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HomeMy WebLinkAbout1906_McGill_renewapplic_20200805Permit Amendment (Renewal) Application McGill Environmental Systems M c (;ILL Trans1by,m n Rebuif{fau Pifx Merry Oaks Facility 634 Christian Chapel Church Road New Hill, North Carolina SECTION 1.0 Facility Information Name of Facility: McGill -Merry Oaks Compost Facility Address of Facility: 634 Christian Chapel Church Road, New Hill, NC 27562 Facility Type: Type 4 Contact Information Owner: McGill Environmental Systems of NC, Inc. — contact, Noel Lyons Owner Address: 634 Christian Chapel Church Road, New Hill, NC 27562 Owner Phone Number: (910) 990-3188 Owner Email: nlyons@mcgillcompost.com Facility Contact: Misti S. Godwin Contact Address: 634 Christian Chapel Church Road, New Hill, NC 27562 Contact Phone Number: (919) 770-4416 Contact Email: mgodwin@mcgillcompost.com Landowner Information Same as applicant. Permit Fee Contact Facility Contact: Misti S. Godwin Contact Address: 634 Christian Chapel Church Road, New Hill, NC 27562 Contact Phone Number: (919) 770-4416 Contact Email: mgodwin@mcgillcompost.com SECTION 3.0 3.1 Please see Attachment A, Merry Oaks 2019 Intake Spreadsheet. All new feedstock customers provide the required analytical data to McGill prior to McGill accepting their intake material. The provided data is then provided to NC DEQ as requested in our permit. 3.2 Please see Attachment A, Merry Oaks 2019 Intake Spreadsheet. There are no significant seasonal variations in feedstock with some exceptions such as yard waste which by its nature varies with the seasons. The most significant variation is a higher portion of grass in the summer versus leaves in the fall. We manage this by adjusting amendment usage. 3.3 Facility capacity (excluding woody amendments): Number of primary bays = 10. Bay residence time = 7 days. Mass per bay = 200 tons. Maximum bay cycles per year 52. Total plant capacity: 10 bays x 52 cycles x 200 tons = 104,000 tons. 3.4 Storage Area Description Size Blending area Waste offloading pit 400 tons Amendment inside storage Storage of amendments 3,200 cubic yards Amendment outside storage Storage of amendments "3,000 cubic yards Process building capacity Bays used for processing 8,500 cubic yards Curing capacity indoors Bays used for curing 4,500 cubic yards Unscreened product storage Storage area for non -screened compost 2,000 cubic yards Screened product storage Storage area for final product —8,500 cubic yards 3.5 Recipes are developed with the objective to achieve both a moisture level of 55-60% and a C:N ratio of at least 20:1. Mixing is performed by wheel loader. The greatest variable is moisture content of amendments. A typical mix might be as follows: • 1 bucket of residuals or biosolids • 2 buckets of overs • 1 bucket of ground yard waste The blending operator is also trained to use the "Squeeze Test" as well as visual inspection to monitor moisture levels in the mix. 3.6 All mixing is performed by wheel loader. Materials of differing consistency are stored separately. Waste material with high nitrogen and moisture content are stored in the pit area within the blending building. Yard waste, is stored outside but near the blending area of the operations building. The separate storage ensures the blending operator can accurately measure the correct portions for the recipe. Grinding of feedstock is done on a regular scheduled basis. A portable grinder is contracted, and there is a designated grinding area for the purpose of preparing yard waste, dimensional lumber, and pallets. These feedstocks are stockpiled outdoors until needed. Wheel loaders are used to transport the ground feedstock into the blending area for mixing. All oversized, woody material (overs) that is removed during the screening process is returned to the blending area for use in future mixes. 3.7 Please see Attachment C — Process Flow Diagram. Equipment Number Size Location of Equipment Liwell screen 1 6 ft. x 24 ft. Under roof Trommel screen 1 6 ft. x 20 ft. Under roof within operations building Front end loaders 4 6.5 cubic yard and 9.0 cubic yard buckets Throughout the facility Bobcat skid steer 1 1.0 cubic yard bucket and power sweeper Throughout the facility Biofilter 3 96,000 cubic feet West of operations building Supply fans 15 7.5 horse power Outside of building Biofilter fans 3 50 horse power West of operations building The quantity of materials by weight and volume requested in Section 3 Part 7 is provided in Section 3 Part 2. al Process Approximate time of duration Receiving 1 day Preparation (blending) 1 day Primary Processing 7 to 10 days Curing 14+ days Distribution 30 to 90 days 3.9 McGill uses an aerated static pile composting process. The process works on a batch basis with each batch being approximately 1,000 cubic yards. The primary processing area, consists of 10 bays, and each is a self-contained unit with its own aeration fan, ducting, and air distribution network embedded in the floor (patented). Each bay is independently monitored and controlled. Below are the steps utilized: 1. A 3-inch layer (approximately) of clean wood chips (or other dry material) is placed on top of the aeration channels to facilitate even air distribution throughout the composting mass, absorb excess moisture, and prevent clogging of the aeration pipes. 2. The blended mixture is placed by front-end loader on top of the wood chips to a height of nine feet. The pile is constructed from back to front. When the pile is about one-half complete, the operator places a sensor in the middle of the batch with the tip about four feet deep. 3. A layer of compost is placed over the end of the pile as a cap in order to insulate the material and improve heat retention and contribute to the overall tidiness and cleanliness of the process area. 4. The bay is filled, and the operator notifies the supervisor to start the bay on the control panel. This initiates the electronic temperature monitoring. The bay number and start date make up the batch number. Compost pile construction The bay temperature probe and supply fan are connected to a centralized processor which monitors and records temperatures. The processor has a proprietary software program that continuously adjusts air flow to insure optimum temperatures and maintain aerobic conditions at all times. Throughout the day, the plant manager will check the data records to verify operating status and troubleshoot, as needed. The system is randomly verified with a hand-held probe. The system is also monitored remotely through cell phones. 3.10 Not applicable as all composting activities are carried out indoors. 3.11 All composting activities are carried out indoors. Any water that comes into contact with the final compost product and is not absorbed has been permitted to combine with stormwater and be directed towards one of the stormwater basins onsite prior to being discharged from the site. 3.12 A small number of customers require sand to be added to the final product prior to distribution. No other amendments such as wood ash, lime, or gypsum are added to the final compost product. 3.13 Several steps are taken to avoid the buildup of dust: • Dusty amendments are off loaded inside the blending building • Batches are thoroughly mixed to ensure sufficient moisture at the beginning of the process • Misting systems are used at both screening plants to both prevent and suppress dust • Loaders are washed down at the end of each shift • Heavy traffic areas are sprayed with water on an as -needed basis Air from inside the processing and curing bays is pulled from the top of the bays through a piping system and forced through a biofilter prior to being released into the environment to curb any other potential air emissions. 3.14 Overs material (large woody pieces) from both screening plants is returned to the blending area for reuse. This process is continued until the overs gradually break down. No recycling of "recyclable products" or other types of material handling is conducted at this facility. SECTION 4 —Operation Plan 4.1 Name Title Email Phone number Nick Kranz Plant Manager nkranz@mcgillcompost.com 919-362-1161 Pete Bashaw Chief Operations Officer pbashaw@mcgillcompost.com 919-362-1161 Noel Lyons President nlyons@mcgillcompost.com 919-362-1161 4.2 Scale: The scale is a GSE scale, model 460. Structures: The operations building is a 112,000 sq/ft building. All floors are constructed of reinforced concrete. Functionally the building is divided into the blending area, primary processing, primary screening, curing, final screening, and product storage. The walls are also reinforced concrete to a minimum height of 10'. The structure is a standard industrial metal building, and steel components are corrosion protected where required. The 10 primary processing bays (within the main building) have concrete walls to a minimum height of 16'. Unloading area: All waste materials are unloaded into the blending area from an outside offloading ramp. The ramp is constructed of reinforced concrete and is sloped into the blending area. Biofilter Odor Control System: In addition to odor prevention practices, the biofilter remains the main method of odor control. Water Source: Water for the facility operation is from an onsite water well. Wheel loaders: Loaders with both 6.5 and 9.0 cubic yard buckets are used for blending materials, filling and emptying bays, loading compost into trailers, and moving compost and amendment materials. Liwell screen: The Liwell screen is used to remove overs from compost. Trommel screen: The Trommel screen is used to remove overs from compost. Bobcat skid steer: The Bobcat has both a bucket and a power sweeper. It is used to move materials, and the sweeper is used to clean bays after they are emptied. Equipment Maintenance All equipment maintenance is performed on a scheduled basis as dictated by the manufacturer's recommendations. Wheel Loaders: All major servicing is performed under a service contract with the supplier/dealer every 250 hours and includes all fluid changes. Daily greasing, fluids inspection and cleaning are performed by the operator. Greasing and fluids check is always as per manufacturers specifications. 2. Fans: Fans are inspected daily. This involves a visual inspection by the manager or maintenance technician. Fans are greased as per manufacturer specifications. Screening Plant: Daily servicing is performed by a maintenance technician or operator. This involves greasing, tracking belts, cleaning pulleys, and visual inspection. Any larger maintenance or repair may be performed by qualified outside vendors. Both screening plants are stationary electric which greatly reduces the maintenance load. 4.3 The facility consists of approximate ly50 acres, of which approximately9 acres are utilized for all activities. The site has one road used to access and exit the site and is located on the southern border of the property. There is a locked gate across the site access road and fences are located at various places around the perimeter of the property. The facility is surrounded by dense woodlands on all sides, and vegetated berms are located around the perimeter of the operations area. The facility is also protected by security cameras at various locations around the facility. The facility is not open to the general public for either feedstock drop off or product sales. 4.4 A McGill employee is onsite at all times while the gate is unlocked. 4.5 The access road is constructed with all-weather materials, and the road is maintained. 4.6 The facility is open to accept materials from contracted customers from 6:30 am to 5:00 pm Monday through Friday and from 7 a.m. to 12 p.m. on most Saturdays. During busy times, the plant personnel may have extended hours. The following are general guidelines for plant employees: 1. At the beginning of each workday, employees meet with the plant manager to go over the rotation of bay schedule, issues still outstanding, and plans for the day. 2. Following the meeting, plant employees go to their assigned area within the plant and inspect their equipment (screens, loaders, etc.) prior to start up. 3. Employees perform their daily tasks as assigned whether it is blending feedstock, moving curing materials from one bay to another, repairing equipment, or cleaning bays after use. 4. When the scale office closes, the gate at the entrance is locked. 4.7 Posted at the entrance of the facility are signs that list the types of PPE required, emergency contact phone numbers, permit number, types of waste received, types of waste not accepted, and operating hours. Listed as the types of waste not accepted are hazardous waste, asbestos containing waste, and medical waste. 4.8 Densely wooded areas surround the facility on all sides. 4.9 The following positions are typically staffed for proper operation of the facility. Plant Manager: Responsible for all day-to-day activities at the facility including production, administration, process control, monitoring and record -keeping, transportation, compliance, invoicing, and human resources (including training). This individual represents McGill at local civic and business functions and is responsible for business development and customer service for the facility. This individual is the direct supervisor of the plant superintendent, dispatcher, drivers, and contract administrator. 2. Team Lead: Responsible for through -put at the plant is the first line supervisor for all processing employees. Responsibilities include proper handling and storage of raw materials including monitoring of all incoming loads to verify documents and material integrity, blending ratios and blend quality, primary processing, screening, curing, and finished product blending and loading. This individual is also the direct supervisor of all processing plant employees. 3. Industrial Mechanic: Responsible for routine maintenance, repair, replacement of motor/blower units, transport vehicles, blending and screening units, loaders, tools, and other equipment; painting and minor structural repairs. 4. Loader Operator: Responsible for the control of blending rates of raw materials to assure a proper mixture according to prescribed ratios, placing blended mixture to composting bays, placing and removing temperature sensors, cleaning aeration channels, operating loaders, screening plant, moving fresh compost to screening and curing, blending market products, loading outbound transport vehicles, scraping the yard, leachate management and collection, daily equipment inspection and maintenance. 5. Dispatcher: Responsible for scheduling and monitoring McGill and contractor vehicles in and out of the facility, scheduling and training driver, scheduling vehicle repair and maintenance, mobilization of equipment, D.O.T. compliance and insurance verification, weigh master. 4.10 Training records, including names of attendees, information covered, trainer, and examples of any training materials/handouts are to be maintained for a period of five years. The following records are kept: 1. All Employees: Orientation, including company overview, personnel policies, health and safety overview. 2. Drivers: Defensive driving, personal safety, drug and alcohol testing, accident response, road hazards, and hours of service. 3. Operational Employees: Equipment operation and maintenance, compost pile construction and breakdown, and quality assurance. McGill plant managers meet the personnel requirements described in Rule .1406 (19)(a). The operational employees meet the requirements described in Rule .1406 (19)(b) and (c). 4.11 Only pre -approved materials are accepted at the facility and may be transported to the facility by McGill, customers, or contract haulers using vehicles and containers appropriate to the feedstock type. Once the driver arrives onsite, the truck is pulled onto the scale. Paperwork is generated with the customer's name, date, truck number, and weight of feedstock. Depending on the type of incoming feedstock, the driver either unloads into the pit of the operations building (biosolids, grease trap waste, food, etc.), or the driver unloads the trailer on the west side of the operations building if the incoming is an amendment such as yard waste or untreated wood. Prior to leaving the site, each driver that has unloaded into the pit is required to rinse out the trailer and let the rinsate drain into the pit. A McGill employee will blend the materials in the pit with amendments using a dedicated loader. This prevents biosolid material from being tracked throughout the operations building. Following the mixing process, the mixture is put into processing bays. This is referred to as the primary processing step. The mixture remains here for 7 days. The continuous aeration system insures optimum biological activity and that temperatures remain above PFRP requirements. This temperature is measured with an electronic probe, and all temperature readings are recorded and stored in a data software system. Following the primary step, the material is removed and screened through the primary screen. The oversized material (overs) is returned to the blending area for future reuse. The screened material is placed in a curing bay where temperatures are again monitored. The curing bays have identical controls to the primary bays. Again, the material is subjected to continuous aeration which allows optimum temperatures to be maintained. VAR is achieved and recorded during this phase. At the end of this phase the compost is eligible for sale; however, the vast majority of the cured material goes through a final screening process. The objectives here are commercial, and a finer product is more valuable to the typical McGill customer. As with the primary screening process, the overs from the final screening are returned to the blending area for future reuse. The screened product is moved to the compost storage area. Product is typically sold by volume, so loader bucket counts are used when loading product. Paperwork is generated documenting the truck, where the compost is going, date, etc. Following the completion of the loading, the truck drives onto the onsite scale where it is measured, and the weight of the truck is noted on the paperwork. The blending, primary processing, curing and screening steps all take place within the operations building as discussed in previous sections of this application. Finished product is stored on the northern side of the operations building. At the beginning of each month, the finished compost is sampled and sent to a certified laboratory to analyze for constituents and properties required by the U.S. Compost Council. Twice a year a sample is collected and sent to a certified laboratory for the analysis of TCLP. The time needed in each of the processes is referenced in Section 3.0, Part 8. 4.12 Only pre -approved materials may be accepted at the facility. A McGill representative visits the waste generator prior to approval in order to have a full understanding of the waste. Extensive pre -acceptance analyses are required for feedstock. As an additional measure, McGill has a clause in its contracts with customers that requires the customer to remove any load that is deemed by McGill as not meeting the agreed -upon, permit -required standards. A McGill employee follows up with the customer regarding the issue. No unacceptable waste is accepted, stored, or disposed of by McGill. The fact that most incoming material is brought to the facility by a McGill employee operated truck or McGill contractor adds another layer of oversight. 4.13 The majority of residuals accepted at the facility have some odor potential, so all are handled in a very controlled manner. All residuals are offloaded into the blending section of the operations building and liquids are kept separate from solid material. This is done to accommodate better management of liquids. Getting incoming residuals properly mixed and on air is an ongoing priority at the Merry Oaks facility. 4.14 Yard waste and clean, shredded wood are the primary amendments introduced to the process on an ongoing basis. These amendments are stored on the northern portion of the operations area of the property. A loader takes the necessary amount to the blending area, and the amendments are mixed in with the other feedstock in the blending area. No wood ash is added as an amendment. The only other major amendment are the overs from the screening operations. 4.15 The only processing activity that is needed to prepare materials for composting is grinding of wood waste and yard waste. This is done on a scheduled basis by a third -party contractor who performs the work at the McGill facility. 4.16 McGill uses a static pile positive aeration process so no windrows are built. Type Average Height Average Width Feedstock in pit 8 feet 40 feet Processing in Primary Bay 9 feet 30 feet Curing in Curing Bay 10 feet 30 feet Yard waste 30 feet 50 feet Wood waste 20 feet 50 feet Final product 12 feet 30 feet The average sizes of the piles are listed above. Between individual piles and between piles and the vegetated berms onsite, a distance of at least 20 feet is maintained in order to have access for fire- fighting vehicles. 4.17 McGill complies with Rule .1406 (11), (12) and (13) regarding time and temperature. Temperatures are monitored and recorded continuously. Each bay, primary and processing, has a dedicated probe which is wired to the central control system where temperature and time are recorded. Probes are placed at the center of each batch. PFRP temperatures are met during the primary phase. Though not required, PFRP is achieved again during the curing phase. VAR temperatures are met and recorded during the curing phase. 4.18 McGill uses probes that record the temperatures of the piles daily, and the temperatures are automatically recorded into the computer software program used. The probes are calibrated at least once per year and documentation is kept in the plant manager's office. The calibration method includes using a real temp probe that is calibrated per manufacturer's specifications and then compared to the reading of the probe after both probes are placed in a bucket of water. 4.19 Moisture of the product within the primary and curing bays is measured at least weekly using the oven drying method. Those readings are recorded by the plant manager. 4.20 All bays, both primary and processing, have an individual and identical, 7.5 horsepower fan. Air is supplied to the bays on a continuous basis. All fans are connected to an individual Variable Frequency Drive (VFD). This allows a wide range of air flow. Throughout the composting process, primary and curing, temperature data is being fed to a central processor. The airflow from the fan is adjusted on a continuous basis based on established criteria of the needs of the composting material. 4.21 McGill Environmental Systems participates in the U.S. Composting Council's Seal of Testing Assurance (STA) program. Finished product samples are sent to lab for analysis per permit requirements. Under the STA program, additional analyses including bulk density, salts, germination, nutrients, and micronutrients are performed. Finished compost samples are taken from stockpiles of product by an employee trained in the sampling procedure. The employee wears dedicated, nitrile gloves to collect the samples, and those gloves are discarded after the sampling is complete. The STA program requires the following sampling protocols: 1. Logs, sampling diagrams, and Chain of Custody documents should be prepared (as directed by the Plant Manager). 2. Avoid excessively moist compost. If balls form during mixing of composite materials, the compost is too wet. 3. Use sterile stainless steel, plastic, glass, or Teflon containers and implements for collecting and mixing samples. Between samples, clean collection tools and containers with soapy water, well - rinsed and dried. 4. Collect samples from no fewer than 15 sample points, randomly selected and visually representative of the material to be distributed. Total number of samples should be sufficient to collect 1 g of material for every 1000 kg of compost (aliquot). 5. Each sampling point shall be at a depth of two to six feet into the pile from the outside surface of the pile. Samples should be of equal size, at least 1000 cubic centimeters (about 1 quart) each. 6. Place quickly in container(s) with minimal stirring. Mix and split samples under sheltered conditions to reduce exposure to wind, temperature, sunlight, and precipitation. 7. Prepare for shipping a composite sample of no less than 1000 cubic centimeters; chill and ship to the laboratory within 24 hours. Any sample collected for testing for pathogens and nutrients shall be a representative composite sample of the compost and shall be processed within a period of time required by the testing procedure. 4.22 Compost is delivered to customers through McGill drivers, customer's drivers, or contract drivers. The compost is primarily used on general landscaping, construction, and sports turf. 4.23 All product is sold in bulk. Typical load sizes are 40-50 cubic yards. McGill is fortunate in that it has built up a strong market for its products over the past 17 years and sells all its production; however, if compost could not be sold due to a change in market conditions, McGill would re-engage with the agricultural market. 4.24 The Plant Manager is responsible for collecting, filing, and distributing all records associated with facility operation. These records are either stored on McGill's computer server, within the proprietary software cloud, or in paper format in the plant manager's office. The annual report for the period July 1 to June 30 is submitted to the Division of Solid Waste by August of each year and contains the required information. An example of the temperature log form for PFRP and VAR requirements is included in Attachment D. 4.25 No process water is generated as part of the composting procedures. Stormwater basins are located around the operational area of the facility. Those basins along with other stormwater best management practices are regulated and inspected under McGill's Stormwater Pollution Prevention Plan and under Permit NCG240005. 4.26 McGill has attained the necessary fire prevention permits from the Chatham County Fire Marshall and undergoes periodic inspections related to the permits. 4.27 McGill employees are trained annually regarding the OSHA required Emergency Action Plan and Fire Prevention Plan. Employees also undergo annual training for how to properly put out a fire using a fire extinguisher. The fire extinguisher training is conducted by a third party. Employees have been trained to either put the fire out using a fire extinguisher or the onsite water wagon and hose. If the fire cannot be safely extinguished by an employee, the fire department will be called. Any fire at the facility will be reported to the Solid Waste Section within 24 hours, and a written notification of the details of the fire will be provided within 15 days of the incident. 4.28 As part of the Stormwater Pollution Prevention Plan training, employees are taught good housekeeping skills which play into all aspects of keeping the facility sanitary. Vector control is achieved by using electronic vector control devices placed throughout the facility. Dust is periodically blown off of equipment and tops of walls within the operational building using compressed air. Throughout the operational area outside of the operational building, water is used for dust suppression as needed. At the end of each day, the concrete pad where the trucks unload feedstock into the pit is cleared and any remnants of sludge or other feedstock is washed into the pit using a hose. All feedstock are either mixed with amendments and put into processing bays by the end of the day or are properly stored in the pit. Having the composting process carried out indoors helps maintain sanitary conditions and good vector control. 4.29 Since McGill's composting process is contained inside of a building, it is relatively weather -independent. Historically only significant weather events that resulted in road closures have impacted the facility. On those occasions, the facility closed until the roads cleared. All screening is done with stationary electric equipment which have far greater reliability than portable diesel units. A sizable inventory of spare parts is kept for each unit. The aeration fans are very reliable and require low maintenance. McGill leases all its wheel loaders. While in service all machines are under warranty and comprehensive service agreement. McGill's policy is to have no loaders that are greater than 3 years old and the mean age of the loaders at the Merry Oaks is under two years. This strategy has greatly diminished any loader downtime. In the event that a loader is down for an extended period the loader supplier is required to supply a loaner. If a long-term power outage occurred, generators would be utilized to keep the electrical equipment running. McGill has not had this occur in its seventeen-year history. Over long periods of time concrete will crack in areas of heavy use. Old concrete is removed and replaced on an as needed basis. Spills are addressed in the Spills and Accident Response Plan, Emergency Action Plan, annual training, and Stormwater Pollution Prevention Plans. Employees have been trained to respond to spills according to the type of spill, location, volume, etc. All spills are reported to the compliance manager for documentation and reporting if necessary. 4.30 Plant personnel undergo monthly training for required OSHA topics as well as other safety topics pertinent to the composting industry. Attendees are required to sign a roster, and the rosters are kept by the human resources department. 4.31 If in the event that the facility permanently closes, all requirements listed in Rule 15A NCAC 13B .1410 will be followed so that North Carolina DEQ's requirements are satisfied. A closure plan would be submitted to DEQ for approval prior to closure. The closure plan will include details on the following: 1. All feedstock and unfinished compost materials shall be removed from the site and taken to a permitted solid waste facility within 180 days; 2. Finished compost materials left onsite shall comply with G.S. 130A-309.05; and 3. McGill shall notify the Division in writing upon completion of the requirements of the removal of the compost materials. Section 5 5.1 A site map labeled as Figure 2 illustrates the location of the biofilter and the blending area and is located in Attachment E. 5.2 The facility maintains the required tree buffer around the operations area. No known true seasonal variations or prevailing winds are present that would affect odor migration from the facility to adjacent facilities on a consistent basis. 5.3 The plant manager records the wind speed and direction weekly in order to determine if there may be a potential issue with odor migration. The date, time, site conditions, weather conditions, and wind direction are noted. Beyond noting the weather conditions, McGill's policy is to process intake materials in a timely manner in order to reduce the potential for odors. 5.4 When an odor complaint is received, the plant manager along with the compliance manager investigate the complaint by noting the time of the complaint, the time that the odor was said to be detected, and the wind direction and speed that day. If the odor is said to be happening currently, either the plant manager or the compliance manager will investigate both onsite and offsite. Records will be researched to determine where incoming feedstocks originated on the day of the odor complaint. The response to the odor complaint will vary with each situation; however, each complaint will be fully investigated and documented by McGill personnel. 5.5 McGill's odor complaint form is located in Attachment F. The form is filled out each time there is an odor complaint and are kept by the compliance manager on McGill's server. The forms will be kept for the duration of the permit as required. 5.6 Though the Merry Oaks facility has extensive odor controls in place, prevention is the primary strategy. Central to this is good housekeeping, prompt and proper mixing and reliability of the aeration system. 1. Employees receive training on methods of how to best control odor through feedstock management. This training occurs when an employee is hired and is discussed during employee meetings. 2. Feedstock characteristics management is part of the process as they are unloaded Keeping solids separate from liquid feedstock, getting feedstock properly mixed, and getting that mixture onto aeration is key in odor management and is part of the composting process at McGill. Attention must be given to both the ingredients and how they are put together. The available waste materials and amendments must, when put together, fall within the correct moisture range, C:N ratio and bulk density. Mixing ratios to acquire the desired C:N ratio are discussed in Section 3.5 of this application. 4. The majority of residuals accepted at the facility have significant odor potential, so all are handled in a very controlled manner. Getting incoming residuals properly mixed with a carbon source and getting the mixture in an aerated pile is important. 5. Moisture is monitored during the composting process in order to determine if there is enough moisture present for microbial activity. 6. The composting procedure followed at the facility requires that piles of material be placed in bays where the compost is exposed to forced air until the composting process is complete. The aeration of the piles is discussed in detail in Section 3.9. 7. Typically, there is no generation of leachate from the composting process, but if any should occur it is mopped and incorporated back into the mixture. All liquids that come into the blending area as a feedstock are blended with solid materials and carbon sources and maintained within the building. 8. Weather is monitored daily for wind direction. However, since the composting process is in a building, weather typically does not often affect the process. 9. Management of airborne emissions: Air removed from the processing and curing bays is forced through a biofilter and is discussed in the following section. 10. Windrows are not utilized at the facility. 5.7 The Merry Oaks facility has a biofilter. Air is extracted from the building through a network of ducting connected to three 50 HP fans. Each fan supplies air to a separate biofilter media section. This is achieved through a header duct which connects to a series of distribution ducting under the media. The media is made up of wood chips and Overs from the composting operation. The most recent media change was in the summer of 2019. It is anticipated that the media will not require changing until at least summer of 2022. The only moving parts on the biofilter are the 3 fans. They are inspected daily and are served as needed per manufacturer's recommendations. Spare components are maintained onsite, and a maintenance person has the expertise to change components if required. Section 6 Name of facility McGill - _Merry Oaks Compost Facility I certify under penalty of law that this document and all attachments were prepared under my direction or supervision and that the information provided in this application is true, accurate, and complete to the best of my knowledge. I understand that North Carolina General Statute 130A-22 provides for administrative penalties of up to fifteen thousand dollars ($15,000.00) per day per each violation of the Solid Waste Management Rules. further understand that the Solid Waste Management Rules may be revised or amended in the future and that the facility siting and operations of this solid waste management facility will be required to comply with all such revisions or amendments. Noel L, Signature Print Name President Title McGill Environmental Systems of NC Inc. Business or organization name 08/04/2020 Date Attachment A Merry Oaks 2019 Intake Spreadsheets Section 3.0 - Part 1 Row Labels Material Accepted from General Public? Description Ajinomoto-Special SLUDGE-131O No Sludge & biosolids Allied Waste (Charles River) ANIMAL WST No Animal Waste Allied Waste Services -Raleigh WWUNGROUND No Wooden pallets Apex, Town of WWGROUND No Wooden pallets Arclin - Moncure NC SLUDGE-131O No Sludge & biosolids Biogen Idec. Inc. SLUDGE-131O No Sludge & biosolids Bullard Septic Service GREASE No Grease trap waste Bunn,Town of (Dewatering) MUNI-131O No Sludge & biosolids Burlington, City of (Dewater) MUNI-131O No Sludge & biosolids Burlington, City of (East) MUNI-131O No Sludge & biosolids Burlington, City of (South) MUNI-131O No Sludge & biosolids Cargill Inc. C/O FSS (Clay) CLAY No Food Waste Cargill Incorporated -Bean SLUDGE-131O No Sludge & biosolids Cary -Apex Town of Water Trmnt ALUM No Sludge & biosolids Cary -North Water Reclamation SLUDGE-131O No Sludge & biosolids Cary -South Town of, WWRF MUNI-131O No Sludge & biosolids Cary -Town of PWU (Yard Waste) YWUNGROUND No Yard waste CCI-Contaminant Control, Inc PROC WASTE No Sludge & biosolids Cottonwood MUNI-131O No Sludge & biosolids DAK Americas (Cedar Creek) WWUNGROUND No Wooden pallets DAK Americas (Dewatering) SLUDGE-131O No Sludge & biosolids Durham County, (Triangle WWTP) MUNI-131O No Sludge & biosolids EMA Resources, Inc. MUNI-131O No Sludge & biosolids Fuquay Varina-Brighton Forest MUNI-131O No Sludge & biosolids Fuquay-Varina, Town (Terrible) MUNI-131O No Sludge & biosolids Grease Outlet, LLC GREASE No Grease trap waste Greasecycle, LLC GREASE No Grease trap waste Greenway Waste Solutions WWGROUND No Wooden pallets Hanes Brand WWTP ALUM No Sludge & biosolids Hillsborough, Town of MUNI-131O No Sludge & biosolids Hoke County WWTP MUNI-131O No Sludge & biosolids Holly Springs, WWTP MUNI-131O No Sludge & biosolids Kellogg Company PO#4800428375 GREASE No Grease trap waste KR Snead Trucking WWGROUND No Wooden pallets NC State Vet School ANIMAL WST No Animal Waste Noble Oil Service, Inc SLUDGE-131O No Sludge & biosolids Orange Water&Sewer Auth. WTP ALUM No Sludge & biosolids Organix Recycling/Wal-Mart(NC) FOOD No Food Waste OWASA (Press) MUNI-131O No Sludge & biosolids Pembroke, Town of MUNI-131O No Sludge & biosolids Pilgrim's Pride -Sanford SLUDGE-131O No Sludge & biosolids Pine Hall Brick WWGROUND No Wooden pallets Plantenders WWUNGROUND INo Wooden pallets Section 3.0 - Part 1 Row Labels Material Accepted from General Public? Description Raleigh, City of Public Utilit MUNI-131O No Sludge & biosolids Republic - Carolina Trace MUNI-131O No Sludge & biosolids Republic Waste - Sheetrock SHEETROCK No Sheetrock Republic Waste (Yard Waste) YWUNGROUND No Yard waste Republic Waste Svcs (Food) FOOD No Food Waste Republic Waste Svcs. (NIEHS) ANIMAL WST No Animal Waste Republic -Ashley Hills WWTP MUNI-131O No Sludge & biosolids River Mill COA, Inc. MUNI-131O No Sludge & biosolids Robbins, Town of WWTP MUNI-131O No Sludge & biosolids Russell Carroll-Rolloff WWUNGROUND No Wooden pallets Russell Carroll -Sawdust DUST No Other - Tobacco dust & Stems Sanford, City of (WP) ALUM No Sludge & biosolids Santa Fe Natural Tobacco Co. DUST No Other - Tobacco dust & Stems Simmons & Simmons WWGROUND No Wooden pallets Sonoco Recycling (Unilever) SLUDGE-131O No Sludge & biosolids Southern Veneer, LLC WOOD ASH No Other - ash This End Up Furniture Company WWUNGROUND No Wooden pallets Triangle Brick (Moncure) WWUNGROUND No Wooden pallets Union Corrugating WWUNGROUND No Wooden pallets Valley Proteins -Fay Grease GREASE No Grease trap waste Waste Industries -Durham WWUNGROUND No Wooden pallets Waste Industries-WWRWRF MUNI-131O No Sludge & biosolids Waste Management Sanford Haul WWUNGROUND No Wooden pallets Zero Waste Recycling, LLC WWUNGROUND No Wooden pallets Grand Total Section 3.0 - Part 2 Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Grand Total Sludge & Biosolids 4,220 1,400 4,800 4,900 6,300 5,200 7,700 6,350 5,200 7,000 6,400 5,800 65,270 Animal Waste 150 100 120 150 120 150 150 150 110 150 100 120 1,570 Food Waste 325 320 350 420 400 250 350 450 450 420 325 275 4,335 Other -Tobacco 50 50 50 50 30 50 50 50 50 50 50 20 550 Grease Trap Waste 300 300 300 300 200 300 500 500 500 550 500 500 4,750 Sheetrock 10 10 10 20 10 10 10 80 Other - Ash 25 20 25 20 10 10 10 10 10 10 10 10 170 Wooden Pallets 475 325 320 400 400 400 300 325 225 275 250 200 3,895 Yard Waste 1,800 1 1,300 900 1,000 1,500 1,000 1,000 1,700 1,000 1,000 900 900 14,000 Grand Total 7,345 1 3,815 6,875 7,240 8,960 7,370 10,070 9,555 7,545 9,465 8,545 7,835 94,620 Attachment B Process Flow Diagram McGill Process Flow Attachment C Example Temperature Logs McGill Environmental Temperature Report Batch Bay Initials Residuals: fwbioywovers 01070219 Bay01 Start Date/Time: Comment 7/2/2019 6:42:40 AM Stop Date/Time: Comment 7/10/2019 &38:10 PM Mrundme: 0 Date/Time Temperature 7/2/2019 5:00:00 PM 147 7/3/2019 5:00:00 PM 138 7/4/2019 5:00:00 PM 137 7/5/2019 5:00:00 PM 136 7/6/2019 5:00:00 PM 136 7/7/2019 5:00:00 PM 135 7/8/2019 5:00:00 PM 135 7/9/2019 5:00:00 PM 125 Friday, July 24, 2020 Page I of I McGill Environmental Temperature Report Batch Bay Initials Residuals: curing 21070219 3ay21 Start Date/Tlme: Comment 7/2/2019 3:55:38 PM Stop Date/Time: Comment 7/16/2019 9:41:25 AM Mruntime: 0 Date/Time Temperature 712/2019 5:00:00 PM 108 7/3/2019 5:00:00 PM 166 7/4/2019 5:00:00 PM 158 7/5/2019 5:00:00 PM 164 7/6/2019 5:00:00 PM 7/7/2019 5:00:00 PM 146 1377/8/2019 Vw 5:00:00 PM 137 7/9/2019 5:00:00 PM 136 7/10/2019 5:00:00 PM 136 7111/2019 5:00:00 PM 135 7/1212019 5:00:00 PM 141 7/13/2019 5:00:00 PM 143 7/14/2019 5:00:00 PM 143 7/1512019 5:00:00 PM 149 Friday, July 24, 2020 Page 1 of 1 McGill Environmental Temperature Report Batch Bay 03080119 Bay03 Start Date/Time: 8/1/2019 4:38:06 PM Stop Date/Time: 8/13/2019 10:32:42 AM Mruntime: 0 Date/Time 8/1/2019 5:00:00 PM 8/2/2019 5:00:00 PM 8/3/2019 5:00:00 PM 8/4/2019 5:00:00 PM 8/6/2019 5:00!00 PM 8/7/2019 5:00:00 PM 8/8/2019 5:00:00 PM 8/9/2019 5:00:00 PM 8/10/2019 5:00:00 PM 8/11/2019 5:00:00 PM 8/12/2019 5:00:00 PM Initials Residuals: Comment Comment Temperature 104 174 154 —7C ':P 137 >�)� 135 135 135 135 135 135 93 Friday, July 24, 2020 Page 1 of I McGill Environmental Temperature Report Batch Bay Initials Residuals: curing 23080719 Bay23 Start Date/Time: Comment 8/7/2019 2:31:20 PM Stop Date/Time: Comment 8/26/2019 4:52:41 PM Mruntime: 0 Date/Time Temperature 8/7/2019 5:00:00 PM 120 8/8/2019 5:00:00 PM 130 8/9/2019 5:00:00 PM 174 8/10/2019 5:00:00 PM 163 811112019 5:00:00 PM 159 8/12/2019 5:00:00 PM 160 8/13/2019 5:00:00 PM 155 8/14/2019 5:00:00 PM 157 ` I 8/1512019 5:00:00 PM 138 \V/ 8/1612019 5:00:00 PM 136 8/17/2019 5:00:00 PM 136 8/18/2019 5:00:00 PM 136 8/19/2019 5:00:00 PM 136 8/20/2019 5:00:00 PM 136 8/21/2019 5:00:00 PM 135 8/22/2019 5:00:00 PM 135 8/23/2019 5:00:00 PM 135 8/24/2019 5:00:00 PM 135 8/25/2019 5:00:00 PM 114 Fridgp, July 24, 2020 Page 1 of 1 Attachment D Figures 1 and 2 Figure 1 Approximate property boundary Parcel ID: 5596 Note: Map source is Chatham County GIS website. Scale is unknown. v,• jai _ Back-u4 P Compost Storage operations' Building Amendment Storage Figure 2 .k Approximate location of vegetated berms Approximate property boundary Wooded area . 0 O Various storage areas Feedstock unloading area Blending Area and pit Biofilter Containment wall Note: Map and aerial obtained from the Chatham yp County GIS site and the scale is unknown. - ,4 S O w e k a sy Plant - - - -` office Driveway . Scale office Attachment E Odor Complaint Form MCGILL The compost people® Odor Complaint Form DATE OF INCIDENT: DATE OF NOTIFICATION: WHO NOTIFIED MCGILL: WHO IS THE COMPLAINTANT: AVERAGE WIND SPEED THE DAY(S) OF ISSUE: AVERAGE WIND DIRECTION THE DAY(S) OF ISSUE: HOW WAS THE COMPLAINT FILED?: OTHER DETAILS AND RESPONSE: REPORTING PROCESS FOLLOWED: AGENCIES AND PERSONS INVOLVED (other than McGill personnel listed above): NAME: AGENCY: PHONE#: AGENCY'S ROLE: Signature: Printed Name: March 2020 Revision NAME: AGENCY: PHONE#: AGENCY'S ROLE: