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HomeMy WebLinkAboutWQ0002702_Final Permit_19930408State of North Carolina Department of Environment, Health and Natural Resources Division of Environmental Management 512 North Salisbury Street - Raleigh, North Carolina 27604 .fames B. Hunt, Jr., Governor Jonathan B. Howes, Secretary April 8, 1993 Mr. Randall F. Andrews Alchem, Incorporated Route 2, Box 521-C Red Springs, North Carolina 28377 A. Preston Howard, Jr., P. E. Director Subject: Permit No. WQ0002702 Amendment Alchem, Incorporated Industrial Recycle - Bauxite Process Wastewater Recycle System Rowan County Dear Mr. Andrews: In accordance with your application received October 19, 1992, we are forwarding herewith Permit No. WQ0002702 as amended, dated April 8, 1993, to Alchem, Incorporated for the continued operation of the two (2) lagoon recycle system and the construction and operation of five (5) additional lagoons. This permit shall void Permit No. WQ0002702 issued December 10, 1990 and shall be effective from the date of issuance until December 31, 1994, and shall be subject to the conditions and limitations as specified therein. Please pay particular attention to the monitoring requirements in this permit. Failure to establish an adequate system for collecting and maintaining the required operational information will result in future compliance problems. If any parts, requirements, or limitations contained in this permit are unacceptable to you, you have the right to request an adjudicatory hearing upon written request within 30 days following receipt of this permit. This request must be in the form of a written petition, conforming to Chapter 150B of North Carolina General Statutes, and filed with the Office of Administrative Hearings, P.O. Drawer 27447, Raleigh, NC 27611-7447. Unless such demands are wade this permit shall be final and binding. Regional Offices Asheville Fayetteville Mooresville Raleigh Washington Wilmington Winston-Salem 704/251-6208 919/486-1541 704/663-1699 9191571-4700 919/946-6481 919/395-3900 919/896-7007 Pollution Prevention Pays P.O. Box 29535, Raleigh, North Carolina 27626-0535 Telephone 919-733-7015 An Equal Opportunity Affirmative Action Employer One set of approved plans and specifications is being forwarded to you. If you need additional information concerning this matter, please contact Ms. Angela Y. Griffin at 919/ 733-5083. Sincerely, A. Presto oward, r., P.E. Director cc: Rowan County Health Department Mooresville Regional Office, Water Quality Section Mooresville Regional Office, Groundwater Section ,lack Floyd, Groundwater Section, Central Office Salisbury Engineering & Planning Facilities Assessment Unit Training and Certificaton Unit NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION DEPARTMENT OF ENVIRONMENT, HEALTH AND NATURAL RESOURCES RALEIGH RECYCLE SYSTEM PERMIT In accordance with the provisions of Article 21 of Chapter 143, General Statutes of North Carolina as amended, and other applicable Laws, Rules, and Regulations PERMISSION IS HEREBY GRANTED TO Alchem, Incorporated Rowan County FOR THE continued operation of two (2) lagoons each approximtely 50' W x 200' L x 10' D and the construction and operation of five additional lagoons, four (4) 180' W x 155' L x 20' D and one (1) 210 W x 155' L x 20' D to serve Alchem, Incorporated with no discharge of wastes to the surface waters, pursuant to the application received October 19, 1992 and in conformity with the project plan, specifications, and other supporting data subsequently Bled and approved by the Department of Environment, Health and Natural Resources and considered a part of this permit. This permit shall void Permit No. WQ0002702 issued December 10, 1990 and shall be effective from the date of issuance until December 31, 1994, and shall be subject to the following specified conditions and limitations: 1. This permit shall become voidable unless the facilities are constructed in accordance with the conditions of this permit, the approved plans, specifications, and other supporting data. 2. This permit is effective only with respect to the nature and volume of wastes described in the application and other supporting data. 3. The facilities shall be properly maintained and operated at all times. 4. This permit is not transferable. In the event there is a desire for the facilities to change ownership, or there is a name change of the Permittee, a formal permit request must be submitted to the Division of Environmental Management accompanied by an application fee, documentation from the parties involved, and other supporting materials as may be appropriate. The approval of the request will be considered on its merits and may or may not be approved. 5. Upon completion of construction of the five lagoons and prior to operation of this permitted facility, a certification must be received from a professional engineer certifying that the permitted facility has been installed in accordance with this permit, the approved plans and specifications. Mail the Certification to the Permits and Engineering Unit, P.O. Box 29535, Raleigh, NC 27626-0535. 6. In the event that the facilities fail to perform satisfactorily, including the creation of nuisance conditions, the Perrittee shall take immediate corrective action, including those as may be required by this Division, such as the construction of additional or replacement wastewater treatment or disposal facilities. 7. The Mooresville Regional Office, telephone number (704) 663-1699, shall be notified at least forty-eight (48) hours in advance of operation of the installed facilities so that an in - place inspection can be made. Such notification to the regional supervisor shall be made during the normal office hours from 8:00 a.m. until5:00 p.m. on Monday through Friday, excluding State Holidays. 8. The sludge generated from these treatment facilities must be disposed of in accordance with General Statute 143-215.1 and in a manner approved by the North Carolina Division of Environmental Management 9. The issuance of this permit shall not relieve the Permittee of the responsibility for damages to surface or groundwaters resulting from the operation of this facility. 10. 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. 11. Diversion or bypassing of untreated wastewater from the treatment facilities is prohibited. 12. Freeboard in the lagoons shall not be less than two feet at any time. 13. Any monitoring deemed necessary by the Division of Environmental Management to insure surface and ground water protection will be established and an acceptable sampling reporting schedule shall be followed. 14. Adequate inspection, maintenance, and cleaning shall be provided by the Permittee to insure proper operation of the subject facilities. 15. The Permittee or his designee shall inspect the wastewater recycle facilities to prevent malfunctions and deterioration, operator errors and discharges which may cause or lead to the release of wastes to the environment, a threat to human health, or a nuisance. The Permittee shall keep an inspection log or summary including at least the date and time of inspection, observations made, and any maintenance, repairs, or corrective actions taken by the Permittee. This log of inspections shall be maintained by the Permittee for a period of three years from the date of the inspection and shall be made available upon request to the Division of Environmental Management or other permitting authority. 16. Any duly authorized officer, employee, or representative of the Division of Environmental Management may, upon presentation of credentials, enter and inspect any property, premises or place on or related to the recycle system at any reasonable time for the purpose of determining compliance with this permit; may inspect or copy any records that must be kept under the terms and conditions of this permit; or may obtain samples of groundwater, surface water, or leachate. 17. The annual administering and compliance fee must be paid by the Permittee within thirty (30) days after being billed by the Division. Failure to pay the fee accordingly may cause the Division to initiate action to revoke this permit as specified by 15 NCAC 2H .0205 (c)(4). 18. Failure to abide by the conditions and limitations contained in this permit may subject the Permittee to an enforcement action by the Division of Environmental Management in accordance with North Carolina General Statute 143-215.6A to 143-215.6C. 2 19. The issuance of this permit does not preclude the Permittee from complying with any and all statutes, rules, regulations, or ordinances which may be imposed by other government agencies (local, state, and federal) which have jurisdiction. 20. A set of approved plans and specifications for the subject project must be retained by the Permittee for the life of this project. 21. Noncompliance Notification: The Permittee shall report by telephone to the Mooresville Regional Office, telephone number (704) 663-1699, 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. Any occurrence at the wastewater treatment facility which results in the treatment of significant amounts of wastes which are abnormal in quantity or characteristic, such as the dumping of the contents of a basin or tank; the known passage of a slug of hazardous substance through the facility; or any other unusual circumstances. b. Any process unit failure, due to known or unknown reasons, that render the facility incapable of adequate wastewater treatment such as mechanical or electrical failures of pumps, aerators, compressors, etc. c. Any failure of a pumping station, sewer fine, or treatment facility resulting in a by- pass directly to receiving waters without treatment of all or any portion of the influent to such station or facility. d. Any time that self -monitoring information indicates that the facility is not in compliance with its permit limitations. Persons reporting such occurrences by telephone shall also file a written report in letter form within 15 days following first knowledge of the occurrence. This report must outline the actions taken or proposed to be taken to ensure that the problem does not recur. 22. Upon classification of the facility by the Certification Commission, the Permittee shall employ a certified wastewater treatment plant operator to be in responsible charge (ORC) of the wastewater treatment facilities. The operator must hold a certificate of the type and grade at least equivalent to or greater than the classification assigned to the wastewater treatment facilities by the Certification Commission. The Permittee must also employ a certified back-up operator of the appropriate type and grade to comply with the conditions of Title 15A, Chapter 8A, .0202. The ORC of the facility must visit each Class I facility at least weekly and each Class 11, III, and IV facility at least daily, excluding weekends and holidays, and must properly manage and document daily operation and maintenance of the facility and must comply with all other conditions of Title 15A, Chapter 8A, .0202 23, The recycle Iagoons shall not be located within 100 feet of water supply wells. 24. Prior to beginning waste disposal operations, three (3) monitor wells, one (1) upgradient and two (2) downgradient, shall be installed to monitor groundwater quality. The well(s) shall be constructed such that the water level in the well is never above or below the screened (open) portion of the well at any time during the year. The exact location and construction details for these wells shall be approved by the Mooresville Regional Office. 3 25. The monitoring wells shall be sampled initially after construction (and prior to waste disposal operations) and thereafter every February and July for the following parameters: TDS pH SO4 Specific Conductivity Aluminum Total Suspended Solids Volatile Organic Compounds - In February only (by Method 1 or Method 2 below). Method l: Method 6230D (Capillary - Column), "Standard Methods For The Examination of Water and Wastewater", 1.7th ed., 1989. Method 2: Method 502.2 "Methods For The Determination of Organic Compounds in Drinking Water", U.S. EPA - 600/4-88/039. The measurement of water level must be made prior to sampling for the remaining parameters. The measuring points (top of well casing) of all monitoring wells shall be surveyed to provide relative elevations of the measuring point for each monitoring well. These elevations shall be provided to the Regional Hydrogeologist within 60 days after well construction. The depth of water in each well shall be measured from the surveyed point on top of the casing. If any volatile organic compounds are detected by method 6230D, or the equivalent method 502.2, then EPA methods 604 and 611 must also be run to detect other organic compounds which may be present. The results of all analyses specified in the monitoring requirements, including 604 and 611 if required, must be submitted simultaneously. The results of the sampling and analysis shall be sent to the N.C. Division of Environmental Management on Form GW-59 (Compliance Monitoring Report Form) every March and August. 26. The CompliiInge Boundary for the disposal system is specified by regulations in 15A NCAC 2L, Groundwater Classifications and Standards. An exceedance of Groundwater Quality Standards beyond the Compliance Boundary is subject to the penalty provisions applicable under General Statutel43-215.6(1)a. The sale of property, by the Permittee, which is within or contiguous to thedisposal site, may alter the location of the Compliance Boundary. For facilities permitted on or after December 30, 1983, the Compliance Boundary is established at the lesser of 250 feet from the storage lagoon, or 50 feet within the property boundary. If the title to any property which may affect the location of the Compliance Boundary is changed, the Permittee shall notify the DEM Director within 14 days. The Director shall then establish a modified Compliance Boundary which will be done as a modification to the Permit. 4 The REVIEW BOUNDARY for the disposal system is specified by regulations in 15 NCAC 2L, Groundwater Classifications and Standards. A REVIEW BOUNDARY is established around disposal systems midway between the Compliance Boundary and the perimeter of the waste disposal area. When the concentration of any substance equals or exceeds the maximum allowable concentration of that substance at the REVIEW BOUNDARY, as determined by monitoring, the permittee shall §i h r (i) demonstrate, through predictive calculations or modeling, that natural site conditions, facility design and operational controls will prevent a violation of standards at the Compliance Boundary; or, (ii) submit a plan for the alteration of existing site conditions, facility design or operational controls that will prevent a violation of standards at the Compliance Boundary, and implement that plan upon its approval by the Director. 27. The lagoon shall have a liner of natural material at least one (1) foot in thickness at all locations with a hydraulic conductivity of no greater than 1 x 10-6 centimeters per second when compacted. Following installation and inspection of the lagoon liner, and prior to waste disposal operations, verification of the liner's compliance with hydraulic conductivity and thickness specifications must be provided to the Division of Environmental Management, Groundwater Section, by the project engineer. 28. All wells that are constructed for purposes of groundwater monitoring shall be constructed in accordance with 15A NCAC 2C .0108 (Standards of Construction for Wells Other Than Water Supply) and any other state and local laws and regulations pertaining to well construction. 29. The Mooresville Regional Office, telephone number (704) 663-1699 shall be notified at least two weeks prior to the construction of any monitoring well so that an inspection can be made of the monitoring well location. Such notification to the regional groundwater supervisor shall be made during the normal office hours from 8:00 a.m, until 5.00 p.m. on Monday through Friday, excluding state holidays. 30. Within sixty (60) days of completion of all monitoring wells, the permittee shall submit two original copies of a scaled topographic map (scale no greater than 1:24000) signed and sealed by a professional engineer or a registered land surveyor that indicates all of the following information: a. the location and identity of each monitoring well, b. the location of the waste disposal system, C. the location of all property boundaries, d. the laititude and longitude of each monitoring well, e. the relative elevation of the top of the well casing (which shall be known as the "measuring point") f. and the depth of water below the measuring point at the time the measuring point is established. All monitoring well locations and elevations shall be surveyed by a registered land surveyor. 31. Upon completion of all well construction activities, a certification must be received from a professional engineer certifying that the monitoring wells are located and constructed in accordance with the Well Construction Standards (15A NCAC 2C) and this permit. This certification should be submitted with copies of the Well Completion Form (GW-1) for each well. Mail certification and the associated GW-1 forms to the Permits and Compliance Unit, Groundwater SEction, P.O Box 29535, Raleigh, N.C., 27626-0535. 5 3 2. For the initial sampling of the well as specified elsewhere in the permit, the permittee shall submit a copy of the GW-1 form with the Compliance Monitoring Form (GW-59) for that well. Compliance Monitoring Forms that do not include copies of the GW-1 form will be returned to the initiation of enforcement activities pursuant to NC General Statutes 143- 215.6. 33. Any additional groundwater quality monitoring, as deemed necessary by the Division, shall be provided. 34. The Permittee, at least six (6) months prior to the expiration of this permit, shall request its extension. Upon receipt of the request, the Commission will review the adequacy of the facilities described therein, and if warranted, will extend the permit for such period of time and under such conditions and limitations as it may deem appropriate. Permit issued this the 8th day of April, 1993 NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION 0-'J. , �G - " C a'p� /� A. Preston loward, Jr., PIE., Director Division of Vhvironmental Management By Authority of the Environmental Management Commission Permit No. WQ0002702 Amendment M Perrnit No. WQ0002702 Amendment April 8, 1993 Engineer's Certification I, , as a duly registered Professional Engineer in the State of North Carolina, having been authorized to observe (periodically, weekly, full time) the construction of the project, for the Project Name Location Permittee hereby state that, to the best of my abilities, due care and diligence was used in the observation of the construction such that the construction was observed to be built within substantial compliance and intent of the approved plans and specifications. Signature Date 7 Registration No. <- N Nc RowuN Co,"4yj plc �a<A II rlrra+y +ed pas+ LaN�� Nye CD Nlasfe Boundary ® Meg �o! WC11 (mw) Sc�.le ° 2S Sa Fame 'of Plant: Owner or Contacts Person: L I Mailing Address: L:2,S11- L County: IZUv.rAt-5 Telephone:_ L-4 NPDES Permit No. NCflO >-\ )o\ Nondisc. Per.�- IssueDate: TAA_10, 4C:6,ca _Expiration Date: Existing Facility ✓ New Facility _ - Rated By: '4, C.pvso,-t Date: \-L4 Reviewed (Train. & Cert.)' Reg. Office Reviewed (Train. & Geri.) Central Office ORC WA Grade r\lA Plant Class: (circle one) 1 11 III IV Total Points? ITEM POINTS (5) SECONDARY TREATMENT UNITS (a) Carbonaceous Stage (1) Industrial Pretreatment Units and/or (i)Aeration - high Purity Oxygen System ..... 20 Industrial Pretreatment Program Diffused Air System ........... 10 (see definition No. 33) 4 Mechanical Air System (fixed, (2) DE2Q FLOW OF PLANT IN GPD floating or rotor) .............. 8 (not applicable to non-canlaminaled cooling waters, sludge Separate Sludge Reaeration ..... 3 handling facilities for water purification plants, totally (if) Trickling Filler closed cycle systems (del. No. 11). and facilities High Rafe ................... 7 eonsiMing only of Item (4) (d) or Items (4) (d) and (11) (d)) Standard Rale ............... 5 0 - 20,000.......................... 1 Packed Tower..........,.... 5 20,001 — 50,000.......................... 2 (iii) Biological Aerated Filter or Aerated 50,001 — 100,000 .......................... 3 Biological Filter ...................... 10 10D,001 - 250,000 ....... . .................. 4 (iv) Aerated Lagoons ..................... . 10 250,001 — 500,000.......................... 5 500,001--1,000,000 .......................... a (v) Rotating Biological Confaclors .......... 10 1,000,001 -- 2,000,000 ........................ 10 2,000,001 (and up) - rate 1 point additional for each (vi) Sand Filters• 200.000 gpd capacity up to a intermittent biological ..... 2 maximum of 30 recirculating biological ..... 3 Design Flow (gpd) (v`a) Stabilization Lagoons ................... 5 (3) PRELIMINARY UNITS (see definition no. 32) (viii)Clarifier .............................. 5 (a) Bar Screens............ .................... 1 (1x) Single stage system for combined or carbonaceous removal of BOD and (b) Mechanical Screens, Static Screens or nitrogenous removal by nitrification Comminuting Devices ........... ............. 2 (see def. No. 12) (Points for this item (c) Gril Removal ............................... 1 have to be In addition to items (5) (a) or (ij through (5) (a) (viR ................. 8 (d) Mechanical or Aerated Grit Removal ........... 2 (x) Nutrient additions to enhance DOD (e) Blow Measuring Device ....................... 1 fernoval ............................... 5 or (xi) Biological Culture ('Super Bugs`) addition (f) instrumented Flow Measurement .............. 2 to enhance organic compound removal ..... 5 (g) Preaeralion................................ 2 (b) Nitrogenous Stage (i) Aeration - High Purity Oxygen System ..... 20 (h) Influent Row -Equalization .................. _ 2 Diffused Air System ..... 1 0 t Grease or Oil Separators - Gravity �) p Y - - • • • - • • • - 2 System (fixed. Mechanical Air System (fixed, Mechanical . _ ........ 3 floating, oriolor) ...... ...... 8 - Dissolved Air Flotation. 8 Separate Sludge Reaeral'son ..... 3 �7 Prechlorination .............................. 5 (ii) Trickling Filter - High Rafe ........... 7 (4) PRIMARY TREATMENT UNrTS Standard Rate ............ 5 (a) Septic Tank (see definition no. 43) .............. 2 Packed Tower ............ 5 (b) Imhofl Tank .................................. 5 (iii) Biological Aerated Filter or Aerated (c) Primary Clarifiers ............................ 5 Biological Filter ......................... 10 (d) Settling Ponds or Se111ing Tanks for Inorganic (iv) Rolaling Biological Contactors ............ 10 Nontoxic Materials (sludge handling facilities (v) Sand Fitter - far water purification plants, sand, gravel, intermittent biological ..... _ .. 2 stone, and other mining operations except recirculating biological .. . . . .. . 3 recreational activities such as em or gold g 2 (vi) Clarifier........ .......... . ...... 5 mining) ...................................... J (6) TERTi,ARY OR ADVANCED TREATMEN'>-.UNIT (a) Activated Carbons Beds - Athout carbon regeneration ........ . . ... s .... . with carbon regeneration ... ....... .... . (b) Powdered or Granular Activated Carbon Feed - without carbon regeneration ................ . with carbon regeneration .................... t�J Air Stripping ............... . ... (d) Denitrification Process (separate process) .... . (e) Electrodiafysis ........ _ .................... (f) Foam Separation ............................. (g) ton Exchange................................ (h) Land Application ofTreated Effluent (see definition no. 22b) (not applicable for sand, gravel, stone and other sunilar mining operations) (i) on agriailturaTly managed sites (See del. r No. a) . •...r (ii) by high rate Infiltration on non -agriculturally managed sites (includes rotary distributors and similar fixed nozzle systems) ........... (W) by subsurface disposal (includes low pressure pipe systems and gravity systems except at plants consisting of septic tank and nitrifica- tion lines only) ...................... . . ... . 01 Microscleens.................................. (1) Phosphorus Remoial by Biological Processes (See del. No. 26) .......................... • . (k) Polishing Ponds - without atralion _ ..... . with aeration .... _ .... . (1) Post Aeration - cascade ......... . . .. . diffused or mechanical .. . (m) Reverse Osmosis .......................... . ... . (n) Sand or Mixed -Media Fillers - low rate ........... high rate .......... (o) Treatment processes for removal of metal or cyanide.................................... (p) Treatment processes for removal of toxic rnalerials other than metal or cyanide .... _ ... . It SLUDGE TREATMENT (10) CHEMICAL ADDITION SYSTEM (S) (See definition No. 9) 5 {not applicable to chemical additions rated as item 1 5 (3) (s}. (5) (a) (xi). (6) (a). (6) (b), (7) (b). (7) (e}. (9) (b), or (9) (c) 5 points each: List: 5 5 5 15 _ 5 5 5 10 5 (11) MISCELLANEOUS UNITS 5 (a) Holding Ponds, Holding Tanks or Settling Ponds 5 for Organic or Toxic Materials including wastes from mining operations containing nitrogen and/or phosphorous compounds In amounts significantly greater than is common for domestic wastewater .......... 4 (b) Effluent Flow Equalization (not applicable to storage basins which are inherent in land application systems). 2 10 (c) Stage Discharge (not applicable to storage basins inherent in land application systems ... ........................... 5 (d) Pumps .........:.... 3 4 (e) Stand -By Power Supply __ ____ 3 ' (f) Thermal Pollution Control Device: . .............. ... ........ 3 4 5 2D 2 5 0 5 5 2 5 15 15 (a) Sludge Digestion Tank - Heated ............... 10 Aerobic ............... 5 Unhealed ............. 3 (b) Sludge Stabilization (chemical or thermal) ....... 5 (c) Sludge Drying Beds - Gravity ................. 2 Vacuum Assisted ....... 5 (d) Sludge EfuldaGan ............................. 5 (e) Sludge Conditioner (chemical or thermal) ........ 5 (f) Sludge Thickener (gravity) ...................... 5 {g) Dissolved Air Flotation Unit (not applicable to a unit rates as (3) n ......... 8 (h) Sludge Gas Utilization (includinQ gas storage) .... 2 (i) Sludge Holding Tank - Aerated ................ 5 Non -aerated ............ 2 (jj Sludge Incinerator - (not including activated carbon regeneration) .. _ .. 10 (k) Vacuum Filler, Centrifuge or Filter Press or other similar dewalering devices .................... 10 (8) SLUDGE DISPOSAL. (including incinerated ash) (a) Lagoons ........................................ 2 (b) Land Application (surface and subsurface) (see definition 22a) wvhere the facility holds the land app. permit ... 10 -by contracting to a land application operator who holds the land application permit ................ 2 -land application of sludge by a contractor who does not hold the permit for the wastewater treatment facility where the sludge is generated ......... 10 (c) Landfilled (burial) ............................. 5 (9j DISINFECTION (a) Chlorination ............................. 5 (b) Dechlorination ........................ 5 (c) Ozone .............................. 5 (d) Radiation .......................... 5 TOTAL POINTS Z CLASStRCATION Class 1- 5 - 25 Points Class It. _ 26- 50 Points Class Ill.......-........_.......51- 65 Points Class IV.-----. _ 66- Up Points Facilities having a rating of one through four points, Inclusive, do not require a certified operator. Classification of all other facilities requires a comparable grade operator In responsible charge. Facilities having an activated sludge process will be assigned a minimum classification of Class 11. Facilities having treatment processes for the removal of melat or cyanide will be assigned a minimum classification of Class 11. Facilities having treatment processes for the biological removal of phosphorus will be assigned a minimum classification of Class Ill. In -plant processes and related control equipment which are an integral part of industrial production shall not be considered waste treatment. Likewise, discharges of wastewater from residences having a design flow of 1,000 gpd or less, shall not be subject to rating.