WQ0003487_Final Permit_20040716

�o� WArFAP Michael F. Easley, Governor
7 William G. Ross Jr., Secretary
r- North Carolina Department of Environment and !Natural Resources
4
p Y Alan W, Klimek, P.E., Director
Coleen H. Sullins, Deputy Director
Division of Water Quality
July 16, 2004
MR. LEE YARBROUGH, GENERAL MANAGER
NOvozymm NORTH AMERICA, INC.
POST OFFICE Box 576
FRANKLINTON, NORTH CAROLINA 27575
Subject: Permit No. WQ0003487
Novozymes North America, Inc.
Novozymes Residuals Composting Facility and
Distribution Program
Distribution of Residuals Solids (503 Exempt)
Franklin County
Dear Mr. Yarbrough:
In accordance with your permit modification application package received on June 19, 2003, we are
forwarding herewith Permit No. WQ0003487, dated July 16, 2004, to Novozymes North America, Inc. for the
operation of a residuals dewatering system and the continued operation of spent biomass storage facilities, time
stabilization facilities, and composted residuals marketing and distribution center.
This permit shall be effective from the date of issuance until April 30, 2005, shall void Permit No.
WQ0003487, issued on December 29, 2000, and shall be subject to the conditions and limitations as specified
therein. Please pay particular attention to the monitoring and reporting requirements contained 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, you have the right to
request an adjudicatory hearing upon written request within thirty (30) days following receipt of this permit. This
request roust 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, 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 matter, please contact Mr. Duane Leith at (919) 733-
5083, extension 370, or via e-mail at [e-mail].
S' rely,
L& Alan W. Klimek, P.E.
cc: Franklin County Health Department
Raleigh Regional Office, Water Quality Section
Raleigh Regional Office, Groundwater Section
Central Office, Groundwater Section
Technical Assistance and Certification Unit
Water Quality Central Files
NDPU Files
1�IT�P11 RPcirli�alc Program f nnrrlinatnr �1�'
Non -Discharge Permitting Unit Internet http://h2o.enr.state.nc.us/ndpu
1617 Mail Service Center, Raleigh, NC 27699-1617 Telephone [phone] Fax [phone]
DENR Customer Service Center Telephone [phone]
An Equal Opportunity Action Employer 50% recycled/10 % post -consumer paper

6
1

NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT COMMISSION
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
RALEIGH
DISTRIBUTION OF RESIDUALS (503 EXEMPT) 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
Novozymes North America, Inc.
Franklin County
Pp.4 t� �OR THE e4 -#,"'o x j
operation of a residuals dewateri g system designed to achieve a solids content of at least 10 percent in
the cake stream at a feed rate o 100 gallons per minute and consisting of a sludge feed pump, a decanter
centrifuge, a cake pump and system components to discharge dried cake into roll -off containers, and
continued operation of a 1.645 million gallon concrete storage tank and loading bay for the storage and
loading of lime -stabilized process waste residuals consisting of one, 1.645 million gallon open top
pretensioned concrete tank with a high water alarm, one, 900 GPM submersible residual loading pump,
three, 30 hp submersible mixers, the upgrade of an existing sump pump to 300 GPM, a 20 foot by 70 foot
concrete loading bay with spillage collection, and all other necessary pumps, valves, and appurtenances
for proper operation, and
continued operation of the distribution of process residuals consisting of the distribution of approximately
41,000 dry tons per year of residuals from, the sources listed in Condition II. 2., including the spent
biomass generated under Permit No. WQ0002806; the
continued operation of a spent biomass storage facilities consisting of one, 292,300 gallon tank, two,
72,000 SBM storage tanks, two, 700,000 gallon SBM storage tanks each with three, 20 HP mixers, two,
150 GPM spent biomass transfer pumps; the
continued operation of a lime stabilization facility consisting of two, 22,000 gallon sludge buffer tank, a
17,400 gallon lime silo, a 1,000 gallon reactor tank with a 2 HP mixer, a 7.5 HP sludge pump, a 2,321
cubic foot lime storage tank with a 60 cubic foot per hour volumetric feeder, a 5,000 gallon mixing tank;
and the
continued operation of a compost material marketing and distribution center of spent biomass consisting
of a 600 GPM loading pump, a truck loading station, and all other necessary pumps, valves, and
appurtenances, with no discharge of wastes to the surface waters, pursuant to the permit modification
request received on October 28, 1996, and in conformity with the project plan, specifications, and other
supporting data subsequently filed and approved by the Department of Environment and Natural
Resources and considered a part of this permit.

This permit shall be effective from the date of issuance until April 30, 2005; shall void Permit No.
WQ0003487, issued on December 29, 2000; and shall be subject to the following specified conditions and
limitations:
I.
PERFORMANCE STANDARDS
1. The distribution of process residuals program shall be effectively maintained and operated as
a non -discharge system to prevent the discharge of any wastes resulting from the operation of
this program.
2. This permit shall become voidable in the event of failure of the residuals program to
adequately protect the assigned water quality standards of the surface waters and
groundwaters.
3. 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 program.
4. In the event that the residuals program is not operated satisfactorily, including the creation of
nuisance conditions, the Permittee shall take any immediate corrective actions as may be
required by the Division of Water Quality (Division).
S. Diversion or bypassing of the untreated residuals or leachate from the residual treatment
facilities is prohibited.
6. Compost shall not be used in areas of intense public use (schools, playgrounds, etc.).
OPERATION AND MAINTENANCE REQUIREMENTS
1. The residuals treatment facilities shall be properly maintained and operated at all times.
2. No residuals other than the following are hereby approved for distribution in accordance with
this permit:
Permit Volume
Source County Number .__ fDry Tons/Year
Novozymes North America Inc. Franklin WQ0003487 41,000*
Novozymes North America Inc. Franklin WQ0002806
* Combined
3. All residuals shall be adequately stored to prevent leachate runoff until treated
4. No other residuals other than those specified under Condition Il 2 above may be distributed.
The Permittee shall request and obtain a permit amendment from the Division for each
additional residual source prior to acceptance of that residual.
01

5. For process residuals to be applied to the land, the following must be satisfied:
The Ceiling Concentrations (Dry Weight Basis) and the Pollutant Monthly Average
Concentrations (Dry Weight Basis) must be maintained:
Ceiling Monthly Average
Concentrations Concentrations
Parameters mg/kg mg/kg
Cadmium
85
39
Copper
4,300
1,500
Lead
840
300
Nickel
420
420
Zinc
7,500
2,800
6. Upon classification of the facility by the Water Pollution Control System Operators
Certification Commission (WPCSOCC), the Permittee shall employ a certified residuals
operator to be in responsible charge (ORC) of the residuals program. The operator must hold a
certificate of the type classification assigned to the residuals program by the WPCSOCC. The
Permittee must also employ a certified back-up operator of the appropriate type to comply with
the conditions of 15A NCAC 8A .0202.
7. All application of compost material shall be carried out by Novo Novozymes North America,
Incorporated personnel.
8. The compost material shall be transported to the application sites by truck and shall be
applied to the fields by..�liquid manure spreader.
�_. - _��
9. No compost material shall be land applied in WS -I watersheds.
10. The quantity of compost material applied per acre shall be determined by the following:
the N, P, and K requirements of the crops/plants that are to be grown as recommended
by the North Carolina Agricultural Service,
b. the plant available nitrogen (PAN) plus the P and K content of the material,
the maximum PAN application rate will not exceed 60% of the North Carolina
Agricultural Extension's recommendations unless a higher application rate is
recommended by a North Carolina Agricultural Extension Agent,
11. The following restrictions apply to areas with seasonal high water tables less than three (3)
feet below the land surface:
a. For areas with a seasonal high water table between one (1) and three (3) feet below the
land surface, the application of compost material shall occur only between May and
October.
b. For areas with a seasonal high water table of less than (1) foot below the land surface,
NO land application of compost material shall occur -
3

III. MONITORING AND REPORTING REQUIREMENTS
1. Any monitoring (including groundwater, surface water, residuals, soil, or plant tissue
analyses) deemed necessary by the Division to insure protection of the environment will be
established and an acceptable sampling and reporting schedule shall be followed.
2. Proper records shall be maintained by the Permittee tracking all residual activities. These
records shall include, but are not necessarily limited to the following information:
a. daily volume of material processed,
b. monthly pH readings of the stabilization process to insure proper operation,
c. volume and analysis of compost material to be applied,
d. cumulative PAN loadings per crop cycle, and
e, name of compost recipient, volume received, and the crops/plants to be grown or
intended use of the compost material.
3. A residual analysis shall be conducted annually from the date of permit issuance by the
Permittee on the following parameters:
Cadmium Copper Lead
Nickel Zinc
A residual analysis shall be conducted monthly from the date of permit issuance by the
Permittee on the following parameters:
Ammonia -Nitrogen
Calcium
Magnesium
Nitrate -Nitrite Nitrogen
Total Solids
Sodium
PH
Phosphorus
Potassium
TKN
Plant Available Nitrogen
(by calculation)
4. Three copies of all required monitoring and reporting requirements as specified in conditions
III 1, 1112, and 111 3, shall be submitted annually on or before March 1 of the following year
to the following address:
NC Division of Water Quality
Water Quality Section
Non -Discharge Compliance/Enforcement Unit
1617 Mail Service Center
Raleigh, North Carolina 27699-1617
5. Noncompliance Notification:
The Permittee shall report by telephone to the Raleigh Regional Office, telephone number
[phone], 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 with the distribution program which results in the land application of
significant amounts of wastes which are abnormal in quantity or characteristic.
4

b. Any failure of the distribution program resulting in a release of material to receiving
waters.
c. Any time that self-monitoring information indicates that the facility has gone out of
compliance with the conditions and limitations of this permit or the parameters on which
the system was designed.
d. Any process unit failure, due to known or unknown reasons, that render the facility
incapable of adequate residual treatment.
e. Any spillage or discharge from a vehicle or piping system during transportation of
residuals.
Persons reporting such occurrences by telephone shall also file a written report in letter form
within five (S) 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.
IV. GROUNDWATER REQUIREMENTS
1. Any groundwater duality monitoring, as deemed necessary by the Division, shall be provided.
V. INSPECTIONS
L The Permittee or his designee shall inspect the residuals storage, transport, and treatment
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 maintain 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 five years from the date of the inspection and shall be made available to the
Division or other permitting authority, upon request_
2. Any duly authorized officer, employee, or representative of the Division may, upon
presentation of credentials, enter and inspect any property, premises or place on or related to
the treatment site or facility 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; and may obtain samples of groundwater, surface water, or leachate.
VI. GENERAL CONDITIONS
1. This permit shall become voidable unless the distribution activities are carried out in
accordance with the conditions of this permit, the supporting materials, and in the manner
approved by this Division.
2. This permit is effective only with respect to the nature and volume of residuals described in the
application and other supporting data.
G

3. This permit is not automatically transferable. In the event that there is a desire for the
facilities to change ownership or a name change of the Permittee, a formal permit request
trust be submitted to the Division accompanied by an application fee, documentation from
the parties involved, and other supporting materials as may be appropriate. The approval of
this request will be considered on its merits and may or may not be approved.
4. Failure to abide by the conditions and limitations contained in this permit may subject the
Permittee to an enforcement action by the Division in accordance with North Carolina
General Statute 143-215.6A to 143-215.6C.
5. 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).
6. 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.
7. 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.
This permit may be modified, or revoked and reissued to incorporate any conditions,
limitations and monitoring requirements the Division deems necessary in order to adequately
protect the environment and public health.
Permit issued this the sixteenth day of July, 2004.
NOR H CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION
r Alan W. Klimek, P.E., Director
Division of Water Quality
By Authority of the Environmental Management Commission
Permit Number WQ0003487