. In the event arty items are used by Aqua -Aerobic Systems, Inc. to fell a subsequent order, then upon receipt of payment for such order, Aqua -Aerobic Systems, Inc, shall pay the Buyer a sum equal to the direct out-of- pocket expenses previously charged and received from Buyer. PROPRIETARY INFORMATION This proposal, including all descriptive data, drawings, material, information and know-how disclosed by Aqua-Aembic Systems, Inc. to Buyer in relation hereto is confidential information intended solely for the confidential use of Buyer, shall remain the property of Aqua -Aerobic Systems, Inc. and shall not be disclosed or otherwise used to the disadvantage or detriment of Aqua -Aerobic Systems, Inc. in arty manner. 6306 N. Alpine Rd. Loves Park, IL 61111-7655 p 815.654.2501 1815.654.2508 www.aqua-aerobic.com Copyright 2018, Aqua -Aerobic Systems, Inc Printed: November 8, 201 g Page 4 of 5 AQUA -AEROBIC Proposal Date: November 8, 2018 Proposal # 51268 SYSTEMS, INC. .u.....0 n TERMS AND CONDITIONS OF AQUA -AEROBIC SYSTEMS, INC. (A Metawater Company) QUALIFIED ACCEPTANCE AND INDEMNITY Page 2 of 2 In the event the acceptance of this proposal by Buyer either is contingent upon or subject to the approval by any third parry such as, but not limited to, a consulting engineer, with respect to goods, parts, materials, descriptive dam, drawings, calculations, or, any oilier matter, then upon such approval by any third party, Aqua -Aerobic Systems, Inc. shall have no liability to Buyer orto any third party so long as the goods sold and delivered by Aqua - Aerobic Systems, Inc. uonfrrm to this proposal. In the event any such (bird party requires modificationsin the proposal prior to the approval thereof, Aqua -Aerobic Systems, Inc may atits sole option and without liability to anyparty elect to cancel this proposal or remm die purchase order to Buyer. In the event Aqua -Aerobic Systems, Inc, elects to modify this proposal to conform to the requirements fir approval by any third parry, Aqua -Aerobic Systems, Inc. in such event shall have no liability to Buyer or to any third party so long as the goods sold and del ivered by Aqua -Aerobic Systems, Inc conform to this proposal as modified. Buyer agree s to indemnify and save hamdess Aqua -Aerobic Systems, lne. from and against all costs and expenses and liability of any kind whatsceverarising out ofor incomnection with claims by third parties solong as the goods sold hereunder conform to therequbements ofthis proposal as approved by any third parry. WARRANTY; LIMITATION OF LIABILITY; ANDDISCLAIMER In return for purchase and full payment for Aqua Aerobic Systems, Inc. goods, we warrant new goods providedby us to be free from defects in materials and workmanship under normal conditions and use for a period of one year from the date the goods are put into service, or eighteen months from date of shipment (whichever first occurs). If the goods include an "Endure Series" motor, the complete Endura Series unit shall be warranted by Aqua -Aerobic to be free from defects in materials and worlananship umdernonml conditions and use forthreeyeirs from the datethe productis put into service or 42 months from the date of shipment (whichever occurs first). OUR OBLIGATION UNDERTHIS WARRANTY IS EXPRESSLY AND EXCLUSIVELY LNIITED to replacing or repairing (at our factory at Loves Park, Illinois) any part or parts returned to our factory with transportation charges prepaid, and whichour examination shall slow to have been defective. Prior to retain of any goods or its parts to our factory, Buyer shall notify Aqua -Aerobic Systems, Inc. of claimed defect, and Aqua - Aerobic Systerm, Inc. shall have the privilege of examining the goods at Buyer's place of business at or where the goods have otherwise been placed in service. In the event this exsmiration discloses no defect, Buyer shag have no authority to return the goods or parts to our factory for the further examination or repair. AI I goods or parts shall be returned to Buyer, F.O.B. Loves Park II lino is. This warranty sbalI not apply to any goods or part which has been repaired or altered outside our factory, or applied, operated or installed contrary to our insruction, asubjected to misuse, chemical atrack/degradation, negligence or aceidemt. This warrmty and any warranty and guaranty ofprocess or performance shall no longer be applicable or valid if any product, including any software program, supplied by Aqua -Aerobic Systems, Inc., is modified or altered without the written approval of Aqua -Aerobic Systems, Inc Our warranty on accessories and component parts not manufactured by us is expressly Iinited to that of the manufacturer thereof THE FOREGOING WARRANTY IS MADE IN LIEU OFALL OTHER WARRANTIES, EXPRESS OR IMPLIED, AND OF ALL OTHER LIABILITIES AND OBLIGATIONS ON OUR PART, INCLUDING ANY LIABILITY FOR NEGLIGENCE, STRICT LIABILITY, OR OTHERWISE; AND ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE IS EXPRESSLY DISCLAIMED; AND WE EXPRESSLY DENY THE RIGHT OF ANY OTHER PERSON TO INCUR OR ASSUME FOR US ANY OTHER LIABILITY IN CONNECTION WITH THE SALE OF ANY GOODS PROVIDED BY US. THERE ARE NO WARRANTIES OR GUARANTEES OF PERFORMANCE UNLESS SPECIFICALLY STATED OTHERWISE. UNDER NO CIRCUMSTANCES, INCLUDING ANY CLAIM OF NEGLIGENCE, STRICT LIABILITY, OR OTHERWISE, SHALL AQUA -AEROBIC SYSTEMS, INC. BE LIABLE FOR ANY INCIDENTAL ORCONSEQUENTIAL DAMAGES, COSTS OF CONNECTING; DISCONNECTING, OR ANY LOSS OR DAMAGE RESULTING FROM A DEFECT IN THE ., GOODS. LIMIT OF LIABILITY: AQUA -AEROBIC SYSTEMS, INC.'S TOTAL LIABILITY UNDER THE ABOVE WARRANTY IS LIMITED TO THE REPAIR OR REPLACEMENT OF ANY DEFECTIVE PART. THE REMEDIES SET FORTH HEREIN ARE EXCLUSIVE, AND OUR LIABILITY WITH RESPECT TO ANY CONTRACTOR SALE, OR ANYTHING DONE IN CONNECTION THEREWITH, WHETHER INCONTRACT, IN TORT, UNDER ANY WARRANTY, OR OTHERWISE, SHALL NOT, IN ANY CASE, EXCEED THE PRICE OF THE GOODS UPON WHICH SUCH LLABILITY IS BASED. Final acceptance of this proposal must be given to Aqua -Aerobic Systems, Inc. at iheiroffice in Loves Park. Illinois. Please acknowledge acceptance by signing the proposal and returning it to Aqua -Aerobic Systems, Inc. Accepted by: Offer Respectfully Submitted, // /eZG 114&2L4,Q� Michaela Villarreal. Rotatina Products Sales Assistant By: Date: Aaua-Aerobic Systems, Inc. 6306 N. Alpine Rd. Loves Park, IL 61111-7655 p 815,654.2501 1815.654.2508 www.aqua-aerobic com Copyright 2018, Aqua -Aerobic Systems, Inc Printed: November 8, 2018 Page 5 of 6 3. Fine Bubble Aeration System Dewberry Novorymes North America, Inc. I Engineering Alternatives Analysis I RPP P4 Lawrence, Jordan From: Jim Cooper <1Cooper@heyward.net> Sent: Thursday, November08, 201812:15 PM To: Poulios, Michael; Lawrence, Jordan Subject: Franklinton, NC - Dewberry Biopharma project - SSI Aeration Biological treatment basin (Q-102518 [A]) Attachments: Dewberry Biopharma project- (Heyward Incorporated )_Q-102518 [A1.docx This message originated from outside your organization ., Michael and Jordan: L] Attached is the revised layout and relevant information on Fine bubble Aeration System for Dewberry Biopharma project based on the lower air flow rate given yesterday (10,000 scfm per basin). This is for the biological basin as we have sent earlier the coarse bubble diffused air recommendation for the EQ, digester and reaeration tanks. The costing and layout is based on each of the three (3) tanks being 107' diameter X 20' tall. .. TOTAL LUMP SUM Budgetary Price: FOB jobsite including site service is $ 895,000.00. The service is 3T/6D. Don't know if that is enough for installation and training and commissioning. Just _ depends on the schedule and your requirements. SSI Aeration kept the same number of diffusers in this revised proposal even with the reduced total air requirement. In the prior or original proposal SSI Aeration used maximum air capacity of diffusers r, now its came down to comfortable range for the diffuser. If you have any questions and / or need clarification we would be glad to assist further. Sincerely, Jim Cooper Heyward Incorporated 704-583-2305 - office 704-591-1270 - cell jcooper@heyward.net 551 Budget Proposal '_ ' an iTi Aeration Performance IThrough1h n ovation Fine Bubble Diffuses DlscType • S • - �r— Reliability Built In -_ Advanced MembraneMaterials.�......�.• �~� H Complete Aeration System.; Designed for You p'me Bubble Diffusers Tube Type TeleiuetrySystems Rea I Time Camera Mon Itoring Retrievable Systems Easyto Maintain OEM Replacement Membranes Retrofit Existing Systems o:Dewberry Revision -A Attention: Jordan Lawrence, EI Date: 25thOctober, 2018 From: SSI Aeration, Inc. Ref:Dewberry Biopharma Project(Heyward Incorporated) r PROPOSAL AERATION EQUIPMENT Revision 'A': Updated with latest airflows provided in email dated on 8th November, 2018 Sir, In response to your email and based on the information, SSI as an ISO-9001 certified corporation is pleased to submit this proposal quotation for the design, manufacture & supply of Aeration Equipment Including all pre-engineered and pre -fabricated 304SS Drop pipe + piping within the tank, all diffusers and accessories required to connect diffusers to pipe, as well 304SS support stands, pipe joints and continuous purge for each grid. (Standard limit of supply from t6" above water level and Isolation valves are not included in SSI Scope of supply). A. Design Information: Parameter PerBioreactor Tank Airflow (SCFM) 10,000 Airflow/Diffuser SCFM 2.24 Diffusers Pcs 4,464 B. SCOPE OF SUPPLY: Fine Bubble Diffuser Equipment with AFD270-EFine bubble diffusers with EPDM membranes for Three (3) BioreactorTanks. Each Bioreactor Tank is 107'(Dia) x 20' (SWD) consists of Four (4) grids andSupplied with Aeration Equipment as follow: G 012" 304SS SCH.10 04" PVC SDR.32.5 Headers R Droppipe + Cooling 012" PVC SCH.40 Manifold c/wfactory drilled holes for field POD270-E Fine I Pipe ±70' mounfing of Saddles & diffusers bubble diffusers D SS 3048S Length SS 304SS Length 304SS PVC Active Blank CouplingSupports PP Coupling P 9 Supports PPo Supports PP Couplings #1 4 11 20' 1 3 1,400' 255 85 1,116 256 #2 4 11 25' 2 5 1,350' 260 88 1,116 238 #3 4 11 20' 1 3 1,400' 255 85 1,116 256 #4 4 11 25' 2 5 1,350' 260 88 1,116 238 Number of AFD270-E Diffusers per Bioreactor tank 4,464 988 Pag. 2SSI Aeration Proposed prepared 11,17010161R (I Ic.x%%md Incorporated) on'9"' October.'018 am am r, FM 9w am am fm am ELI dim a= am 0107' x 20'(SWD) BIOREACTOR TANK LAYOUT PLAN TOTAL THREE (3) REQUIRED AS SHOWN ABOVE COMMON FOR THREE (3) BIOREACTOR TANKS Total number of AFD270-E Active Diffusers for Three (3) Bloreactor Tanks (4,464/Tank) *3 = 13,392 Total number of AFD270-E Blank Diffusers for Three (3) Bioreactor Tanks (988/Tank) *3 = 2,964 C. Spares: • AFD270-E Diffuser Membranes-100 • 4" 304SS Supports —10 • 4" PVC Couplings — 5 D. Freight to jobsite:Raleigh, NC 27607, USA E. Manufacturer's site services: 6 days / 3trips (Installation inspection, startup assistance and 0 & M training) am I Pag. 3SSI Aeration Proposal prepared RI=Q101618 (HeN and Incorporated) on 2-01 October. 2018 F. TOTAL LUMP SUM PRICE (for all listed above)..............................................................$ (To be provided by Jim Cooper of Heyward Incorporated our local rep Email. jcoopertPheyward.net) COMMERCIAL BASIS OF OFFER 1. Delivery Program: • Approval Submittals and 0 & M Manuals; 1-2 weeks after receipt of P.0 and all information necessary to prepare submittals. • Ready to ship: after receipt of approved submittals : 6-8 weeksfor Bioreactor#1 : 10-12 weeksfor Bioreactor#2 : 14-16 weeksfor Bioreactor#3 2. Payment Terms: • For Municipal/Govt projects 95% net 30 days after shipment and balance 5% at the time of startup or 75 days after shipment whichever comes earlier. • For private and overseas jobs: 30% with PO , 30% with approve submittal and balance 40% net 30 days afer shipment (subject to credit approval) 3. Quotation Validity:Valid from date of proposal for a period of 45days. 4. Exclusions: • All local taxes import custom duties, brokerage etc. • Freight cost CIF jobsite unless otherwise noted • Offloading upon delivery to site • Site services for installation inspection and start up assistance. • Field assembly if any, installation, site work and relevant field tests. • Any localized bank charges and L/C charges are to be paid by the customer or by agreement. • Field tests • Factory Oxygen transfer efficiency (OTE) test • Blowers, Isolation valves and air main piping • Any items and services not itemized within the above scope of supply. S. SSI Quality Assurance: SSI is an IS09001 certified company. 6. Warranty: Products manufactured by Seller are warranted to be free from defects in materials or workmanship for 18 months from date of shipment or 12 months from the date of start-up, whichever comes first. SSI's responsibility is limited to the cost of the defective parts, and specifically excludes damages because of maintenance activities, excessive airflow, foreign debris in the airstream, or excessive exposure to heat or other elements. Fouling because of bio film or chemical precipitation or solvent exposure do not constitute defects. Unless fieldwork has been contracted to SSI, labour is excluded from warranty coverage. We thank you for the inquiry with the opportunity to quote on the Aeration equipment of this project and look forward to work with you in the very near future. Pag. 4SS1 Aeration Proposal prepared RFQ101618 (Heyward Incorporamd) on 25"' October.'018 M so am am dft fm O. am MR am me We would be pleased to assist you further if you have any questions or need clarification on this proposal. Yours truly, SSI Aeration., INC Kiran Banala, (Ext .308) Manager — Engineering kiran@ssiaeration.com Cc: Jim Cooper of Heyward Incorporated our local rep Email: jcooper@heyward.net, Phone: 704-591-1270 Pag. 5SS1 Aeration Proposal prepared RFQ101618 (Heyward Incorporated) on 25"' October. 2018 0 CEMM1 SSI Aeration SMART IDEAS FOR WATER What Makes the SSI 9" Disc Diffuser Systems a Worldwide Choice? The SSI g" Disc Diffuser System combines engineering excellence, superior component quality, and a technically advanced product design. Proven highly durable and efficient in thousands of municipal and industrial installations around the world, this advanced system has reliability built into 1111 every stage of performance. Grommet Connection POD Connection Disc Diffuser �osrnaRmml rma..nm- &J�IM\OT PxPau f RelaiR nut 1p'NRr 1 o�unaae bw SSI `( +emu. •- -�. ^M „� ��T iYYYY +�Y„iYY a��YYY �^�a 't 1y♦Y 1Y'��� Yyre"yR ���1�"�\ Aeration Pag. 6SSI Aernliun Prupo A prepared RI Q 101618 (1Ic,N�iud Incorpor.ucd) oil _a'�' Oea�ber. '_UI8 iM r r M iiiiiiii r 1111111, Unique System Strengths Complete product line -creating the system that fits your needs SSI manufactures disc diffusers and coarse bubble diffusers, and we mount these products on a wide range of piping materials including PVC, CPVC, PP and Stainless Steel We have the ability to attach diffusers to pipe using saddles, grommets, or pre -assembled PODS. We can provide retrievable systems or raced grids, and systems in kit form or mostly factory assembled. We try to understand and anticipate your needs, and fit our recommendations to your situation. Piping system integrity -thicker wall pipe and double anchors for fewer breakages Our piping is 38%thicker and has double rod support stands as standard -two anchors for each support location means twice the resistance to hydraulic and thermal loads. Most often supports fail due to temperature and water velocity. SSI locates two anchors where support is needed most, helping to Increase product longevity. Comprehensive design service and after sales support SSI provides full design services, Including biological and mixing calculations, process simu- lations and hydmule studies. We maintain a full drafting department with 3D and animation capabilities and we can assist with specifications and CAD drawings. Our service and installation crew can hold your hand during the early stages of the project and our worldwide multilingual staff is dedicated to your complete satisfaction. Intelligent Upgrade Options Patented PfFE membranes prolong efficiency and reduce wholelHe costs SSI's patented PrFE membrane banter properties not only reduce plasticizer extraction, shrinking, and membrane hardening but also 11mit dynamic changes that can result from swell, such as creep. Compared with unmated products that are more susceptible to increases in DWP due to more aggressive fouling and changes In physical properties and weight, the PTFE coated mem- brane improves consistency of DWP (Headloss) values overthe product life. This directly impacts long-term power costs and the ability of the system to distribute air uniformly across the tank floor. SSI Telemetry -the inside story solves maintenance problems At the click of a mouse, you will know the DWP of your diffuser membranes, airflow rate to those monitored diffusers, and airtemperature in the submerged piping system. You can sense vibra- tion, pipe roll over, and water in the grid. Autom atic moisture purging and automatic acid dosing systems are available. Through multiple cameras, you can see both inside the grids, and surface bubble patterns. Wet probes are also available for DO and WIN temperature. Tracking all this data on a user-friendly online dashboard facilitates communication between consultant and client, manufacturer and rep. This smart technology lets you locate problem areas and allocate resources more efficiently. SSI Telemetry is your preventive maintenance hub in the heart of the plant. Airflowsm'/hr 0 2.5 35 5.6 i.a as 10.0 y O ,,.. 3 26 _- .. I so E 2 6.5 p 1.5 —i — iU d - I—�—1 11.5 w s a — __o C, o i ] 5 0 5 6 i Airflow-SCFM SSI Aeration Stamford Scientific International, Inc. Grommet Connection Simple to install on site, compact to slip and move. Affordably priced and time tested over 15 years worldwide. 11�11-11111111111111�9! 1 „ is ------ ll,-00--- too.i::i�llllllll■1 10 , �� ------------ , r I Pag. 7SS1 Aeration Proposal prepared RPQ 10 16 18 (1leyxvard Incorporated) on 20i October. 1018 T E C H N I C A L D A T A S H E E T MUDDLES Z Quick ConnectSilo' NIT Saddlesmount on nominal US 4" or metric 114.3mm OD pipThey allow retrofit o to 9" discs without changing the piping system. Quick Connect NPT Saddles are made of polypropylene, and install into a 5/8" (16mm) hole. GROMMETS Grommets are available for round A* plastic or square stainless steel pipes in US or Metric dimensions. Installation is simple. Multiple sizes are available based on pipe wall thickness. Grommets install into a 1.1/4" (32mm) chamfered hole. CHECK VALVES SSI fine and coarse bubble diffusers are available with optional check valves. These are not required for proper operation since most is diffusers are self -checking, but they may give peace of mind to the designer or operator. u Tile Dl©1xr deck ralIM EXPANSION JOINT MONS Expansion joints are available in three types: y Flexible PVC with SS Shell, Rigid Bolted SS, and Anti -rotation, Telescoping PVC. The flexible expansion joints are recommended for disc installations and the ftid positive locking type for "twin' tube diffuser projects. rta,.ua Slotted band joints with stainless steel shear wl tee 5IMI rings are suitable for disc -type fine bubble and capitype coarse bubble lateral plastic piping systems, in conjunction with SSI's fixed and guide support stand system to manage thermal expansion and contraction. Positive locking bolted less steel couplings are suitable for drop pipes, stainless joints, and for all tube diffitser piping systems to restrict header pipe rotation. ,Vilkalalla PleanpiugPVC Ts Sliding Expansion joint is an anti - rotational telescopic union which absorbs pipe expansion and contraction to up to 1.5" (38mm). ConrseBand (WMi ckxk raters ' n Y. e �� cbrck rallrs , D& sbmi,itg check tnity itwallalioa Wwi 4 TUCKER DRIVE S • POUGHKEEPSIE, NEW YORK 12603 USA SSI Aeration SSI AERATION, INC. +1-845-454-8171TEL www.ssicier(ition.com SMART IDEAS FOR WATER +1-845-454-8094 FAx EMAIL: InfoOssiaera11tM.com •"• 'Mi IMI to ., iMi Pag. 8SSI rAerition Piopo>ai prepared RI010161S (ile%s'ord hieorpoiated) kill "5" Ociohei. 110I8 - - r - - •1a M T E C H N I C A L D A T A S H E E T MOISTURE PURGE SYSTEM An airlift type purge System is used in all SSI fine bubble aeration systems to remove condensate from the piping system. Purging entrained water helps ensure even air distribution to all diffusers in a id. A ball valve is supplied with the system and is opened manually. Continuous ur a toms are available for retrievable - type aerat on systems, or where it is not possible to fasten a purge line ton tank wall. STANDS Support Stands arc available In 304SS, i 316SS or in ABS 4 plastic. SST's standard is 304SS with drop -in anchor bolts.lnour aeration piping systems, support stands fulfill the dual role of anchoring pipes to the floor and controlling thermal expansion and contraction. Special support stands for uneven tank floors, for installing into concrete ballast forms, and for ranks with significant channel velocity (with lateral supports) are also available. ABS support stands are primarily used with disc diffusers and plastic pipe, where a low capital cost is the primary objective. ABSdrufi['supporlAttrrd La We SSI Aeration SMART IDEAS FOR WATER PRESSURE MONITORING SYSTEM Throughout the life of at aeration system, oxygen efficiency may decline somewhat when diffuser become fouled, but hea can increase dramaticall in ram increases energy c A pressure monitoring s the operator to better dei frequency of the membr by aeration zone, hence i least one system in each: TELEMETRY SYSTEM Adding a Telemetry System to your aeration system will allow you to remotely monitor factors inside your tank from any PC, tablet or mobile device. Telemetry can be installed in new systems or retrofitted through an end cap into existing systems. Telemetry sensors are available to monitor variables in your system such as temperature, vibration, humidity, water detection, DO, and other environmental factors. ACID DOSING SYSTEM In.situ Acid Dusine Systems are available to control calcareous deposits in the perforations which will reduce nicinbranc backpic suit. 4 TUCKER DRIVE POUGHKEEPSIE, NEW YORK 12603 USA SSI AERATION, INC. +1-845454-8171 TEL www.ssiaeration.com +1-845-454-8094 FAX EMAIL: Info@wlawatlon.com M I Pag. 9SS1 Aeration Proposal prepared RI:Q101618 (liectcard Incorporated) on'_i°i 0cwher.'_018 4. Pumps c) WAS Pumps d) RAS Pumps e) Primary Clarifier Pumps f) Effluent Pumps Dewberry Novozymes North America, Inc. I Engineering Alternatives Analysis I APP M P: 336.665.0250 TE yjC" VA F: 336.665.0303 1116 Pleasant Ridge Rd. MACHINERY COMPANY Greensboro, NC 27409 SERVING INDUSTRY SINCE 1978 Project Name: WAS Pumps Date: 11/7/2018 ^ Quote Number: NWE102818 Invitation to Bid No.: Quoter: Nathan Edens Package Name: WAS a -Mail: nedens(atencarva.com CONDITIONS OF SERVICE ^ Pumpage: WAS Temperature (OF): 68 Flow (gpm): 111 NPSHa (ft): not specified TDH (ft): 36 Solids: not specified ^ EQUIPMENT DESCRIPTION I Type: Self Priming End Suction Centrifugal Pump Speed (RPM): 1750 Make: Gorman -Rupp Motor Speed (RPM): 1800 Model: T2 Motor Power (HP): 3 Letter Code: T2A60S-B/F Motor Voltage: 460 Size: 2" Motor Phase: 3 Construction: Cast Iron with Ductile Iron Impeller Motor Frequency (Hz): 60 Connections: Flanged Motor Frame Size: 182T Mounting: Vertically Driven V-Belt Motor Enclosure: S.D. M&C PE EQUIPMENT SPECIFICATIONS To view a PDF of the equipment including drawings and curves, please double click the icon: ... I—r1�:.._ +:I PRICING AND AVAILABILITY Unit Cost: $11,792 Shipping: Best way-PPA. Unless otherwise specified. Quantity: 2 Freight on Board: Shipping Point Total Price: $23,584 Payment Terms: Net 30 Lead Time: 5-6 weeks Note: Price does not include tax or freight. Quotation is valid for 30 days. ^ Comments: Package includes pump, motor, base/guard, belts/sheaves, casing heater, air release valve, gauge kit, and 316SS check valve. Pumps can be fitted with Austempered Ductile Iron Impellers for a $1,487 adder ^ P: 336.665.0250 Tom' yjE"VA F: 336.665.0303 1115 Pleasant Ridge Rd. MACHINERY COMPANY Greensboro, NC 27409 SERVING INDUSTRY SINCE 1978 Project Name: RAS Pumps Data: 11/7/2018 Quote Number: NWE102318 Invitation to Bid No.: Quoter: Nathan Edens Flow (gpm): 2084 TDH (ft): 31 S.G.: 1 Type: Self Priming End Suction Centrifugal Make: Gorman -Rupp Model: T10 Letter Code: T10A60S-B/FM Size: 10 Construction: Cast Iron w/ Ductile Iron Impeller Connections: Flanged Driven V-Belt Temperature (OF): 68 NPSHa (ft): not specified Solids: not specified Pump Speed (RPM): 850 Motor Speed (RPM): 1800 Motor Power (HP): 25 Motor Voltage: 460 Motor Phase: 3 Motor Frequency (Hz): 60 Motor Frame Size: 284T and curves, please double click the icon: PRICING AND AVAILABILITY Unit Cost: $31,591 Shipping: Best way-PPA. Unless otherwise specified. Quantity: 3 Freight on Board: Shipping Point Total Price: $94,773 Payment Terms: Net 30 Lead Time: 5-6 weeks Note: Price does not include tax or freight. Lead time is subject to change based on shop work load. Quotation is valid for 30 days. Comments: Package includes pump, motor, base/guard, belts/sheaves, casing heater, air release valve, gauge kit, and 316SS check valve. Pumps can be fitted with Austempered Ductile Iron Impellers for a $3,679 adder ar nn ^- P: 336.665.0250 r"y VA F: 336.665.0303 1115 Pleasant Ridge Rd. MACHINERY COMPANY SERVING INCUSTRY SINCE 1878 Greensboro, NC 27409 Project Name: Primary Clarifier Pumps Data: 1117/2018 Quote Number: NWE102318 Invitation to Bid No.: Quoter: Nathan Edens Pumpage: Primary Clarifier Influent Temperature ff): 68 Flow (gpm): 1210 NPSHa (ft): not specified TDH (ft): 30 Solids: not specified S.G.: 1 Viscosity (SSU): not specified ^ EQUIPMENT DESCRIPTION Type: Self Priming End Suction Centrifugal Pump Speed (RPM): 850 Make: Gorman -Rupp Motor Speed (RPM): 1800 Model: T8 Motor Power (HP): 20 ^ Letter Code: T8A60S-B IF Motor Voltage: 460 Size: 8" Motor Phase: 3 Construction: Cast Iron wl Ductile Iron Impeller Motor Frequency (Hz): 60 Connections: Flanged Motor Frame Size: 256T ^ Mounting: Vertically Driven V-Belt Motor Enclosure: S.D. I EQUIPMENT SPECIFICATIONS To view a PDF of the equipment including drawings and curves, please double click the icon: PRICING AND AVAILABILITY Unit Cost: $23,644 Shipping: Best way-PPA. Unless otherwise specified. Quantity: 2 Freight on Board: Shipping Point r Total Price: $47,288 Payment Terms: Net 30 Lead Time: 5-6 weeks Note: Price does not include tax or freight. Lead time is subject to change based on shop work load. .r Quotation is valid for 30 days. Comments: Package includes pump, motor, baseiguard, belts/sheaves, casing healer, air release valve, gauge kit, and discharge check valve. Pumps can be fitted with Austempered Ductile Iron Impellers for a $1,918 adder r� P: 336.666.0250 TE C" VA F: 336.666.0303 1116 Pleasant Ridge Rd. MACHINERY COMPANY Greensboro, NC 27409 SERVING INDUSTRY SINCE 1978 Project Name: Effluent Pumps Date: 11/7/2018 Quote Number: NWE102318 Invitation to Bid No.: Quoter: Nathan Edens Package Name: Effluent Pumps 9-Mail: nedensAtencarva.com Flow (gpm): 1400 TDH (ft): 66 S.G.: 1 Type: Self Priming End Suction Centrifugal Make: Gorman -Rupp Model: T8 Letter Code: T8A60S-B /F Size: 8" Construction: Cast Iron w/ Ductile Iron Impeller Connections: Flanged Mounting: Vertically Driven V-Belt Temperature (°F): 68 NPSHa (ft): not specified Solids: not specified Pump Speed (RPM): 1200 Motor Speed (RPM): 1800 Motor Power (HP): 50 Motor Voltage: 460 Motor Phase: 3 Motor Frequency (Hz): 60 Motor Frame Size: 326T and curves, please double click the icon: PRICING AND AVAILABILITY Unit Cost: $25,081 Shipping: Best way-PPA. Unless otherMse specified. Quantity: 2 Freight on Board: Shipping Point Total Price: $50,162 Payment Terms: Net 30 Lead Time: 5-6 weeks Note: Price does not include tax or freight. Lead time is subject to change based on shop work load. Quotation is valid for 30 days. Comments: Package includes pump, motor, base/guard, belts/sheaves, casing heater, air release valve, gauge kit, and discharge check valve. Pumps can be fitted with Austempered Ductile Iron Impellers for a $1,918 adder Y r rr, 5. Bioreactor Tanks ff Dewberry Novozymes North America, Inc- I Engineering Alternatives Analysis I APP M _ LIQUID TECH TANK SYSTEMS, INC. Send To: Jim Cooper Company: Heyward Subject: Dewberry Bio Pharma/Franklinton, NC Date: October 19, 2018 Bid #: 1842 We are pleased to offer the following proposal for your review. Liquid Tech Tank Systems, Inc. will provide all tank materials for the prices listed on the following pages. Aqua -Spec Builders, Inc. will provide all the installation for the prices listed on their bid contained in a separate document. If you have any questions or concerns, please feel free to contact us and we will be more than happy to help you. If you are interested in purchasing, please complete both order forms, provide two separate purchase orders accordingly, and return to the appropriate office. Buss Web Site: www.liauidtechtanks.com E-mail: bblttsla)comcast.net LIQUID TECH TANK SYSTEMS, INC. BID SHEET Liquid Tech Tank Systems, Inc. 125 Old Orchard Road (Accounts Payable/Receivable) 53 South York Road (Physical/Shipping) Dillsburg, PA 17019 Send To Heyward Attention Jim Cooper Subject Dewberry Bio Pharma/Franklinton, NC Total pages: 2 LTTS MODEL 107-22 1,379,769 gallons • Sizes are nominal w/2' freeboard Phone (717) 796-7056 Fax (717) 796-7058 From Brian Badger Date October 19, 2018 Bid #: 1842 $627,750 each PRICE INCLUDES • Submittal information, delivery to job site • Complete tank package, 304 bolted stainless steel tank shell, shell manway, galvanized hardware, stainless steel bolts, galvanized stairs and landing • Concrete foundation (which may be ground -formed) and monolithically poured concrete floor (performed by sub -contracted installation crew) DOES NOT INCLUDE • Leveling tank site to sub -grade (10" - 11" below finished tank floor level), below grade rock excavation, obtaining 2,000 psf soil bearing capacity (soil analysis of prepared site shall be the responsibility of others) • Licenses, permits, bid bonds, performance and payment bonds, sales/and or use taxes • If the project is exempt, the Buyer must provide LTTS with a tax -exemption certificate upon ordering or applicable taxes will be added. • Provisions for any piping to tank, valves, mixers, lighting, wiring, control systems, and other auxiliary equipment are supplied and installed by others • Concrete testing, insulation, and heaters are the responsibility of others • Representative mark-up • Items not expressly stated above on this bid are not included. PAYMENT TERMS • 50% due within 7 days of receipt of purchase order • 50% due prior to shipment • No Retainage Applicable BB/ss Web Site: www.licuidtechtanks.com E-mail: bbltts(a)comcast. net LTTS Bid Sheet CONDITIONS • WARRANTY: Seller warrants its product against defects in workmanship and material for a period of one (1) year ,from the date of installation or delivery (but not to exceed 15 months from date of delivery of the product to the site upon which it is to be erected). Buyer must provide written notice of any claim under this warranty within 30 days after they become aware of the defect and must provide access to the product for Seller's investigation. a. This warranty only applies to the original purchaser and only to equipment manufactured by the Seller. It does not apply to components used in conjunction with the Seller's product that was not manufactured by the Seller. Seller will have sole discretion to approve warranty coverage. The warranty also does not apply to the erection or installation of Seller's products, which are not factory -trained installers. b. Any replacement part or accessory provided in accordance with this warranty will carry a warranty for the balance of the period of warranty applicable to the part it replaces. The Seller will supply the replacement part F.O.B. the Seller's factory, or the Seller, at its option will repair or allow credit for such part. The Seller does not cover corrosion rust through in applications that are not within the guidelines of 304/316 Stainless Steel Corrosion Limits, or if there is evidence of abuse, due to periods of high concentrations of highly corrosive chemicals. c. Seller shall not be liable for any person or persons working on or around the tank, or any other persons gaining access to the tank, after installation is complete. • AFFILIATES: Buyer and Seller further agree that Seller's Affiliates may perform work for Buyer. In such event, the references to Seller in this Agreement shall mean Seller and such Affiliate of Seller. The Affiliate and Buyer shall be deemed to ratify, and agree to be bound by the terms and conditions of this Agreement with respect to its subject matter. • STAGING: Adequate area for material staging adjacent to foundation is required. Typical 100' laydown area is requested with 3600 clear access provided. • ADDITIONAL WORK: No extra labor, materials, or parts will be furnished under this Agreement, unless it has been ordered by Buyer's change order, and the prices and terms of sales are approved by Seller. Seller may at its option subcontract labor, material, and parts required by this Agreement without Buyer's consent. Unless otherwise agreed to, Seller shall not be responsible for unpacking, storage, field assembly of goods, or construction of foundations. Furthermore, Seller shall not be responsible for the installation, attachment, or connection of piping, conveying, and ventilating equipment or other attachment of accessories or components not sold hereunder. • THEFT: Buyer is required to provide protection to prevent theft of material from job site. • CANCELLATION: Buyer's cancellation of any order is required to be in writing, and Buyer is subject to pay a _ cancellation fee equal to 25% of the total purchase price plus all non -recoverable costs and expenses. • FAILURE: In the event the Buyer fails to abide by the terms and conditions of the Agreement, requiring LTTS to collect on amounts due, purchaser agrees to pay all interest, all attorney fees and costs incurred by LTTS as a result. • INDEMNIFICATION: LTTS will be responsible for their negligence only. SCHEDULE • Submittals: 2-3 weeks after order placement • Manufacture: 8-10 weeks after receipt of approval (pending current workload) • Erection by dedicated sub -contractor: 2-4 weeks depending on tank size and weather conditions If this schedule is not satisfactory, every effort will be made to meet your requirements. Aluminum domes can significantly change the schedule. If one is required, please ask for an update. * PRICE VALID FOR 15 DAYS FROM ABOVE DATE TO PLACE AN ORDER, FILL OUT THE REQUIRED INFORMATION, SIGN & RETURN The undersigned Is authorized to purchase products on behalf of the company they represent. .� Printed Name Title Purchase Order Number Was Web Site: www.liquidtechtanks.com Signature Date Requested Delivery Date E-mail: bbltts(a)comcast.net AQUA•SPE'C BUILDERS, INC. BID SHEET AQUA SPEC BUILDERS, INC. PO SOX567 Lm Z, PA 17543 SEND TO HEYWARD ATTENTION JIM COOPER SUBJECT DEWBERRY BIO PHARMA/FRANKUNTON, NC TOTAL PAGES: 2 PHONE (71" 663 8976 FAX (717) 626.4585 FROM IVAN REIFF DATE OCTOBER 19, 2018 LTTS MODEL 107-22 $192,500 EACH PRICE INCLUDES • COMPLETE ERECTION OF LIQUID TECH TANK INCLUDING FOOTER EXCAVATION, FOUNDATION INSTALLATION, AND MONOLITHICALLY POURED CONCRETE FLOOR, STAIRS AND LANDING, EQUIPMENT RENTAL IF REQUIRED, TRAVEL EXPENSES - DOES NOT INCLUDE • LEVELING TANK SITE TO SUB -GRADE 0 0" - 1 1 " BELOW FINISHED TANK FLOOR LEVEL), BELOW GRADE ROCK EXCAVATION, OBTAINING 2,000 PSF SOIL BEARING CAPACITY (SOIL ANALYSIS OF PREPARED SITE SHALL BE THE RESPONSIBILITY OF OTHERS) • SUPPLYING ELECTRICITY (1 1 0/220) FOR ERECTION ADJACENT TO SITE • DUE TO THE TIME FRAME OF ERECTION, DELAYS DUE TO INSTALLATION OF PIPING, AND/OR THE AVAILABILITY OF WATER AT THE SITE; WE CANNOT HYDROSTATICALLY TEST THE TANK. — WE WILL HOWEVER RETURN TO CORRECT ANY LEAKS SHOULD THEY OCCUR. IF REQUIRED, DISINFECTION IS TO BE HANDLED BY OTHERS. • PREVAILING WAGES, SANITARY FACILITIES, TRASH DUMPSTER _ • ITEMS NOT EXPRESSLY STATED ABOVE ON THIS BID ARE NOT INCLUDED. ADDERS: DEDUCTS: PAYMENTTERMS • 50% DUE WITHIN 7 DAYS OF RECEIPT OF PURCHASE ORDER. • 40% DUE IMMEDIATELY UPON COMPLETION OF EACH TANK IF MORE THAN ONE TANK IS PURCHASED. — • 1 0% RETAINAGE DUE UPON SATISFACTORY LEAK TEST, START-UP, OR WITHIN 60 DAYS FROM COMPLETION (WHICHEVER COMES FIRST) Ifts - Web Site: www.licuidtechtanks.com E-mail: ireiff00@mail.ptd.net r AQUA -SPEC BUILDERS, INC. BID SHEET CONDITIONS • INSTALLATION: PRICE IS QUOTED ON SUMMER WEATHER CONDITIONS. INCREASED COSTS MAY APPLY DURING WINTER WEATHER CONDITIONS. A. INSTALLATION PRICING IS BASED ON FREE AND CLEAR ACCESS ALL AROUND THE FOUNDATION WITH NO OVERHEAD OBSTRUCTIONS. B. LEVEL AND COMPACTED TERRAIN TO AND AROUND WORK AREA IS REQUIRED. C. OUR BID IS BASED ON OPEN WORK HOURS, UTILIZING ALL DAYLIGHT HOURS, 7 _ DAYS/WEEK. CONTINUOUS INSTALLATION IS REQUIRED, ELIMINATING THE NEED FOR LOST TIME. D. FOUNDATION CENTERLINES WILL BE ESTABLISHED BY OTHERS PRIOR TO INSTALLATION CREW ARRIVING AT JOB SITE. E. ONSITE SAFETY ORIENTATION UPTO ONE HOUR HAS BEEN INCLUDED IN PRICING. IF ADDITIONAL SAFETY ORIENTATION OR CLASSES ARE REQUIRED, ADDITIONAL CHARGES MAY BE APPLICABLE. IN THE EVENT THE PURCHASER FAILS TO ABIDE BY THE TERMS AND CONDITIONS OF THE CONTRACT, REQUIRING ASB TO COLLECT ON AMOUNTS DUE, PURCHASER AGREES TO PAY ALL INTEREST, ALL ATTORNEY FEES AND COSTS INCURRED BY ASB AS A RESULT. 'PRICEVALIDFOR 15DAYSFROMABOVEDATE' TO PLACE AN ORDER, FILL OUT THE REQUIRED INFORMATION, SIGN & RETURN The undersigned is authorized to purchase products on behalf of the company they represent. Printed Name Title Purchase Order Number Signature Date Requested Delivery Date NOTE: Typically Aqua -Spec Builders, Inc. will do the installation of the Liquid Tech tank. However, due to scheduling conflicts other factory trained installation contractors maybe required. The other contractors will be required to abide by all conditions set forth in this bid. Rlss Web Site: www.liouidtechtanks.com E-mail: ireiff00@mail.ptd.net