The URL can be used to link to this page

Home My WebLink AboutNCG500621_Permit (Issuance)_20041029®I NCDENR Kirk Marcuson Murphy Brown, LLC P.O. Box 856 Warsaw, NC 28398 Dear Mr. Marcuson: Michael F. Easley Governor William G. Ross, Jr., Secretary North Carolina Department of Environment and Natural Resources Alan W. Klimek, P.E., Director Division of Water Quality October 29, 2004 Subject: General Permit No. NCG500000 Certificate of Coverage NCG500621 Murphy Brown, LLC-The Chief Feedmill Duplin County In accordance with your application for discharge, the Division is forwarding herewith the subject Certificate of Coverage to discharge under the subject state-NPDES general permit. This permit is issued pursuant to the requirements of North Carolina General Statue 143-215 .1 and the Memorandum of Agreement between North Carolina and the US Environmental Protection agency dated May 9, 1994 (or as subsequently amended). The following information is included with your permit package: • A copy of the Certificate of Coverage for your treatment facility • A copy of General Wastewater Discharge Permit NCG500000 • A copy of a Technical Bulletin for General Wastewater Discharge Permit NCG500000 If any parts, measurement frequencies or sampling requirements contained in this general permit are unacceptable to you, you have the right to request an individual permit by submitting an individual permit application. Unless such demand is made, the certificate of coverage shall be final and binding. Please take notice that this Certificate of Coverage is not transferable except after notice to the Division of Water Quality. The Division of Water Quality may require modification or revocation and reissuance of the certificate of coverage. This permit does not affect the legal requirements to obtain other permits which may be required by the Division of Water Quality or permits required by the Division of Land Resources, Coastal Area Management Act or any other Federal or Local governmental permit that may be required. If you have any questions concerning this permit, please contact Jackie Nowell at telephone number 919/733-5083, extension 512. cc: Central Files NPDES General Permit Files Wilmington Regional Office, Water Quality N. C. Division of Water Quality / NPDES Unit 1617 Mail Service Center, Raleigh, NC 27699-1617 Internet: h2o.enr.state.nc.us Sincerely, repAlan W. Klimek, P.E. Phone: (919) 733-5083 fax: (919) 733-0719 DENR Customer Service Center: 1 800 623-7748 STATE OF NORTH CAROLINA DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES DIVISION OF WATER QUALITY CERTIFICATE OF COVERAGE NCG500621 GENERAL PERMIT NO. NCG500000 TO DISCHARGE DOMESTIC WASTEWATERS FROM SINGLE FAMILY RESIDENCES AND OTHER DISCHARGES WITH SIMILAR CHARACTERISTICS UNDER THE NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM 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, Murphy Brown, LLC is hereby authorized to discharge of boiler blowdown from a facility located at the Murphy Brown, LLC- The Chief Feedmill 210 Chief Lane Rose Hill Duplin County to receiving waters designated as UT Reedy Branch in the Cape Fear River Basin in accordance with the effluent limitations, monitoring requirements, and other conditions set forth in Parts I, II, III and IV of General Permit NCG500000 as attached. This certificate of coverage shall become effective October 29, 2004 This Certificate of Coverage shall remain in effect for the duration of the General Permit. Signed this day October 29, 2004 Z,Alan- W. Klimek, P.E., Director Division of Water Quality By Authority of the Environmental Management Commission _ -..- -_-.../ ---- ' : , .. . . .. \ $..: ,__:• -- • ',., %•,/----.-•_,41--•--....--1 G - - - . ei_r....-.-\,...1111 .•.,.' .'' 1 1-• • ,Z/ Ti000w;Keor ur ' ' • ,-_-__- --...• ) - . ' . .. 1 r C•! .,1 • ., . -•• ---. • , 1102 - ,/•. -.--- __• . fr.._ ; . ..3 I. ----. .,---- .„--- , -- - - . , f. ; , _cv. ,I • - 96.-7-- • . : "---1:1 • . -- .'..._-.- ' - ''''• - l • - \ i •••‘, ..-..'..- A !.,,,,e 01 pf06 \Ilk ___---------1 ` ---'---- \ _ . 0.1...al --" \ 1G. \ .. , .,.,:.••,•• • -• ' - • 1 s..-4.-c-"' - • 40 , , \ , • • . - vit , _ - - .11,_!.411ltlitt Ift , . _I 0 c• ,..-.., 1 - ' _ . • , ---. . r-.•' • --_ • -- - - I I ..--- . . -- .--- • 1 _---- ..--- ' , • PA . I- .3 -,---- .' ' 1 ‘ , • -7SeWage • _,. Cem • --_.,.:.-•""--- •-•-•:.1--* . , _ • ___ ' . ,.•:. ---- ..,..- - 5 '..`, . , ...... -11 • Jerom - • 7, ..._, . -..-... :q-,•:-.--___. --::- _" .s.,__,-":1-,-- . 'i ...- ‘. --- - • ... :),:-:_l__:-.,-1 .--"e-S----''Ci -"• - 81 ._:"-- . .____....;„ ,...-• Substation • • Murphy .11.6 •,- ,....L.....„....„..... — ‘ ..• *--- . -- ' i I. ''.11 •..1,1/1 Brown, LLC / ,... C:) ;:k7,...:"-•_:;,:::-.-'..-7-ni1 ..------..-t, • • • '..----&11' ‘Ni....,A i l'ee if L••• .......--• i \ The Chief Feed Mill '4-• • ,... I's\ r.•• .., ...... , .• , . i ..... ..._.....___,.. -------....____--' - -/ • / . .. . • - _ _ g - -.../ -.• .,„ :E e.;..,.00-• 4:4o425s: 41 1-4 5 4 :•.-.4._.: ./ . .. ..- - ..,„... , +, i — --. .:.\ R • - - - 1,-_ , er -i:r,!• -__.,_.•....' 14"--tre1,--, -:-\ • •• ElIN 4 ' 44 . ' -.... * '''':. '---1.-.• I i . . • r- ' .,-7")./ --I • ( 1146 , ••=••=• ° % - • 4 . . , • ,... , . 79/ ... ler• ' • .• A o o o .._ ....o -7 •:. .5 Z , --- ... 0 . : 1 1 al 1 'N.'s\ 11 I P • o 0 .. ,, 7) l'' (1133,i 1 i .., 1. i \, -' j 0,1 • • - \\...._/...._." - .6.s .. .4 .9, _ - - • /r ..... r '•,. .,----; ; ..-7 „_, ...... • il -7r.- - —•'' -;....-*'' %. • •,../• i'l i\7"---/ ..• '----C\ r\* ‘‘.. -' • ( "-: ern 0 .<.''' • s' •f•-.1. seq" 5 :-.%"••• -. . . _,===e-•• , We - via ,......, ....,---•••- 1 _ • ‘Ni\,... . ... .-7:-.-.-------- t r.1( - ,,, i -. t c k )---.--._--, ,.....-------150-"'" . pm Ar,,ft•-m- , N ill V 41$ .."_...< • * dir . At ;I, ../ / II , _ ,..--7.....-..,- -- . • . f ....... • . ' . 0 f. --- Latitude: Facility 34° Information 48' 38" Sub -Basin: 03-06-22 Facility Location Longitude: 78° 01' 30" - Quad #: Rose Hill (H26SE) Stream ClaRR: C Sw Murphy Brown, LLC- The Chief Feed Mjil Receiving Su -earn: UT Reedv Branch North 1 NCG500621 DIVISION OF WATER QUALITY October 21, 2004 MEMORANDUM To: Jackie Nowell NPDES Permits Unit From: Ed Beck Through: Rick Shiver Subject: Er, , ii ,„, , C T 2 0 2004 DENR - WATER QUALITY POINT SOURCE BRANCH General Permit COC No. NCG56 '6/1' •:'"`y 'y -" u`" "-. Murphy Brown, LLC / The Chief Feed Mill Duplin County The applicant has requested coverage under the general permit for boiler blowdown from The Chief Feed Mill which has been in operation for over ten years. Two large boilers serve the mill which grinds grain, mixes and blends it with additives, and forms palletized feed for hogs. The boilers blow down on a continuous basis at an average rate of approximately 14,400 GPD. Chemtreat brand chemicals are used as conditioners in the boilers. It is understood that calculations indicate that the constituents should not be a concern in the discharge. Boiler blowdown and other miscellaneous flows from the boiler room are routed to a sump that discharges to the stormwater conveyance system. Monitoring can be done at the sump prior to mixing with stormwater. The flow appeared clear and free of oil and other floating material at the time of the site visit. It is recommended that coverage under the general permit be given. Unnamed Tributary to Reedy Branch Class C Sw 34 48' 38" 78 01' 30" eb: NCG500621.104 cc: Wilmington Regional Files, Ed Beck Central Files nee C ,L1i 17Sec 3See LSe, \ • .••- - • • • • • suapieD wan undna - ' -1 Japeki. • WIN 113_471.117 't P33d AND OIL / DTI • • 1-7:-.1=•10 ZO! /rj I N. / - ( . 92E6i9=:. t • Ved tulla--'1 • • - -• a • 17-' c I. ,,, , • c____.,- 9,1_,11-)i. = •:-.. • !, - _ - `11Maiff Atid.inw,. -lc- -----_-----':3''',-. I _ ; :11: t• --;------ 4.—,!...— • CZ ' \ -•• Ns N 4103 sliam • t=„ 711 7)7 (/ -7•?\ t..1:471 I!! .'tt - • t.••• • • Prrm 1 _ . - : - - Jamoi , . • • • .uope)sqns -- • Ift•-- • • • .4;,_ ' • W93 - \\ • -4 ' ! wa3 • 96 • • r • Murphy Brown September 1, 2004 �a� t•a ..G.irl%_�I�o+•...• r 5 13 li 1'.I Jul i S E P 7 2004 Stormwater and General Permits Unit 1 Division of Water Quality DE.;.±ii - w",TER QUALITY 1617 Mail Service Center ? t Pof'1T 1;3u;iCE r:AN H, . Raleigh, North Carolina 27699 -1617 P.O. Box 856 �.^Warsaw, NC 28398 -3434 -7551 Fax Subject: Submission of The Chief Feed Mill NPDES Notice of Intent for Coverage under General Permit NCG500000 To Whom It May Concern: Enclosed please find a complete NPDES Notice of Intent requesting coverage of the existing The Chief Feed Mill under General Permit NCG500000. The Chief Mill, located in Duplin County, North Carolina, manufacturers ground and pelletized animal feed. As part of the manufacturing process, the mill operates a boiler system with approximately 14,400 gallons per day of boiler blowdown. The blowdown is discharged to a stormwater drain, which conveys the discharge to a ditch on the facility property. The necessity to obtain a NPDES Boiler Blowdown Permit became evident as part of a voluntary self - assessment. Murphy -Brown, LLC takes permitting gaps very seriously and is committed to applying to all applicable rules and regulations. Please contact me at (910) 293-3434 Ext. 5245 if you have any additional questions or concems. Katie A. Elmer, PE Environmental Engineer cc: Kirc Marcuson — The Chief Feed Mill Manager File Enclosures (3) —NPDES NOI Packages The Chief Feed Mill Introduction Murphy Brown, LLC's — The Chief Mill site manufactures ground and pelletized animal feed. The maximum annual production for this facility is approximately one million tons of feed per year. The feed mill processing includes grain and feed ingredient receiving, storage, hammermilling, mixing, pelletizing, and load -out operations. The facility also operates two boilers to provide process steam. Animal feed is prepared for shipment to animal livestock offset operations. Grain and feed ingredients are received in rail and truck dump pits. The initial feed materials may be stored in a series of grain and ingredient storage bins. Received feed materials are processed in a hammermill. The hammermill grinds grain and ingredients into smaller particles. Hammermilled ingredients and other additives which may or may not have been hammermilled are mixed together and stored in ground and mixed feed storage .bins. During mixing, liquid feed additives (i.e., animal fats) are applied as additional feed ingredients. The ground and mixed animal feeds then enter the pellet cooler line. The pellet mill shapes the feed into small pellets and the pellet cooler cools the feed. Liquid feed ingredients may be applied to the pelleted animal feed before load -out. The final animal feed products are loaded into trucks through the feed load -out chutes and then distributed to offsite livestock operations. The following NPDES permit application is for process water discharge. The process water discharge is boiler water blowdown from two boilers. The boiler system has a continuous blowdown that discharges into a dry ditch on the facility property. This water flow is approximately 10 gallons per minute (total both boilers), or 14,400 gallons per day. Some additives are added to the boiler water to prevent scaling and other forms of solids buildup inside the boiler. However, based on the MSDS sheets for each of the products currently used at The Chief facility, none of the chemicals listed on the NCG500000, Notice of Intent are.present in the discharged water. Supplement to Item # 14 of the NPDES Permit Application for Coverage Under General Permit NCG500000 The Chief Feed Mill Site, Murphy -Brown NARRATIVE OF TREATMENT ALTERNATIVES CONSIDERED Pumping boiler blowdown discharge water to Rose Hill is not an option afforded by the Town to Murphy Brown; therefore, no costs were estimated relative to this alternative. The attached calculations and cost estimates provide a cursory basis for evaluating the impact of treating the boiler blowdown discharge water by a low-pressure subsurface disposal system or by a spray irrigation system. Specifically, it is estimated that the total project cost for constructing a low pressure pipe disposal system would exceed $52,000, and the total project cost for constructing an irrigation disposal system would exceed $50,000. In addition to these up -front costs, operation and maintenance costs would be incurred throughout the life of the system. It is noted that the costs presented above assumed that disposal sites would be reasonably close to the mill and that the soils that would receive the water would be reasonably porous. Assuming sites further away and/or sites with "tighter" soils would entail even higher costs. The costs incurred by changing to a low pressure subsurface pipe system or irrigation system are not warranted. The operation of the current treatment system is much simpler and it provides adequate treatment of the boiler blowdown discharge water. W K Dickson Job # 30549.00.WL January 30, 2004 Supplement for Coverage Rough Design Calculations and Given: Maximum Discharge Volume Assumed: Soil Group I Long Term Application Calculations Relative to Primary LPP to Item # 14 of the NPDES Application Under General Permit NCG500000 The Chief Feed Mill, Murphy -Brown Water Discharge with gal. gal. per day per SF 3,675 gal. say 4,000 gal. 6,800 SF 1,360 ft. Estimate of Cost for Treating On -Site Low Pressure per Day, Qmax Rate, LTAR System Components Boiler Blowdown Pipe System 3400 0.5 of laterals Select Size of Tanks (gal.) based on 0.75 x Qmax + 1,125 .. Area of LPP Field based on 3,400 gal/day at assumed LTAR Length of 1 1/4 inch PVC LPP Field Pipe based on 5' spacing Rough Cost Estimate Item Description Quantity Unit Price Cost 4,000 Gallon Pump Tank lump sum $10,000 $10,000 Effluent Pump and Controls lump sum $8,000 $8,000 1 1/4" PVC LPP Lines with 12" x 12" Gravel Bed 1360 LF $8 $10,880 4" Pressure Manifold 50 LF $8 $400 2" PVC Dosing Main 500 LF $5 $2,500 Miscellaneous Valves and Fittings lump sum $1,500 $1,500 SUBTOTAL Contingency Hydrogeologic Investigations Engineering Design Surveying Construction Observation $33,280 $4,720 $4,000 $6,000 $2,000 $2,000 TOTAL ESTIMATED PROJECT COST $52,000 W K Dickson Job # 30549.00.WL DMC 1/30/04 Supplement for Rough Design Calculations Blowdown Water Given: Maximum Discharge Volume Assumed: 1" per week application Calculations Relative to Primary LPP Select Size of Tanks (gal.) based 3,400 gal./day = 23,800 gal./wk = At 1"/wk application rate, area of spray With sprinkler spacing on 50' grid, Cost Estimate to Item # 14 of the NPDES Application Coverage Under General Permit NCG500000 The Chief Feed Mill, Murphy -Brown Boiler gal. 3,675 gal. say 4,000 gal. and Estimate of Cost for Treating Discharge with On -Site Irrigation System per Day, Qmax 3400 rate System Components on 0.75 x Qmax + 1,125 3,182 cf/wk field = 38,200 SF total number of sprinklers approx. = 16 Item Description Quantity Unit Price Cost 4,000 Gallon Pump Tank lump sum $10,000 $10,000 Irrigation Pump and Controls lump sum $10,000 $10,000 Irrigation Risers and Sprinkler Heads 16 EA $75 $1,200 1 1/2" PVC Irrigation Field Lines 600 LF $4 $2,400 3" PVC Dosing Main 600 LF $6 $3,600 Miscellaneous Valves and Fittings lump sum $4,000 $4,000 SUBTOTAL Contingency Hydrogeologic Investigations Engineering Design Surveying Construction Observation $31,200 $4,800 $4,000 $6,000 $2,000 $2,000 TOTAL ESTIMATED PROJECT COST $50,000 W K Dickson Job # 30549.00.WL DMC 1/30/04 79 0 0.3 kf 0.6 • J • ` 'p, AR�o0em - ussUl . f 1 6 1, 0.9 1.2 1.5 km 0 0.2 0.4 0.6 0.8 1 mi Map center is UTM 17 772263E 3856889N (WGS84/NAD83) Rose Hill quadrangle - TopoZone Pro elevation display Projection is UTM Zone 17 NAD83 Datum \IG. M=-8.972 G=1.701 WK r DICKSON Engineers • Ptannert • Surveyors Landscape Architects 909 MARKET STREET WLMINCTON. NC 28401 (910) 782-4200 Atlanta. CA Charlotte. NC Columbia. SC Hickory. NC Raleigh, NC Wilmington. NC Date : 12/29/03 Scale: AS SHOWN Drawn : MNH Chk: MNH Pro} No: 30550.00.WL MURPHY-BROWN, LLC MURPHY BROWN THE CHIEF MILL SITE 210 THE CHIEF LANE ROSEHILL, NC 28458 Murphy BrownLL ��tir►.