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HomeMy WebLinkAboutNC0003719_NPDES Permit_20110719r A NCDENR North Carolina Department of Environment and Natural Resources Division of Water Quality Beverly Eaves Perdue Coleen H. Sullins Dee Freeman Governor Director Secretary July 19, 2011 Mr. Craig Lette, Site Manager - DAK Americas LLC-Cedar Creek Site P.O. Box 1690 Fayetteville, North Carolina 28302 Subject: Draft NPDES Permit Permit NC0003719 DAK Americas LLC-Cedar Creek Site Cumberland County Facility Class I Dear Mr. Lette: Enclosed with this letter is a copy of the draft permit for your facility. Please review the draft very carefully to ensure thorough understanding of the conditions and requirements it contains. The draft permit contains the following significant changes from your current permit: - • Outfall 001 was added. to the permit. The Outfall 001 has a combination of non -contact cooling water and stormwater. • The permit limits have recalculated based on the latest OCPSF production information. • The winter BOD limits were eliminated from the permit based on the requirements of §40 CFR 414. • The plastic bottle recycling facility has received an allocation for BOD and TSS. Please submit any comments to me no later than thirty days following your receipt of the draft. Comments should be sent to the address listed at the bottom of this page. If no adverse comments are received from the public or from you, this permit will likely be issued in late September, with an effective date of November 1, 2011. 1617 Mail Service Center, Raleigh, North Carolina 27699-1617 . Location: 512 N. Salisbury St. Raleigh, North Carolina 27604 Phone: 919-807-63001 FAX: 919-807-6492 \ Customer Service:1-877-623-6748 Internet: www.ncwaterquality.org An Equal Opportunity \ Affirmative Action Employer - NorthCarolina !aatllraIII If you have any questions about the NPDES permit process, please contact me at the following e-mail address: sergei.chernikov(ncdenr.gov, or telephone number: 919-807-6393. Sincerely, Sergei Chernikov, Ph.D. Environmental Engineer II Complex NPDES Permitting Unit cc: NPDES Files Fayetteville Regional Office / Surface Water Protection Section. (e-copy) Aquatic Toxicology Unit (e-copy) TACU (e-copy) EPA Region IV (with application, fact sheet, and RPA) 1617 Mail Service Center, Raleigh, North Carolina 27699-1617 Location: 512 N. Salisbury St. Raleigh, North Carolina 27604 Phone: 919-807-6300 \ FAX: 919-807-6492 \ Customer Service:1-877-623-6748 Internet: www.ncwaterquality.org An Equal Opportunity \ Affirmative Action Employer One NorthCarolina Vaturaij r Permit NC0003719 STATE OF NORTH CAROLINA DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES DIVISION OF WATER QUALITY Draft PERMIT TO DISCHARGE WASTEWATER UNDER THE NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM (NPDES) In compliance with the provision of North Carolina General Statute 143-215.1, other lawful standards and regulations promulgated and adopted by the North Carolina Environmental Management Commission, and the Federal Water Pollution Control Act, as amended, DAK Americas LLC is hereby. authorized to discharge wastewater from a facility located at DAK Americas LLC - Cedar Creek Site 3468 Cedar Creek Road, Fayetteville Cumberland County to receiving waters designated as the Cape Fear River in the Cape Fear River Basin in accordance with effluent limitations, monitoring requirements and other conditions set forth in Parts I, II, III and IV hereof. This permit shall become effective This permit and authorization to discharge shall expire at midnight on October 31, 2016. Signed this day Coleen H. Sullins, Director Division of Water Quality By Authority of the Environmental Management Commission Permit NC0003719 SUPPLEMENT TO PERMIT COVER SHEET All previous NPDES Permits issued to this facility, whether for operation or discharge are hereby revoked, and as of this issuance, any previously issued permit bearing this number is no longer effective. Therefore, the exclusive authority to operate and discharge from this facility arises under the permit conditions, requirements; terms, and provisions described herein. DAK Americas LLC is hereby authorized to: 1. continue to operate an existing 0.500 MGD wastewater treatment plant (WWTP) consisting of • flow equalization, • spill basin • pH adjustment • oil skimming • dual aeration basins • dual spill and settling basins (500,000 gallons capacity each) • clarifier • parshall flume • sludge pump station • an aerobic digester •, aerated biosolids holding basin • biosolids drying beds, and associated equipment located at the DAK Americas LLC - Cedar Creek Site, 3468 Cedar Creek Road, south of Fayetteville in Cumberland County, and 2. discharge from said treatment works and plastics recycling facility via Outfall 002 (located on the attached map) and discharge non -contact cooling water and stormwater from Outfall 001.into the Cape Fear River, a Class C waterbody within the Cape Fear River Basin. Permit NC0003719 A. (1.) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS During the period beginning on the effective date of this permit and lasting until expiration, the Permittee is authorized to discharge from Outfall 002. Such discharges shall be limited and monitored by the Permittee as specified below: Effluent Characteristics Limits , Monitoring Requirements Monthly Average Daily Maximum Measurement Frequency : Sample Type Sample Location 1 Flow 0.500 MGD Continuous Recording I or E Total Suspended Solids (TSS) 180 lbs /day 394.5 lbs/day • 1/Week Composite 2 E BOD5, 20°C 157.6 lbs /day 286 lbs /day 1/Week Composite 2 E NH3-N (April 1-October 31) 13 lbs /day ' 26 lbs /day 1/Week Composite 2 E NH3-N (November 1 — March 31) 26 lbs /day 52 lbs /day 1/Week Composite 2 E Fecal Coliform (geometric mean) 1/Week Grab E Total Residual Chlorine 3 28 µg/L 1/Week Grab E Temperature (°C) 1/Week Grab E Dissolved Oxygen 4 1/Week Grab E pH Not <6.0 nor-> 9.0 standard units 1/Week Grab E Total Nitrogen (NO2 + NO3 + TKN) 1/Quarter Composite 2 E Total Phosphorus 1/Quarter Composite 2 E Acute Toxicity 5 1/Quarter Composite 2 E Dissolved Oxygen 6 1/Week Grab U & D Temperature (°C) 6 1/Week Grab U & D Conductivity 6- 1/Week Grab U & D Footnotes: 1 E = Effluent; I = Influent; U = upstream 2 mi. from Outfall. D = downstream, 100 yards upstream of Lock and Dam #3. 2 Composite samples must be refrigerated. 3 Total Residual Chlorine (TRC) - The Division shall consider all effluent total residual chlorine values reported below 50 µg/L to be in compliance with the permit. However, the Permittee shall continue to record and submit all values reported by a North Carolina certified laboratory (including field certified), even if these values fall below 50 µg/L. 4 Effluent dissolved oxygen (DO) shall not fall below 5 mg/L. The Permittee shall collect effluent DO samples from the box combining effluents of Outfalls 001 and 002. 5 Whole Effluent Toxicity (WET) testing; acute toxicity P/F at 90% using Fathead Minnow. WET tests shall be conducted in February, May, August and November [See Part A. (2.)]. The Permittee shall collect toxicity samples from the box combining effluents of Outfalls 001 and 002. 6 Receiving Stream Monitoring — As a member of the Middle Cape Fear River Basin Association, the Permittee's instream monitoring responsibilities are hereby waived by Memorandum of Agreement. However, should this membership terminate for any reason, the Permittee shall notify the Division immediately, and the Permittee shall immediately resume instream monitoring requirements, as specified herein. The Permittee shall add no chromium, zinc, or copper to the treatment system except as pre -approved additives to biocide compounds or those resulting from the normal degradation of process piping or equipment. The Permittee shall discharge no floating solids or foam visible in other than trace amounts. Permit NC0003719 A. (1.) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS (Continued) During the period beginning on the effective date of the permit and lasting until expiration, the Permittee is authorized to discharge from Outfall 002. Such discharges shall be limited and monitored by the Permittee for OCPSF parameters, as specified below: Effluent Characteristics a Limits Monitoring -Requirements DAILY MAXIMUM (pounds/day) MONTHLY AVERAGE - (pounds/day) Measurement Frequency. Sample - Type Sample Location Acenaphthene 0.105 0.039 - 1/Year Grab Effluent Acenaphthylene 0.105 0.039 1/Year Grab Effluent Acrylonitrile 0.430 0.171 1/Year Grab Effluent Anthracene 0.105 0.039 1/Year Grab Effluent Benzene 0.242 0.066 1/Year Grab Effluent Benzo(a)anthracene 0.105 0.039 1/Year Grab Effluent 3,4-Benzofluoranthene 0.108 0.041 1/Year Grab Effluent Benzo(k)fluoranthene 0.105 0.039 1/Year Grab Effluent Benzo(a)pyrene 0.108 0.041 1/Year Grab Effluent Bis(2-ethylhexyl) phthalate 0.496 0.183 1/Year Grab Effluent Carbon Tetrachloride 0.068 0.032 1/Year Grab Effluent Chlorobenzene 0.050 0.027 1/Year Grab Effluent Chloroethane 0.476 0.185 1/Year Grab Effluent Chloroform 0.082 0.037 1/Year Grab Effluent 2-Chlorophenol 0.174 0.055 1/Year Grab Effluent Chrysene 0.105 0.039 1/Year Grab Effluent Di-n-butyl phthalate 0.101 0.048 1/Year Grab Effluent 1,2-Dichlorobenzene 0.290 0.137 1/Year Grab Effluent 1,3-Dichlorobenzene 0.078 0.055 1/Year Grab Effluent 1,4-Dichlorobenzene 0.050 0.027 1/Year Grab Effluent 1,1-Dichloroethane 0.105 0.039 1/Year Grab Effluent 1,2-Dichloroethane 0.375 0.121 1/Year Grab Effluent 1,1-Dichloroethylene 0.044 0.028 1/Year Grab Effluent 1,2-trans-Dichloroethylene 0.096 0.037 1/Year Grab Effluent 2,4-Dichlorophenol 0.199 0.069 1/Year Grab Effluent 1,2-Dichloropropane 0.409 0.272 1/Year Grab Effluent 1,3-Dichloropropylene 0.078 0.052 1/Year Grab Effluent Diethyl phthalate 0.361 0.144 1/Year Grab Effluent 2,4-Dimethylphenol 0.064 0.032 1/Year Grab Effluent Dimethyl phthalate 0.083 0.034 1/Year Grab Effluent 4,6-Dinitro-o-cresol 0.492 0.139 1/Year Grab Effluent 2,4-Dinitrophenol 0.218 0.126 1/Year Grab Effluent Ethylbenzene 0.192 0.057 1/Year Grab Effluent Fluoranthene 0.121 0.044 1/Year Grab Effluent Fluorene 0.105 0.039 1/Year Grab Effluent [Part A. (1.) continues on next page] Permit NC0003719 A. (1.) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS (OCPSF - Continued) Effluent' Characteristics Limits Monitoring Requirements DAILY MAXIMUM (pounds/day) MONTHLY AVERAGE (pounds/day) Measurement Frequency Sample Type Sample - Location Hexachlorobenzene'i 1.6 µg/L 1.6 µg/L 1/Year Grab Effluent Hexachlorobutadiene - 0.087 0.036 1/Year Grab Effluent Hexachloroethane 0.096 0.037 1/Year Grab- Effluent Methyl Chloride - .0.338 0.153 - 1/Year Grab . Effluent Methylene Chloride 0.158 0.071 1/Year Grab _ Effluent Naphthalene 0.105 0.039- 1/Year Grab Effluent Nitrobenzene 0.121 0.048 1/Year Grab Effluent 2-Nitrophenol 0.123 0.073 1/Year Grab Effluent 4-Nitrophenol. - 0:220_ 0.128 - 1/Year Grab Effluent 2,6-Dinitrotoluen el - 49.0 µg/L 49.0 µg/L, 1/Year Grab - Effluent' Phenanthrene 0.105 0.039 - 1/Year Grab Effluent Phenol 0.046 - 0.027 - 1/Year Grab Effluent Pyrene - 0.119 0.044 - 1/Year Grab Effluent Tetrachloroethylene 0.099 - 0.039 1/Year Grab Effluent Toluene 0.142 0.046 1/Year Grab Effluent 1,2,4-Trichlorobenzene - 0.249 0.121 - - 1/Year Grab - Effluent 1,1,1-Trichloroethane 0.096- ' 0.037 1/Year Grab. Effluent 1,1,2-Trichloroethane 0.096 0.037 1/Year Grab . Effluent Trichloroethylene 0.096 0.037 1/Year Grab Effluent Vinyl Chloride" 0.476 ' 0.185 1/Year Grab Effluent Metals and Toxicants Total Chromium 4.92 1.97 1/Year Grab Effluent Total Copper-, 6.0 2.58 1/Year Grab Effluent Cyanide - 2.13 0.75 1/Year - Grab Effluent Total Lead 1.23 0.57 1/Year Grab Effluent Total Nickel , 7.07 3.0 1/Year Grab Effluent Total Zinc 4.64 1.87 1/Year Grab Effluent 1. Water -quality based limit. Permit NC0003719 SPECIAL CONDITIONS AND MONITORING REQUIREMENTS , A. (2.) ACUTE TOXICITY PASS/FAIL PERMIT LIMIT (QUARTERLY) The Permittee shall conduct acute toxicity tests 1/Quarter using protocols defined in the North Carolina Procedure Document entitled "Pass/Fail Methodology for Determining Acute Toxicity in a Single Effluent Concentration" (Revised July, 1992 or subsequent versions). The monitoring shall be performed as a Fathead Minnow (Pimephales promelas) 24-hour static test. The effluent concentration, at which there may be at no time significant acute mortality, is 90% (defined as treatment two in the procedure document). Effluent samples for self -monitoring purposes must be obtained during representative effluent discharge below all waste treatment. The tests will be performed during the months of February, May, August, and November. All toxicity testing results required as part of this permit condition will be entered on the Effluent Discharge Monitoring Form (MR-1) for the month in which it was performed, using the parameter code TGE6C. Additionally, DWQ Form AT-2 (original) is to be sent to the following address: Attention: NC DENR / DWQ / Environmental Sciences Section 1621 Mail Service Center Raleigh, N.C. 27699-1621 Completed Aquatic Toxicity Test Forms shall be filed with the Environmental Sciences Section no later than 30 days after the end of the reporting period for which the report is made. Test data shall be complete and accurate and include all supporting chemical/physical measurements performed in association with the toxicity tests, as well as all dose/response data. Total residual chlorine of the effluent toxicity sample must be measured and reported if chlorine is employed for disinfection of the waste stream. Should there be no discharge of flow from the facility during a month in which toxicity monitoring is required, the Permittee will complete the information located at the top of the aquatic toxicity (AT) test form indicating the facility name, permit number, pipe number, county, and the month/year of the report with the notation of "No Flow" in the comment area of the form. The report shall be submitted to the Environmental Sciences Branch at the address cited above. Should any single quarterly monitoring indicate a failure to meet specified limits, then monthly monitoring will begin immediately until such time that a single test is passed. Upon passing, this monthly test requirement will revert to quarterly in the months specified above. Should the Permittee fail to monitor during a month in which toxicity monitoring is required, then monthly monitoring will begin immediately until such time that a single test is passed. Upon passing, this monthly test requirement will revert to quarterly in the months specified above. Should any test data from either these monitoring requirements or tests performed by the North Carolina Division of Water Quality indicate potential impacts to the receiving stream, this permit may be re -opened and modified to include alternate monitoring requirements or limits. NOTE: Failure to achieve test conditions as specified in the cited document, such as minimum control organism survival and appropriate environmental controls, shall constitute an invalid test and will require immediate follow-up testing to be completed no later than the last day of the month following the month of the initial monitoring. NOTE: Failure to achieve test conditions as specified in the cited document, such as minimum control organism survival and appropriate environmental controls, shall constitute an invalid test and will require immediate follow-up testing to be completed no later than the last day of the month following the month of the initial monitoring. Permit NC0003719 SPECIAL. CONDITIONS AND MONITORING REQUIREMENTS, A. (3.) BIOCIDE APPROVAL The Permittee shall obtain approval from the Division'. s Aquatic Toxicology Unit prior to discharging any biocide (not previously approved by the Division) under this permit. Approval for use of any biocide not previously The Permittee shall request approval of any new unauthorized biocide at least 90 days in advance of planned usage. Contact the Aquatic Toxicology Unit for detailed instructions on requesting .biocide. approval: NC DENR / DWQ / Aquatic Toxicology. Unit 1621 Mail Service Center Raleigh, North Carolina 27699-1621 Concentrations of chromium; copper, or zinc added to biocides shall not exceed applicable water quality standards or action levels in the receiving stream. •A. (4.) LABORATORY TEST -METHOD QUANTITATION LEVELS AND COMPLIANCE For any given parameter, the Permittee must apply a state -certified analytical test method with a practical quantitation level (PQL) at or below the NPDES permit limit. If such level of analytical sensitivity is not technologically. feasible, the Permittee shall employ a state -certified analytical method with the lowest available test -method PQL, and values reported as `,`not detected" by this lowest available PQL shall be deemed "compliant" with this permit. . A. (5.) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS , During the period beginning on the effective date of the permit and lasting until permit expiration, the Perrriittee is authorized to.discharge from outfall(s) serial number 001 (Non -Contact Cooling Water and .Stormwa ter).. Such discharges shall be limited and monitored by the permittee as specified below: STORMWATER - ` ,` " DISCHARGE ;CHARACTERISTIC LIMITS , ,•. MONITORING REQUIREMENTS Units` Limit Measurement >, , Frequencyl"„• Sample : ' , Type Sample •.' -•LocationZ, Total Flow3 MG Annual SW-1 Total Rainfall3 Inches Annual SW-1 Event Duration3 Minutes Annual SW-1 • Total Suspended Solids - mg/L 100.00 . Annual Grab SW-1 Notes: 1. Measurement frequency. Once per year. The facility must perform -analytical sampling during the first full year and last year of the permit term regardless of cut-off concentration conditions. Analytical results from sampling during the final -year of the permit term must be submitted with the permit renewal application. Failure to monitor storm events in accordance with the specified - frequency shall constitute a violation of this permit. - .2. Sample Location. Samples to be collected at the stormwater discharge outfall (SW-1) located north• of the river water intake pump overflow and south of the sludge drying beds. 3. For each sampled representative storm event the total precipitation; storm duration, and total flow must be monitored.. Total flow shall be either: (a) measured continuously, (b) calculated based on the amount of area draining to the outfall, theamount of build -upon (impervious) area, and the - total amount of rainfall, or (c) estimated by the measurement of flow at 20 minute intervals during the rainfall event (not to exceed three hours).- - - Permit NC0003719 For purposes of the stormwater sampling required in this permit, all samples shall be collected from a discharge resulting from a representative storm event.