8203_TerrBlue_20160320

Compliance History Review Checklist
Compliance History Review 1 r Cl �- ti . 'r C✓ �3 LL-7YL t
Database No. Is -017'C) Date From T
Invoice Number `� Date Paid
1. Obtain Permit Application Review Form
a. Put into the Database
2.
Initiate the CHR Financial Qualification Form
a. Mailed the CHR FQ Form
b. Followed Up on FQ Docs
c. Received FQ Docs
> J
3.
Initiate the CHR Org Chart Form
a. Mailed the CHR Org Chart Form
0
b. Followed Up on OEg Chart
c. Received OEg Chart
4.
Initiate the CHR Questionnaire Form
a. Mailed the CHR Questionnaire Form
fp
b. Followed Up on Questionnaire
c. Received Questionnaire
S.
Initiate the Staff email
a. Followed Up on Staff emails
b. Received all Staff Emails
i. Compliance Hydro
ii. Environmental Scientist
6.
Compliance Check
7.
Permit Name Check
S.
Initiate the ECHO
9.
Initiate the Secretary of the State
`
10.
Review of CHR
11.
Send out Final Yay or Nay for CHR
,3 /1
Version 4.
SMR 03115 Y L 0 ✓ T
�iJ ,J

N
PERMIT APPLICATION REVIEW FORM
Review Requested by: Tony Gallagher Date Requested: 3/20/2016
Facility Name and Permit ID
Terra Blue, Inc., 8203 - Compost
Applicant (Owner) Name
Dr. Ray Campbell
Description of Permit Request
(1)a. New — New Facility
[This is the action the applicant is
(1)b. New — Expand Facility Boundary
requesting in accordance with
❑ (1)c. New — Expand Waste Boundary
NCGS 130A-295.8(b)]
'❑ (1)d. New — Substantial Amendment
❑ (2)a. Amendment — Next Phase of the Approved Facility Plan
X (2)b. Amendment — Five-year Renewal
❑ (2)c. Amendment — Change in Ownership
(3)a. Modification — Change to Approved Plans (No CHR)
❑ 3 b. Modification — Subsequent Permit to Operate No CHR
Permit Fee
1 250.00
Date Application Received
3/15/2016
Contact Name, Title & Phone #
Dr. Ray Campbell, Executive Vice President 919-851-5751
Email Address
crcampbAbellsouth.net
Company
Terra Blue, Inc.
911 Address
484 Hickory Grove Road
Mailing Address
484 Hickory Grove Road
City/State/Zip
Clinton NC 28328
Parent Company
N/A
Known Subsidiaries
N/A
Other known names business has
N/A
operated under
Known Counties of Operation
Sampson
Does the applicant have a past or
Yes x No ❑ Unknown ❑
current solid waste permit?
Facility Type: Large Type III Compost facility Permit #: 8203 -
Compost
Did the permit applicant submit
Yes ❑ No ❑ N/A x Not Needed ❑
Financial Assurance cost
estimates?
N/A
Other notes
Modified on 3.21.2016
Revision #3

ti
TERRA BLUE, `INC.
484 HICKORY GROVE ROAD
CLINTON, NORTH CAROLINA 28328
[phone]
March 15, 2016
Mr. Martin A. Gallagher, Supervisor
Composting & Land Application Branch
Division of Waste Management
NC Department of Environmental Quality
217 West Jones Street, Green Square Office Complex.
1646 Mail Service Center
Raleigh, North Carolina 27699
Subject_ : Terra Blue Inc.
Large.TYlie III Solid Waste Composting Facility
Permit Renewal Request
Facility Permit No..S WC-82=03
Dear Mr. Gallagher.
Since April 7, 2011; Terra Blue, Inc. has operated .a Large Type III composting Facility under
Permit No. SWC-82-03 at 484 Hickory Grove Road; Clinton, NC, 28328. We would like to
request a renewal of this permit on April 7, 2016.
Attached is a copy of our current permit. We request to continue the same operation with the
exception that ourroutine composting will now be totally windrow rather than a combination of
windrow and a bin system. The windrow system offers greater flexibility and improved
efficiency. As allowed in the previous.permit, we would like to continue R & D work with static
pile and other composting options to fiirther advance our current operation.
The size of our facility is the same as it was after our expansion in 2011. We project to continue
the same size operation as approved at that time_ All of our compost meets "Class A"
requirements and is used as an ingredient in value-added products currently manufactured and
distributed.
The administrative page of the permit has changed some over time as indicated below:
Dr. C. Ray Campbell, PhD
Executive VP, Research and Development
Terra Blue., Inc:
484 Hickory Grove, Road
Clinton; NC 28328
[phone] office
[phone] cell
[e-mail]
Duties: Overall responsibility for composting facility, manufacturing, and permit compliance.

Mr. Harold E. Howrey
Compost Operator
Terra Blue, Inc.
484 Hickory Grove Road
Clinton, NC 28328
[phone] office
Duties: Completes daily dudes and maintains records on receiving, composting, monitoring,
removal, and storage of finished product under the direction of Dr. Campbell.
We appreciate the support and guidance that your office has provided over the years. We will be
glad to provide additional information if needed for the renewal of our existing permit. Please
contact me at [phone] if additional information is needed.
Sincerely yours,
:C. Ray Campbell, Ph.D,
Executive VP, Research & Development
Terra Blue, Inc.
[phone] cell
Enclosures: Terra. Blue, Inc. Permit

PERMIT APPLICATION
LARGE TYPE III SOLID WASTE COMPOST FACILITY
Terra Blue, INC.
484 Hickory Grove Road
Clinton, North Carolina 28328
[phone] office
[phone] fax
Overview
Since May 9, 2006, Super Soil Systems USA, Inc., now Terra Blue, Inc., has been permitted to
operate a Small Type III Solid Waste Composting Facility at 484 Hickory Grove Road in
Sampson County, North Carolina (Permit Number 82-03). Since that time, the facility has been
used to process swine solids, cotton gin trash, and wood chips into "Class A" compost that can
be used to manufacture value-added products for the horticultural and agricultural markets. The
effort began operation under a Pilot/Demonstration Permit issued by the Division of Solid Waste
in 2002 as part of efforts to develop superior waste treatment systems for swine under the
Smithfield foods/Premium Standard Farms/Front Line Farmers agreements with the Attorney
General of North Carolina. The technology report covering the on -farm treatment phase of the
Super Soil technology was issued July 26, 2004 by the Waste Management Center at NCSU. The
technology report covering the central processing facility (Demonstration Compost Facility) was
released July 25, 2005 by the Waste Management Center. Conclusions in these reports indicate
both the on -farm and central facility treatment systems meet technical criteria to be designated
superior waste treatment technologies. In 2008, a report on the second generation Super Soil
technology was released indicating that the advanced system still met very stringent technical
requirements while cost was decreased by 2/3 'ds that of the first generation model.
After receiving approval for a Small Type III facility in 2006, Super Soil has continued to
receive solids from the second generation farm and process them into value-added products for
distribution and sales. In 2007, the General Assembly of North Carolina passed legislation which
contained economic incentives for farmers to place the new treatment technology on their farms.
Super Soil was also awarded a grant to expand the composting facility to handle solids from
additional farms. In 2009, USDA and North Carolina teamed up to support placing the treatment
system on an additional farm under this program. Construction is now underway for one of these
projects and a Clean Water Management Trust Fund Project that will place the treatment system
on a large farrow -to -finish operation that includes the supporting sow facilities.
In order to handle the solids removed from all of these farms, Terra Blue, Inc.is requesting
permission to expand the current facility to a Large Type III Solid Waste Composting Facility.
To meet expected composting demand, Terra Blue will continue operating the current Bin
System that supports two or more standard size farrow-to-finsh farm units while adding covered
windrow or additional bin systems to support solids received from additional farms. In total, the
facility will be expanded to handle a minimum of 2,915 cu R of compost material (swine solids +
bulking agent) per day 5 days per week. As with the current bin system, a windrow compost
process will take 30 days and will be followed by a 30 day curing period. New facilities will be

designed to handle the 30 day compost load and a 30 day curing load. Both composting and
curing processes will be under a covered structure with partially closed sides and open ends for
access. The new composting/curing facility will be constructed parallel to the current facility as
indicated on the attached drawing. This will allow easy access for bringing in new composting
materials and removal of cured product to the manufacturing facility.
Existing Bin Composting System
Proposed Windrow Composting System
2

TABLE OF CONTENTS
AERIAL / FEMA PHOTOGRAPHS..................................................................... 4
ZONING...................................................................................................... 4
COMPLIANCE WITH SITING/DESIGN STANDARDS FOR SOLIDS WASTE COMPOST
FACILITIES.................................................................................................. 4
TYPES, SOURCE, AND QUANTITIES OF WASTE AND BULKING AGENTS TO BE
COMPOSTED................................................................................................6
SOILS EVALUATION..................................................................................... 6
RESPONSIBLE PARTIES................................................................................. 7
PERSONNEL........................................ ..................................................... 7
FACILITY DESIGN & LAYOUT ............................................ ..................... 7
OPERATION AND PERCEEDURES.................................................................... 8
CONTINGENCY PLAN ...............................................................................I I
OPERRATIONS MANUAL..............................................................................11
QUALITY ASSURANCE.................................................................................11
PROCESSING FACTS.....................................................................................12
PRODUCT MARKETING AND DISTRIBUTION...................................................13
RESEARCH AND DEVELOPMENT...................................................................13
REFERENCES..............................................................................................14
ATTACHMENTS.......................................................................................... 14
3

Aerial PhotoPranh
Attached are aerial Farm Service and FEMA photographs of the site on which the central solids
processing facility will be expanded. FEMA records indicate that the site is not in a flood zone
and is approved for use as a compost facility. The solids processing facility is located on a 150
acre farm on Hickory Grove Road (SR 1336) about 1/4' mile from US 421. A soils evaluation
on the farm indicates large acreages of Norfolk Soil Series which is well drained and will
provide an excellent foundation for the composting/processing facility.
Zoning
The site is zoned I -Industrial and is acceptable for the composting /processing facility. Adjacent
properties utilized by Super Soil Systems, USA, Inc. are zoned R/A-Residential/Agricultural and
are also suitable for the compost facility. Attached is a letter from the Sampson County Planning
and Development Department confirming zoning and approval of the facility.
Comlian_ ce with Siting / Design Standards for Solid Waste Com��ost Facilities
The site for the central processing facility meets minimum standards in Rule .1404. It is located
on a Norfolk Soil Series that has superior drainage characteristics and is not in a flood zone.
Surface drainage at the site is excellent. A 50 ft minimum grass buffer will be maintained around
the facility to filter any runoff during heavy rainfall. Riparian buffers are generally between the
grass buffers and the property lines. This provides additional protection from nutrient movement.
The site, along with composting procedures, and plans for developing the central facility have
been reviewed and meet approval of NRCS officials.
The site was inspected by Dr. C. Ray Campbell, Licensed Soil Scientist, on July 29, 2005.
Borings to 48 inches were done at six locations on the property to confirm soil type and drainage.
Based on the borings and the soil survey published in 1985, the compost facility will be located
on a Norfolk loamy sand 0-2 % slope (NoA). The Norfolk soil series is a well drained upland
soil that is considered very productive. It is a member of the Ultisol order and the suborder Typic
Paleudults. Soils in the Norfolk series are considered favorable sites for sanitary facilities and
construction/development. There were no signs of a seasonal high water table within 24 inches
of the surface at any of the boring sites.
A 100 ft minimum buffer is maintained between all property lines and compost areas. The
closest residence is approximately one -forth mile from the compost area. The closest well is 150
ft from the composting, receiving, and curing areas. There are no streams within 100 ft of the
compost area. The nearest Blue Line stream is 1.25 miles from the compost facility. After the
new facility is constructed, the surrounding areas will be graded and graveled to support trucks
and loaders and to divert surface water to grassed areas where it is filtered before entering
riparian buffers or ditches associated with the highway. There will be no swales or berms that
will restrict access of the compost area by fire fighting equipment.
Due to soil type and deep seasonal water table (greater than 24 inches), composting on concrete
slabs under cover, grass and riparian buffers along perimeters of the facility, and control of
surface runoff, the site meets the following water quality requirements: A. The site will not cause
discharge of materials or fill materials into wetlands of the state in violation of Section 404 of the
Clean Water act. B. The site will not cause a discharge of pollutants into waters of the state in
0

violation of the requirements of the National Pollutant Discharge Elimination System (NPDES).
C. The site will not cause non -point source pollution of waters of the state that violates assigned
water quality standards.
The site will meet the following groundwater requirements: A. Due to its location, construction
(All composting and mixing are done on a concrete pad.), and operating procedures, the site will
not contravene groundwater standards as established under 15A NCAC 2L. B. Depth to the high
water table is > 24 inches where the facility is located. Cotton gin trash (bulking agent) is stored
in compressed bales that are protected from rainfall. Wood chips are stored in piles and protected
from rainfall as necessary to control moisture and runoff. Swine waste solids are routinely
unloaded, mixed, and composted on a covered concrete pad the day in which they are received.
If due to equipment failures, etc. swine solids must be stored for a brief period, they will be
stored in transportation containers or in temporary piles on the mixing pad. Composted product
is dried to approximately 50 % moisture before storage in curing piles for 30 days. With the
expansion, adequate curing space will be provided under cover. If cured product is stored
outside, it will be covered as necessary to avoid run-off and/or leaching.
Public access to the compost facility will be controlled. The site will meet requirements of the
Sedimentation Pollution Control Law (15A NCA 4) and the Air Pollution Control Law (15A
NCAC 2D) which minimizes fugitive emissions and odors. Runoff will be minimized by
composting on a concrete pad in a covered facility. Proper composting blends, mixing and
aeration will all contribute to minimizing odor and emissions.
5

T` }es. Source and O uantities of Waste and Bulkin A eats to be Com osted
Waste and bulking materials in the table below will be used at the compost facility. Swine solids
will be received from farms for which Terra Blue is contracted to remove solids from their
production unit. The swine solids will be approximately 70-75 % moisture and will contain
approximately 4-5 % Total Nitrogen, 1-1.5 % P, 0.09-1.3 % Zinc, and 0.03 -1.4 % Copper. No
recycling will be done at the facility.
CURRENT
PLANNED
MATERIAL
PURPOSE
SOURCE
QUANTITY
EXPANSION
cu yd/quarter
cu yd/quarter
Swine Solids
N/C-Source
Participating Farms
300
2,350
Cotton Gin
Trash (Dom.)
C-Source/Bulking
Area Gins
600
4,700
Area Livestock
Wood Chips
C-Source/Bulking
Trucking
0
60
Clinton /Right of
Yard Waste
C-Source/Bulking
Way
0
20
Coastal Hay
C-Source/Bulking
Area Farms
0
20
Vegetable
Waste
N/C-Source
Area Farms
0
20
Area Cabinet/Wood
Saw Dust
C-Source/Bulking
Shops
60
60
Soils Evaluation
The site was inspected by Dr. C. Ray Campbell, Licensed Soil Scientist, on July 29, 2005.
Borings to 48 inches were done at six locations on the property to confirm soil type and drainage.
Based on the borings and the soil survey published in 1985, the compost facility will be located
on a Norfolk loamy sand 0-2 % slope (NoA). The 6 borings were very similar and indicated a
grayish brown loamy sand surface soil to a depth of 0-8 or 9 inches. At 8-9 inches, there was a
rather abrupt transition to a yellowish brown sandy clay loam. At 15 inches the clay brightened
to a yellowish orange and clay content increased. A similar material was found to a depth of 34
inches where there was some bright red clay mottles. In two of the bores there were also some
brownish -gray mottles at 32 inches. In most of the bores, there was some small gravel found
between 32 and 38 inches. The yellowish -orange clay with red clay mottles continued until 48
inches. There was no indication of a shallow seasonal water table within any of the profiles.
The Norfolk soil series is a well drained upland soil that is considered very productive. It is a
member of the Ultisol order and the suborder Typic Paleudults. Soils in the Norfolk series are
considered favorable sites for sanitary facilities and construction/development.
on

Responsible Parties
Mr. Lewis Fetterman, Sr. ( Deceased as of September, 2010)
CEO and Chairman
Terra Blue, Inc.
484 Hickory Grove Rd.
Clinton, North Carolina 28328
[phone] office
[phone] cell
Dr. C. Ray Campbell
VP Res. & Dev.
[phone] office
[phone] cell
Mr. Nelson Rinfrow
Operations and Maintenance
[phone] office
[phone] cell
Personnel
Currently Open
Compost Operator
[phone] office
This position manages the compost operation ensuring that daily requirements are met in mixing,
monitoring data collection, composting, and product removal.
Currently Open
Product Manufacturing
(910) 564 -5545 office
This individual assists with composting and monitoring and processes cured compost to
manufacture fertilizer, soil amendment, potting soil, and container mix.
Facility Design & Lay -out
The attached drawing indicates overall design and traffic patterns of the existing and proposed
expanded facility. The current Bin composting system consists of a covered shed 40 ft wide by
250 ft long under which five bins, approximately 6.5 ft wide, are located. Bin walls and the floor
of the facility are constructed of concrete. A mobile composting unit moves along tracks to mix
and aerate the compost materials in each bin.
The expanded composting facility will consist of a "Clear -Span" or steel type structure 150 ft
wide and 300 ft long located parallel to the existing bin facility. The top and sides of the building
7

will be covered to limit blowing rain from adding excess moisture to the compost windrows and
cured product.
Bulking agents will continue to be stored in adjacent areas near the compost facility and covered
as required to control moisture and limit premature composting. The storage area will be graded
to provide adequate surface water control. Access roads will be graded and graveled to support
movement of vehicles and other equipment around the facility.
Operation and Procedures
Current bin Facility
The facility is designed for operation 7 days a week. Swine solids are received only from
contracted farms. Cotton gin trash and wood chips are received from contracted facilities
Monday thru Friday. Bulking agents including cotton gin trash and hardwood chips are
maintained on site and available for mixing at all times. When swine solids arrive at the facility,
they are mixed according to the appropriate recipe immediately. This minimizes odor and
facilitates pest control. Swine solids and bulking agents are inspected for foreign matter when
mixed. Prior to mixing, any foreign matter found is placed in trash containers for disposal.
Two compost recipes are currently used at the facility. One targets fertilizer and soil amendment
production while the other targets a basic organic material that can be used in the production of
potting soil, and container mix. The compost recipes are proprietary but can be reviewed by
inspectors as deemed necessary for regulatory purposes.
Recipes 1 and 2 are maintained in separate bins in the compost facility. Daily records are
maintained indicating the amount of swine solids and each bulking agent mixed, and the amount
of product removed to curing piles. There are fifteen 12 ft-long bays separated by support post
along each compost bin. Temperatures are collected from 15 bays in each bin daily (See attached
example of compost records). Moisture samples are taken and moisture content determined
weekly on outside bins and the middle bin. This allows monitoring both recipes and outside bins
where moisture may vary due to blowing rain. The composting machine provides the required
aeration and is run in each bin Monday -Friday (5 days a week) depending on space requirements
and moisture & temperature requirements. From noon Friday until noon on Monday, the
compost machine is not run in order to ensure continuous temperatures of 131 F + for 72 hours.
The compost moves approximately 7 linear feet each time the aeration/mixer is run. In general,
highest temperatures are recorded during the first three weeks after thorough mixing.
Temperatures will generally remain above 131 F in the first 8 bays. Since compost stays in a
single bay for at least two days, a temperature of 131 F + is generally maintained for 16-22 days
of the 30-day processing period. The compost process meets the requirements for "process to
further reduce pathogens" (PFRP) and exceeds general requirements for "vector attraction
reduction" (VAR) (maintain temperatures of 104 F or higher and an average of 113 F for 14
days) or longer. Records of temperatures in curing piles indicate that after piling, the compost
reaches temperatures of 131-150 F and remains there for approximately 25 days. Curing piles are
not mixed during this process. Sampling at the end of this period indicates excellent pathogen
kill (See attached evaluation reports).

During periods of heavy rainfall, snow, etc., outdoor activity is minimized and equipment is not
ran except as required to obtain bulking agent to mix incoming swine solids. Bulking agent is
maintained under covers to minimize moisture accumulation. The composting area is checked
for signs of runoff and appropriate action is taken as necessary. Curing piles are covered with
plastic as necessary to minimize water penetration and leaching.
Pesticides are used for fly and ant control. Operators monitor fly population and apply fog
treatments in and over the compost bins in early morning and/or late afternoon once weekly or as
needed. Bulking agent storage areas and curing areas are inspected weekly for fire ants and
control chemicals are administered if infection sites are identified.
After curing, compost is removed to the manufacturing facility where it is ground and/or
screened to manufacture soil amendment, fertilizer, potting soil, container mix, or mulch.
Overages are reprocessed until all of the material is utilized in value-added products. Solids are
also being evaluated as an alternative fuel.
Initially, the compost will be processed to manufacture soil amendment, organic fertilizer,
potting soil, container mix, and mulch. If compost fails to meet quality standards for pathogen
kill or other factors, it will be reprocessed with new mixes to ensure the compost meets required
standards. If all the compost cannot be utilized and marketed as planned, it will be utilized on the
Super Soil farm land and/or local farmers will be contacted and requested to utilize the material
in routine crop production. After receiving approval from participating farms, the excess
compost will be trucked and spread on identified fields at rates required to meet crop
requirement for the most restrictive nutrient (N, P2O5, Cu, or Zn). Records of disposal by this
method will be maintained along with marketed products.
New Windrow Facility
A new windrow system will operate similarly to the bin system with the exception that
temperature requirements will be different. In the case of the windrow system, temperatures will
be taken five days per week in each windrow at 50 ft intervals to confirm that 131 F is
maintained for a 15 day period. During this same period, the windrow will be turned a minimum
of 5 times to ensure that all the material in the windrow has been exposed to pathogen -killing
temperatures. Moisture samples will be taken from each windrow as needed and used as a tool to
ensure that proper aerobic composting conditions exists. These samples will be taken at 50 -100
ft intervals. Water will be added to the windrows as needed to maintain acceptable composting
conditions. Records of all these measurements will be maintained as part of the permanent record
system of the facility.
As daily loads of swine solids come in to the facility, they will be dumped at the end of
individual windrows. Required amounts of bulking agents will be placed over the swine solids.
This limits exposure of the swine solids to the atmosphere and minimizes odor. The compost
turner will be operated to thoroughly mix the swine solids and bulking agent and accelerate the
composting process. The compost will then be turned daily or as needed to provide proper
aeration and moisture control and ensure that minimum temperature requirements are met. As the
compost turner moves material approximately 6.5 ft linearly each turn, finished compost moves
to the far end of the building just as in a bin system. Finished product will be removed from ends
C

of windrows and placed in the proper storage bin. Individual storage bins will be filled
completely before moving to the next bin. This will ensure a minimum of one month curing time.
During curing, the compost further stabilizes to become premium "Class A" compost for use in
manufacturing value-added products. The compost is stored in the curing bin until needed for
manufacturing. Quarterly samples of the cured compost will be taken to confirm that the material
meets "Class A" standards as required by the permit.
After a minimum of 30 days curing, the compost product will be processed and mixed with other
ingredients, to manufacture value-added products. It is anticipated that product demand will
utilize material coming out of the compost and curing process and that no additional storage will
be required. If this is not the case, additional storage will be provided and/or storage piles placed
under covers to maintain proper moisture and protection from rainfall.
Records/Monitoring
Basic record -keeping procedures currently used in the Small Type III Facility will be utilized in
the Large Type III Facility after expansion. Volumes of materials (swine solids and bulking
materials) placed in each bin or windrow will be recorded daily along with volumes of
composted product removed and placed in curing piles. Records of daily mixing for each bin or
windrow will also be recorded. Temperatures will be recorded for both bins and windrows along
with moisture determinations and maintained as part of permanent records at the facility.
Amounts of each of the final products sold will be recorded.
Moisture determinations will be completed with Terra Blue quality control equipment in the
manufacturing facility. Samples of the compost material at least 6 inches below the surface will
be taken with a scoop from each bay or windrow section, placed in a paper bag, and weighed in
grams to two decimal places before drying. After drying, weights will be recorded to the same
accuracy and percent moisture calculated and recorded in the spreadsheet.
Effectiveness of on -going compost operations will be monitored by observing temperature and
moisture determinations. Records will indicate how many days compost stays in each bay of a
bin by noting when the bin was mixed. The number of days which the temperature is maintained
at 131 + F can then be determined. In general, the compost mix stays in each bay two days. The
number of days at which the temperature was over 131 F can then be calculated from the records.
The attached records illustrate how this determination is made. Temperatures recorded for curing
piles during initial evaluation of the compost process indicate the compost maintains
temperatures of 131-150 F in the curing piles for 25-30 days. The curing time ensures pathogen
kill and provides ample time for the compost to thoroughly stabilize before processing.
Samples will be taken from curing piles and placed on ice until delivered to laboratories for
analytical work.
Air emissions are minimized during composting by maintaining proper recipe and mixing the
day the swine solids are received at the facility. Bins are routinely mixed to be sure that adequate
air is maintained in the compost bin. Surface water is managed in the bulking agent storage areas
with proper surface drainage combined with adequate grass and riparian buffers to contain any
nutrient movement. Fertilizer is not applied to buffers unless required to develop an adequate
sod.
10

Every 6 months or 20,000 tons of compost, samples will be taken from curing piles to determine
percent foreign matter; pathogen, and nutrient content. Terra Blue will determine percent foreign
matter in composite samples of the compost according to procedures outlined in the regulations.
Composite samples at least 2 ft under the surface of the month -old cured compost will also be
taken using sterile gloves and evaluated for fecal coliform by a qualified laboratory. Samples
will be placed on ice and delivered directly to the laboratory. Samples for nutrient and metals
analysis will be delivered to the NCDA & CS Laboratory.
Records for windrows in the expanded system will be similar to those of the bin system as shown
in the attachment and will indicate volumes of compost ingredients going into the system each
day, when the windrow was mixed/turned, temperatures every 50 ft daily, moisture every 50-100
ft on an as needed basis, and records of product removed and placed in curing bins daily.
Continemev Plan
In the event of equipment breakdown, Terra Blue will first minimize the amounts of solids
delivered to the facility during the breakdown period. A repair staff will be available at all times
to provide quick response to identified problems. Solids that are delivered to the compost site
during breakdowns will be stored in hauling containers or in temporary piles on the loading pad
until processing can continue. Only swine solids and bulking agents listed in composting plans
will be accepted. Any undesirable operating conditions including odor, air pollution, pests, noise,
or fires will be addressed according to plans in the Operations Manual. Preventive programs to
control odor, pests, air pollution and fires will be strictly followed to minimize development of
unacceptable conditions. A volunteer fire department is located within one mile of the facility
and will respond to any emergency calls.
Operations Manual
An overview of the Operations Manual and procedures can be found in the Operations and
Procedures section of this document beginning on page 8. A separate Operations/Procedures
Manual for the Compost Facility is attached.
Quality Assurance
Records of materials input (volumes) will be maintained on a daily basis. Daily monitoring of
operating conditions will ensure optimum compost conditions and high quality products.
Nutrient/metals, foreign matter, and pathogen analyses will ensure compost quality. Product
removal from the compost unit to the curing piles will be recorded. Curing piles for bins and
windrows containing the same recipe will be combined. Records of compost and value added
product (soil amendment, fertilizer, container mix, and potting soil) sales and shipping will be
maintained and related back to compost and manufacturing conditions as needed to provide
quality assurance.
The compost process will be monitored by taking daily temperatures from all active bays in each
bin and from all compost windrows still in the 15 day temperature period. Moisture samples will
be taken from outside bins along with windrows and at least one example of each compost recipe
weekly. Wet and dry weights will be determined and percent moisture calculated.
11

Every six months or 20,000 tons of compost produced, samples will be taken for nutrient,
pathogen, and foreign matter determinations. Terra Blue will determine foreign matter. The
Agronomic Division laboratory of NCDA & CS will determine nutrient and heavy metal
concentrations. An approved laboratory will evaluate samples for pathogens. Accepted industry
procedures will be followed in collecting samples and transporting them to the laboratory. A
copy of all records will be maintained in the Super Soil office.
Processing Facts
1. One standard farm (5,145 - 5880 head topping facility or equivalent) produces
approximately 120 cu ft of swine solids per day five days each week.
2. Swine solids weigh an average of 49 lbs/cu ft. at 83 % moisture. With further moisture
reduction, using second and third generation solids removal equipment, solids are
produced at 75 % moisture and weigh approximately 46 lbs/cu ft.
3. Cotton Gin trash weighs approximately 7.51bs/cu ft and is approximately 13-15 %
moisture. Wood chips weigh approximately 26 lbs/cu ft. and are generally 60 % moisture.
Sawdust weighs approximately 17.9 lbs/cu ft and is generally 6.5 % moisture.
4. Compost recipe 1 targets fertilizer manufacturing and soil amendment production while
recipe 2 targets potting soil and container mix production.
5. Based on a one-year Pilot Project and experience on the second generation project, the 5-
Bin compost facility currently under operation will accommodate solids from a maximum
of 2 standard 5,145 head/farm equivalents.
6. An as -built schematic drawing and equipment specifications for the Compost-A-Matic
bin system are attached.
7. The one-year on -farm Smithfield Project has been completed. A copy of the Principal
Investigators Report indicating the Solids Removal Technology meets technical
requirements to be designated a Superior Technology has been provided to the Solid
Waste Section.
8. The one-year Pilot Project for the Central Processing Facility has been completed. The
Principal Investigators report indicates the solids processing facility meets technical
requirements to be designated a Superior Technology. A copy of the Principal
investigator's Report has been previously provided to the Solid Waste Section.
9. The Second Generation Solids Removal Project (FPPC) has been completed. A copy of
the final report has been provided to the Solid Waste Section. The final report
summarizes solids removal and value-added product production from a 4,400 head
facility during a one-year period.
10. The Second Generation Attorney General project has now been completed and a copy of
the Final report is attached to this application.
11. Composting Capacity:
Existing facility Compost Capacity: 750.75 cu ft/day or 1,668.33 cu yd/quarter
Proposed Bin System Capacity: 2,716.56 cu ft/day or 6,036.8 cu yd/quarter
Proposed Windrow System Capacity: 3,701.1 cu ft/day or 8,224.67 cu yd/quarter
Total Capacity (Bin System Alternative): 3,467.31 cu ft/day or 7,705 cu yd/quarter
Total Capacity (Bin System + Windrow Alternative): 4,451.85 cu ft/day or 9,893 cu
yd/quarter.
12. The new proposed storage area will accommodate a minimum of 72,000 cu ft of compost.
12

Product Marketing and Distribution
Terra Blue is currently marketing Soil Amendment and Container Mix manufactured from the
compost. Additionally, Terra Blue is exploring the option of marketing the composted solids as
an alternative fuel for co -firing with coal at electric generation plants in North Carolina or use in
a pyrolytic generating system on -site. The North Carolina DOT is considered a major market for
soil amendment to be used in roadside stabilization and beautification projects. Terra Blue has an
agreement with a major agricultural products distribution company to market Container Mix,
Soil Amendment, and fertilizer products.
Terra Blue has now introduced new product labeling and is preparing for mass marketing of
products. Efforts are also underway to register the products by OMRI and distribute them for
organic food production.
The Terra Blue fertilizer grades have been evaluated in South Carolina by a number of turf
professionals and in North Carolina by Dr. Charles Peacock at NC State University Turf Center.
Results indicate the fertilizers perform equal or superior to other turf fertilizers on the market.
RESEARCH AND DEVELOPMENT
Terra Blue requests approval to continue to complete research and development work with static
pile and other composting methods as necessary to optimize compost conditions and economics.
We also request approval to continue R & D work with vermi-compost procedures on a limited
basis and to market previously vermi-composted product that has been stored and tested to
demonstrate pathogen kill and safe metal concentrations. Terra Blue will complete foreign matter
determinations of these materials while samples will be delivered to a qualified laboratory for
pathogen and metals analysis.
13

REFERENCES
Campbell, C. Ray, VP Research & Development, Super Soil Systems USA, Inc. 2005. Solids
Removal System for Reducing Environmental Impact of Swine Production. FPPC Technology
Summit, May 4-6, 2005, St. Petersburg Florida.
Campbell, C. Ray, VP Research & Development, Super Soil Systems USA, Inc. 2005. Final
Report: Solids Removal System for Reducing Environmental Impact of Swine Production. July
2003-February 2005. Submitted July 28, 2005 to FPPC, St. Petersburg Florida.
Vanotti, Matias, PI., USDA-ARS Florence. 2004. Evaluation of Solids Removal System to
Reduce Environmental Impact of Swine Production- Progress Report. July 12, 2004.
Vanotti, Matias, PI, USDA-ARS Florence. 2004. Evaluation of Environmentally Superior
Technology: Swine Waste Treatment System for Elimination of Lagoons, Reduced
Environmental Impact, and Improved Waster Quality. Phase I: Solids separation / nitrification-
denitrification / soluble phosphorus removal. Final Report. May 25, 2004.
Vanotti, Matias, PI, USDA-ARS Florence. 2005. Evaluation of Environmentally Superior
Technology: Swine Waste Treatment System for Elimination of Lagoons, Reduced
Environmental Impact, and Improved Waster Quality. Phase 11: Centralized Composting Unit.
Final Report. January 15, 2005.
Attachments
Response to Questions/Comments from Technical Review
Engineered Drawings C000, C 100, C200
Clinton Planning Department Site Location — General Location
Clinton Planning Department Site Location — Property Lines
Clinton -Sampson County Planning Department Letters (2)
Compost-A-Matic Model 210-610 Specifications
Backhus Model 16.36 Specifications
As Built Drawing — Existing Composting Facility
Terra Blue Composting System — Process Flow Diagram
Terra Blue Product Labels — Soil Amendment, Container Mix
Example — Terra Blue Composting Records
Typical Swine Solids Waste Analysis
Terra Blue — Operations/Procedures Manual — Compost Facility
14