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HomeMy WebLinkAboutNC0003719_Engineering Alternatives analysis_20041208NPDES DOCIMENT !;CANNING COVER SHEET NC0003719 Cedar Creek site WWTP NPDES Permit: Document Type: Permit Issuance Wasteload Allocation Authorization to Construct (AtC) Permit Modification Complete File - Historical Engineering Alternatives (EAA) Correspondence Owner Name Change Monitoring Report Instream Assessment (67b) Speculative Limits Environmental Assessment (EA) Document Date: December 8, 2004 This document is printed on reuse paper - ignore any content on the reYerse side DAK Americas FIBERS, MONOMERS & RESINS December 8, 2004 Mr. David A. Goodrich, P.E. Point Source Branch North Carolina Division of Water Quality 1617 Mail Service Center Raleigh, North Carolina 27699-1617 Re: Engineering Alternatives Analysis (EAA) DAK Resins, LLC Cumberland County NPDES Permit No. NC0003719 Dear Mr. Goodrich: This letter is being submitted to address the comments in the letter dated October 21, 2004 from the Point Source Branch of the Division of Water Quality (DWQ) for the above referenced project. We have reiterated the questions presented in the October 21 st letter prepared by DWQ followed by our responses. Our responses can be found in Amendment 1. We request DWQ consider the responses in this letter an amendment to the EAA dated August 26, 2004. If you have any questions or need additional information, please do not hesitate to contact myself at 910-371-5082 or Penny Mahoney at 910-371-5232. Respectfully Jeff Richardson DAK Americas Attachments Cc: Penny Mahoney — DAK Americas Alexandra Kantardjieff, P.E., DEE — Stearns & Wheler, LLC Susan Wilson, NCDWQ Paul Rawls, NCDWQ Fayetteville Regional Office DAK Americas, LLC File Room 3500 Daniels Road, N.E. • Leland, NC 28451 1-877-432-2766 www.dakamericas.com AMENDMENT 1 1) In the meeting held July 6, there was discussion about the types and percentages of flow being discharged from the facility. Please document how much flow is related to each facility (DAK and DTF) and the amount/types of process flow, non -contact cooling water, domestic flow etc., for each. If exact numbers are not known, please indicate where estimates are used. Both typical and average flows should be provided. The wastewater flow contribution from both facilities is provided in the industrial wastewater survey and permit application report prepared by the Public Works Commission of the City of Fayetteville (PWC). This report was included in Appendix B of the EAA. Approximately 67 percent and 33 percent of the wastewater flow is generated by DTF and DAK, respectively. The average and maximum flows from the various sources are summarized below in Table 1. Table 1 Wastewater Sources and Comuosition .f. x " ilgate L4 eri,Hw�`9' 60MiSa .T1 ' •.: „ unt, O;3td -Process Water ,WCAM 65,660 109,100 Washdown Water 2,000 3,500 Domestic — toilets and potable water 4,100 5,900 Cooling Water, Process Non -Contact 50,000 60,000 Other: Condensate 2,880 4,320 Stormwater 28,620 209,680 -Process Generated Water 50,000 100,000 Totals 203,260 492,500 The flows summarized in Table 1 are approximations, which are based on water consumption records and process requirements at the time of the estimate. The aggregate influent flow to the wastewater treatment for both facilities (DAK and DTF) and decant from the sludge storage basin and the sand drying beds is determined from the flow measurements recorded at the effluent Parshall flume. 2) Please provide detailed documentation of the BUDS and TSS values to determine costs (especially with regard to discharge to PWC). What values were estimated for no treatment, partial treatment, etc.? The EAA considered three alternatives with respect to discharging wastewater to the PWC Rockfish Creek Water Reclamation Facility (WRF). The three alternatives included: Alternative No. 3 - Alternative No. 4 Alternative No. 5 Discharging untreated wastewater to the Rockfish Creek WRF. - Upgrading the Cedar Creek WWTP to reduce energy consumption followed by discharging treated effluent to the Rockfish Creek WRF. - Discharging the current effluent to the Rockfish Creek WRF. Attachment No. 1, summarizes the wastewater data for the months of January through June of 2004. The average values for April through June are expected to be more representative, since the plant experienced process upset conditions and a equipment failure with the secondary clarifier from January through March. The wastewater data for January through June of 2004 in conjunction with the flow data provided in Table 1 were used to approximate the organic loadings and flows for Alternatives 3, 4 and 5. Surcharge fees that would be assessed to DAK Americas for flow and specific pollutant constituents were provided to us by PWC via e-mail. Attachment No.2 includes the e- mail from PWC for your reference. The $3.29 per 1,000 gallons applied in the EAA for flow is the industrial wastewater rate provided by PWC. It was also provided to Steams & Wheler on August 9, 2004 during a phone conversation with PWC. The surcharge fees for BOD and TSS are assessed when the effluent concentrations exceed 300 mg/L. The maximum BOD concentration that PWC will accept is 800 mg/L, according to the industrial pretreatment permit issued to DAK Americas from PWC. Refer to Attachment No. 3 for the industrial pretreatment permit issued to DAK Americas from PWC. This maximum BOD concentration of 800 mg/L is less than the average raw influent BOD concentration at the Cedar Creek WWTP. As noted in the wastewater data summary, the plant only measures influent COD. A BOD : COD ratio of 0.53 was applied to convert the influent COD concentrations to BOD values. The applied ratio of 0.53 is based on an extensive wastewater characterization study performed at another DAK Americas facility located in Moncks Corner, SC with comparable production and wastewater characteristics. Surcharge fees for BOD and TSS were not applied for Alternatives Nos. 4 and 5, since the current average and maximum effluent concentrations do not exceed 300 mg/L. 3) DAK should provide documentation from PWC stating how much flow it can accept from the facility and potential BOD5 and TSS limits (and any other limit requirements). Attachment No. 3 includes an industrial pretreatment permit, which was provided to DAK Americas from PWC. The permit indicates a monthly average and daily maximum flow of 0.060 mgd and 0.110 mgd, respectively. Effluent BOD5 and TSS concentrations indicated in the permit are 800 mg/L and 3 mg/L, respectively. 4) Alternative 3 may be eliminated from consideration if DAK can provide written confirmation that PWC will not accept untreated wastewater. Alternative No. 3 is not considered a cost-effective alternative. The surcharge fees that would be assessed to DAK Americas are cost prohibitive given the nature of the raw wastewater, regardless of whether, or not, the Fayetteville PWC accepted DAK's untreated wastewater. 5) The present value costs of operation and maintenance for each alternative should be based on a 20-year period. Also, please use the current EPA discount rate (this may be found at http://www.nccgl.net/fap/cwsrf/201gui.html; the current rate is 5.625% but was suppose to be updated effective October lst). The present value costs presented in Table 4-3 of the EAA have been updated based on an interest rate of 5.625% and a return period of 20 years. Table 4-3 (Revised) Opinion of Probable Present Worth Opinion of Cost Alternative ! No. 1 No. 2 No. 3 No. 4 No. 5 l Capital Cost $0 $960,000 $0 $960,000 $0 O&M Cost $1,007,896 $640,000 $1,380,000 $1,160,000 $1,393,000 • Present Value $12,000,000 $8,500,000 $16,400,000 . $14,700,000 $16,500,000 Alternative No. 3 can be eliminated from consideration, since the average raw influent BOD concentrations exceed the maximum BOD concentration accepted by PWC. 6) For Alternative 5, please provide detailed documentation on costs. We are unsure how Stearns & Wheler arrived at the electrical costs. Additionally, we would think that both electrical costs and laboratory/chemical costs would be significantly lower that those for Alternative 1 (since less stringent limits would likely have to be met with a discharge to PWC — laboratory costs and process control limits could be reduced; also, the treatment plant might not have to be run at the same level as that required to meet the stringent NPDES limits). Alternative Nos. 1 and 5 are based on using the existing equipment, since the equipment is required for both treatment and mixing. Therefore, the electrical costs are expected to remain identical for both alternatives. The average power consumption for the wastewater treatment facility is 700 kWH, according to DAK Americas. The average electricity cost for January through June was $0.0444 per kWH, as shown in Attachment No. 4. This electrical cost in conjunction with the 700 kWH was used to calculate the annual electrical cost for the wastewater treatment facility. The annual laboratory cost of $156,000 applied in the EAA was based on past expenses incurred by DAK Americas. The annual cost for lab analysis is not anticipated to vary significantly considering both permits have comparable monitoring requirements. For example, even if the annual lab cost for Alternative No. 5 were 50 percent of that which is required for Alternative No. 1 the 20-year present worth value for Alternative No. 5 would still be approximately $15,600,000. 7) For Alternatives 4 and 5, please outline how the flow and costs were developed, and why they would be different. Alternative No. 4 considers upgrading the wastewater treatment facility to reduce annual O&M costs compared to maintaining the current operational practices, as described by Alternative No. 5. Both alternatives could produce effluent in compliance with DAK's current NPDES permit limits. The maximum flows, recorded by the facility from January 2004 to June 2004, rounded to 400,000 gallons per day were used in each case. It is our opinion that maximum flows must be used in this analysis, and not average values. Discharge of all wastewater to Fayetteville PWC will be required 100 percent of the time, even in case of upset conditions. We would like to ask you very kindly to correct one typo error that is shown in Appendix F on the table showing the O&M costs for alternative No.5. Under item 6 (electricity) the quantity should read 700 kWh, and not 0. The total cost was calculated with 700 kWh. Attached is the corrected table reflecting this change and can be found in Attachment 5. Please replace this page in the EAA. ATTACHMENT NO. 1 Wastewater Characteristics (January through June 2004) Minimum Average Maximum Minimum Average Maximum Parameter Excluding upsets conditions Excluding Upsets conditions Excluding Upset conditions Including upsets conditions Including Upset conditions Including Upset conditions Flow (gpd) 0* 231,000 416,000 0* 231,000 416,000 TSS (mg/1) 5 183 - 1,170 2 17.5 86 COD (mg/1) 2,240 4,746 12,740 2,200 9,995 58,900 COD (lb/d) 1,848 6,615 18,919 105 12,850 110,653 pH - 5.2 7.61 3.9 7.47 11.89 * Clarifier shut down ATTACHMENT NO. 2 Alex4ndra Kantard !eff 'rom: •ent: To: Subjeft; SOD! {Tot TSS: {Tot NH3: {Tot Rob Allen [robert.allen@faypwc.com] Monday, August 09, 2004 11:28 AM akantardjieff@steamswheeler.com Surcharge Rates IF({Average Sample Result} 1 Flow by volume } (G (M) ] IF({Average Sample Result} 1 Flow by volume } [G (M) ] IF({Average Sample Result} 1 Flow by Volume } [G (M) ] Rob Allen System Protection Supervisor Public Works Commission Phong: 910-223-4699 Ce11 910-263-1434' Page Fax: Emai: Webs- : 910-677-3526 910-483-1153 : x'ob . allen®faypwc . com te: www.faypwc.com [mg/L3 > 300, ((({Average sample Result} (mg/L: -300) *8.34) * 0.31150) , 0 ) [mg/L3 > 300, ((({Average Sample Result} [mg/L] -300) *8.34) * 0.13420),0 ) [mg/L3 > 50, ((({Average Sample Result} [mg/L] -50) *8.34) * 0.68560),0 ) QwQ'r => YL.'G-UL } ,, 20W it000edtan I?00 0 6►A-titorI ATTACHMENT NO. 3 City of Fayetteville, North Carolina Permit To Discharge Wastewater Under the Public Works Commission's Industrial Pretreatment Program In compliance with the provisions of the Fayetteville City Code, North Carolina General Statute 143-215.1, other lawful standards and regulations promulgated and adopted by the North Carolina Environmental Management Commission, and the City of Fayetteville. DAK Resins, LLC is hereby authorized to discharge wastewater from a facility located at 3216 Cedar Creek Road Fayetteville, North Carolina Cumberland County into the City of Fayetteville's municipal sanitary sewer system and municipal wastewater treatment facility located at: Rockfish Water Reclamation Facility NPDES No. NC0050105 2536 Tracy Hall Rd Cumberland County in accordance with the effluent limitations, monitoring requirements, and other conditions set forth in parts I, II, and III hereof. This permit shall become effective on [INSERT DATE]. This permit and the authorization to discharge shall expire at midnight on [INSERT DATE]. Signed this day of , 2004. Steven K. Blanchard, General Manager Public Works Commission City of Fayetteville North Carolina Permit Number 2116RF 40 CFR Category 414 IU Name: DAK Resins1LC Permit#: 2116RF Pipe#: 01 40 CFR#: 414 Supplement to Permit Cover Sheet DAK Resins, LLC is hereby authorized to: 1. Continue operation of the existing pretreatment facility, consisting of the following methods of treatment: DAK Sanitary waste sump, 2 DAK Process waste sumps, Comminutor Pit, Existing Lift Station, Sample Point, 2 EQ Tanks, pH Adjustment Pit, Aeration Basin, Clarifier, Digester, Contact Chamber, and New Lift.Station pumping to PWC lift station 2. After receiving Authorization to Construct from the Public Works Commission, construct and operate pretreatment units as needed to meet final effluent limitations as set forth in this permit. 3. Discharge from said pretreatment works facility into the Public Works Commission's Rockfish Water Reclamation Facility, NPDES #NC0050105 Highway 87 South Cumberland County. 2 DAK Resins, LLC Permit Outline PART I. Effluent Limitations and Monitoring Requirements A. 1. Description of Discharge 2. Location of Monitoring Point 3. Permit Modification History B. Effluent Limits and Monitoring Requirements C. Monitoring and Reporting PART II. General Permit Conditions PART III. Special Permit Conditions IU Name: DAK Resins.LLC Permit#: 2116RF Pipe#: 01 40 CFR#: 414 3 PART I. EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS IU Name: DAK Resisns, LLC Permit#: 2116RF Pipe#: 01 40 CFR#: 414 PART I. EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS A. 1. Description of Discharge(s) Pipe Number Description 01 Process wastewaters; Equipment/facility washdown; Domestic; Non Contact Cooling water; stormwater run-off that has come in contact with OCPSF regulated wastestreams, to sewer (After pretreatment) - all regulated under 40 CFR Part 414 - the Organic Chemicals, Plastics, and Synthetic Fibers Category. (Thermosetting Resins & Commodity Organic Chemicals). 2. Location of Monitoring Point(s) See attachment. Pipe 01 After final pretreatment stages, sample to determine compliance with OCPSF (40 CFR 414) standards is to be drawn from [ 4 PART I. EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS 3. DAK Permit Modification History IU Name: DAK Resisns, LLC Permit#: 2116RF Pipe#: 01 40 CFR#: 414 a. Original Permit issued on [INSERT DATE] expires [INSERT DATE]. 5 PART I. EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS IU Name: DAK Resisns, LLC Permit#: 2116RF Pipe#: 01 40 CFR#: 414 PART I. B.1.EFFLUENT LIMITS AND MONITORING REQUIREMENTS 1. Receiving POTW Name: Rockfish Creek Water Reclamation Facility Receiving POTW NPDES#: NC0050105 Effective Date for These Limits: Effective Date of this Permit Expiration Date for These Limits: Expiration Date of this Permit Pipe #: 01 - Regulated (OCPSF) under 40 CFR 414. This discharge shall be limited and monitored as specified below. .Pollutants and prohibitions not regulated or enumerated below shall be discharged in accordance with the City of Fayetteville's Sewer Use Ordinance. ' LimteParameer i .R. }# Y.I Effluent` .. miiatiot , Ibs/day( )JpI t1 t 7L } , : : .; 4 t 11 o itonng= , . �:u�:�. u..,:.ti; Frequency, a Dl aximumAverageGab1 Mn y osite Jl��-r� tt .Pee.riii -�=sT.f"l'.I- r _ , UV acenaphthene 0.174 Grab 1/6 Months 1/ Calendar Year Anthracene 0.174 Grab 1/6 Months 1/ Calendar Year Benzene 0.495 Grab 1/6 Months 1/ Calendar Year Bis phthalate 0.952 Grab 1/6 Months 1/ Calendar Year carbon tetrachloride 1.403 Grab 1/6 Months 1/ Calendar Year Chlorobenzene 1.403 Grab 1/6 Months 1/ Calendar Year Chloroethane 1.089 Grab 1/6 Months 1/ Calendar Year Chloroform 1.200 Grab 1/6 Months 1/ Calendar Year Di-n-butyl phthalate 0.159 Grab 1/6 Months 1/ Calendar Year 1,2 dichlorobenzene 2.931 Grab 1/6 Months 1/ Calendar Year 1,3-dichlorobenzene 1.403 Grab 1/6 Months 1/ Calendar Year 1,4-dichorobenzene 1.403 Grab 1/6 Months 1/ Calendar Year 1,1 DCA 0.218 Grab 1/6 Months 1/ Calendar Year 1,2 DCA 2.119 Grab 1/6 Months 1/ Calendar Year 1,1 DCE 0.222 Grab 1/6 Months 1/ Calendar Year 1,2 trans DCE 0.244 Grab 1/6 Months 1/ Calendar Year 1,2 Dichloropropane 2.931 Grab 1/6 Months 1/ Calendar Year 1,3 Dichloropropene 2.931 Grab 1/6 Months 1/ Calendar Year Diethyl phthalate 0.417 Grab 1/6 Months 1/ Calendar Year Dimethly phthalate 0.174 Grab 1/6 Months 1/ Calendar Year 4,6 Dinitro-o cresol 1.023 Grab 1/6 Months 1/ Calendar Year Ethylbenzene 1.403 Grab 1/6 Months 1/ Calendar Year Fluoranthene 0.199 Grab 1/6 Months 1/ Calendar Year Fluorene 0.174 Grab 1/6 Months 1/ Calendar Year Hexachlorobenzene 2.931 Grab 1/6 Months 1/ Calendar Year Hexachlorobutadiene 1.403 Grab 1/6 Months 1/ Calendar Year hexachloroethane 2.931 Grab 1/6 Months 1/ Calendar Year 6 PART I. EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS IU Name: DAK Resisns, LLC Permit#: 21 16RF Pipe#: 01 40 CFR#: 414 PART I. B.1.EFFLUENT LIMITS AND MONITORING REQUIREMENTS 1. Pipe #: 01 - Regulated (OCPSF under 40 CFR 414 (continued). Limited Parameter Effluent Limitation in Ibs/day(*2) Sample Type Composite or Grab Monitoring Frequency Daily Maximum Monthly Average by Permittee by PWC Methyl chloride Grab 1/6 Months 1/ Calendar Year Methylene chloride Grab 1/6 Months 1/ Calendar Year Naphthalene Grab 1/6 Months 1/ Calendar Year Nitrobenzene Grab 1/6 Months 1/ Calendar Year 2-Nitrophenol Grab 1/6 Months 1/ Calendar Year 4-Nitrophenol Grab 1/6 Months 1/ Calendar Year Phenanthrene Grab 1/6 Months 1/ Calendar Year Pyrene Grab 1/6 Months 1/ Calendar Year Tetrachloroethylene Grab 1/6 Months 1/ Calendar Year Toluene Grab 1/6 Months 1/ Calendar Year Total Cyanide Grab 1/6 Months 1/ Calendar Year Total Lead Grab 1/6 Months 1/ Calendar Year Total Zinc Grab 1/6 Months 1/ Calendar Year 1,2,4 Trichlorobenzene Grab 1/6 Months 1/ Calendar Year 1,1,1 TCA Grab 1/6 Months 1/ Calendar Year 1,1,2 TCA Grab 1/6 Months 1/ Calendar Year TCE Grab 1/6 Months 1/ Calendar Year Vinyl chloride Grab 1/6 Months 1/ Calendar Year 7 PART I. EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS IU Name: DAK Resisns, LLC Permit#: 2116RF Pipe#: 01 40 CFR#: 414 PART I. B.2.EFFLUENT LIMITS AND MONITORING REQUIREMENTS 2. Receiving POTW Name: Rockfish Creek Water Reclamation Facility Receiving POTW NPDES#: NC0050105 Effective Date for These Limits: May 13, 2002 Expiration Date for These Limits: June 30, 2005 Pipe #: 02 - Regulated (OCPSF) under 40 CFR 414. This discharge shall be limited and monitored as specified below. Pollutants and prohibitions not regulated or enumerated below shall be discharged in accordance with the City of Favetteville's Sewer Use Ordinance. Effluent Limitatlon i S iF In mg/L F _ .... Sample: Type Monitoring Frequency, Limited �' Parameter . _ -- Dai1 y lmu ; Max m - -� Month ; < 8 , rage. -:' A.^verage r Composite gr Graf►, Y * Permittee, 4) Flow 0.1 IAMGD 0.060MGD Continuous (*2) 1/6 months BOD 800 , 800 Composite 1/ weekly 1/6 months TSS *3 ✓ Jf *3 Composite 1/ month 1/6 months Ammonia *3 *3 Composite 1/ month 1/6 months Oil & Grease 250 Grab 1/ month 1/6 months Total Phos. *3 Composite 1/6 months 1/6 months pH *1 Grab 1/ weekly 1/6 months Arsenic *3 Composite 1/6 months 1/6 months Cadmium *3 Composite 1/6 months 1/6 months Chromium *3 Composite 1/6 months 1/6 months Copper *3 Composite 1/6 months 1/6 months Cyanide *3 Grab 1/6 months 1/6 months Lead *3 Composite 1/6 months 1/6 months Mercury *3 Composite 1/6 months 1/6 months Molybdenum *3 Composite 1/6 months 1/6 months Nickel *3 Composite 1/6 months 1/6 months Selenium *3 Composite 1/6 months 1/6 months Silver *3 Composite 1/6 months 1/6 months Zinc *3 Composite 1/6 months 1/6 months Phenol *3 Grab 1/6 months 1/6 months See Page 9 for Limit Page Notes and Page 11 for Definitions. 8 PART I. EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS Limits Page Notes: *1 IU Name: DAK Resisns, LLC Permit#: 2116RF Pipe#: 01 40 CFR#: 414 The pH shall not be less than 6.0 or greater than 10.0 standard units. pH will be determined by field analysis on a grab sample of final effluent. *2 Flow measurement: See Part III. Special Condition D. for additional requirements. *3 Monitoring requirement only. Permittee shall monitor these pollutants during the first and third quarters of each calendar year. If monitoring results indicate the presence of pollutants in amounts which could cause endangerment, upset, pass -through, or hinder the operation of the collection system or the treatment facility in any way, pollutant specific limits may be applied. 9 PART I. EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS C. Monitoring and Reporting 1. Representative Sampling IU Name: DAK Resisns, LLC Permit#: 2116RF Pipe#: 01 40 CFR#: 414 Samples and measurements taken as required herein shall be representative of the volume and nature of the monitored discharge. All samples shall be taken at the monitoring points specified in this permit and, unless otherwise specified. Monitoring points shall not be changed without notification to, and approval by, the PWC. 2. Self -Monitoring and/or Additional Monitoring If the permittee is required to self -monitor by this permit, using EPA approved analytical methods, the results of such monitoring shall be submitted to the PWC's Pretreatment Program Office before the tenth of the month following sample collection. The PWC may require more frequent monitoring, or the monitoring of additional pollutants not required in this permit, by written notification. If the sampling performed by the permittee indicates a violation, the permittee shall notify the PWC within 24 hours of becoming aware of the violation. The permittee shall also repeat the sampling and analysis and submit the results of the repeat analysis to the PWC within 30 days after becoming aware of the violation. 3. Test Procedures Test procedures for the analysis of pollutants shall be performed in accordance with the techniques prescribed in 40 CFR Part 136 (U.S. Environmental Protection Agency), and amendments thereto unless specified otherwise in the monitoring conditions of this permit. 4. Certified Laboratory Analysis Pollutant analysis shall be performed by a North Carolina Division of Environmental Management Certified Laboratory that is certified in the analysis of the particular pollutant in wastewater. 10 PART I. EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS 5. Reporting IU Name: DAK Resisns, LLC Permit#: 2116RF Pipe#: 011 40 CFR#: 414 If the permittee monitors any pollutant at the location(s) designated herein more frequently than required by this permit, using approved analytical methods as specified above, the results of such monitoring shall be submitted to PWC. Monitoring results obtained by the permittee and all other reports required herein shall be submitted to the PWC at the following address: System Protection Supervisor Public Works Commission Post Office Drawer 1089 Fayetteville, North Carolina 28302 6. Recording Results For each measurement or sample taken pursuant to the requirements of this permit, the permittee shall record the following data: a. the exact place, date, and time of sampling, b. the date(s) the analyses were performed; and c. the person(s) or approved laboratory who performed the analysis. 7. Defmitions a. A composite sample, for monitoring requirements, is defined as a minimum of four (4) grab samples collected at equally spaced two (2) hour intervals (during an 8-hour workday), or once every two (2) hours if facility runs continuously for 24-hours. Sampling day shall be a typical production and discharge day. b. A grab sample, for monitoring requirements, is defined as a single "dip and take" sample collected at a representative point in the discharge stream. c. A daily monitoring frequency shall mean each working day. 11 PART II. IU Name: DAK Resins, LLC GENERAL PERMIT Permit#: 2116RF CONDITIONS Pipe#: 01 40 CFR#: 414 Part II. GENERAL PERMIT CONDITIONS A. Duty to Comply The permittee must comply with all conditions of this permit. Any permit non- compliance constitutes a violation of the City of Fayetteville Sewer Use Ordinance and is grounds for possible enforcement action(s). B. Duty to Mitigate - Prevention of Adverse Impact The permittee must take all reasonable steps to minimize or prevent any discharge in violation of this permit which has a reasonable likelihood of adversely affecting human health, the POTW's discharge, the water receiving the POTW's discharge, or the environment. C. Facilities Operation, Bypass The permittee shall, at all times, maintain in good working order, and operate as efficiently as possible, all control facilities or systems installed or used to achieve compliance with the terms and conditions of this permit. By-pass of treatment facilities is prohibited except as provided for and in accordance with the requirements set forth by this permit. By-pass approval shall be given only when such by-pass is in compliance with 40 CFR 403.17. D. Removed Substances Solids, sludges, filter backwash, or other pollutants removed in the course of treatment or control of wastewaters shall be disposed of in a manner such as to prevent any pollutants from such materials from entering the sewer system. The permittee is responsible for assuring its compliance with any requirements regarding the generation, treatment, storage, and/or ultimate disposal of "Hazardous Waste" as defined under the Federal Resource and Recovery Act (RCRA). The permittee shall identify to the PWC the hazardous/toxic waste hauler used for removal of such substances and notify the PWC of any change of said hauler. 12 PART II. IU Name: DAK Resins, LLC GENERAL PERMIT Permit#: 2116RF CONDITIONS Pipe#: 01 40 CFR#: 414 E. Upset Conditions An "upset" means an exceptional incident in which there is an unintentional and temporary non-compliance with the effluent limitations of this permit because of factors beyond the reasonable control of the permittee. An upset does not include non-compliance to the extent caused by operational error, improperly designed or inadequate treatment facilities, lack of preventative maintenance, or careless and/or improper operations. An upset may constitute an affirmative defense for actions brought for the non- compliance. The permittee has the burden of proof to provide evidence and demonstrate that none of the factors specifically listed above were responsible for the non-compliance. F. Right of Entry The permittee shall allow the staff of the State of North Carolina Department of Environment, Health, and Natural Resources, Division of Environmental Management, the Regional Administrator of the Environmental Protection Agency, the City of Fayetteville, the Public Works Commission, and/or their authorized representatives, upon the presentation of credentials: 1. to enter upon the permittee's premises where a real or potential discharge is located or in which records are required to be kept under the terms and conditions of this permit; and 2. at reasonable times to have access to and copy records required to be kept under the terms and conditions of this permit; to inspect any monitoring equipment or monitoring method required in this permit, and to sample any discharge of pollutants. G. Availability of Reports and Records/Record Retention The permittee shall retain records of all monitoring information, including all calibration and maintenance records as well as copies of reports and information used to complete the application for this permit for at least three years. All records that pertain to matters that are subject to any type of enforcement action shall be retained and preserved by the permittee until all enforcement activities have concluded and all periods of limitation with respect to any and all appeals have expired. These records include, but are not limited to, production records, wastewater self - monitoring records, and State and Federal EPA required records. 13 PART II. IU Name: DAK Resins, LLC GENERAL PERMIT Permit#: 2116RF CONDITIONS Pipe#: 01 40 CFR#: 414 Except for data determined to be confidential under the City of Fayetteville's Sewer Use Ordinance, Section 31-68, all reports prepared in accordance with terms of this permit shall be available for public inspection through the office of the Public Works Commission of the City of Fayetteville. As required by the Sewer Use Ordinance, effluent data shall not be considered confidential. H. Duty to Provide Information The permittee shall furnish to the Manager of the Public Works Commission or his designee, or the Division of Environmental Management, within a reasonable time, any information which the above parties may request to determine whether cause exists for modifying, revoking and re -issuing, or terminating this permit or to determine its compliance with this permit. The permittee shall also furnish, upon request, copies of records to be kept by this permit. I. Signatory Requirements All reports or information submitted pursuant to the requirements of this permit must be signed and certified by a ranking official or duly authorized agent of the permittee. J. Toxic Pollutants If a toxic effluent standard or prohibition (including any schedule of compliance specified in such effluent standard or prohibition) is established under Section 307(a) of the Federal Clean Water Act for a toxic pollutant which is present in the discharge, and such standard or prohibition is more stringent than any limitation for such pollutant in this permit, this permit may be revised or modified in accordance with the toxic effluent standard or prohibition and the permittee so notified. K. Civil and Criminal Liability Nothing in this permit shall be construed to relieve the permittee from civil or criminal penalties for non-compliance. L. Federal and/or State Laws Nothing in this permit shall be construed to preclude the institution of any legal action or relieve the permittee from any responsibilities, liabilities, or penalties established pursuant to any applicable Federal and/or State Laws or regulations. 14 PART II. IU Name: DAK Resins, LLC GENERAL PERMIT Permit#: 2116RF CONDITIONS Pipe#: 011 40 CFR#: 414 M. Penalties for Violation of Permit Conditions The City of Fayetteville Sewer Use Ordinance provides that any person who violates a permit condition is subject to a civil penalty not to exceed $10,000.00 per day of such violation, with each day deemed as a separate violation. N. Need to Halt or Reduce Not a Defense It shall not be a defense for a permittee in any enforcement action that it would have been necessary to halt or reduce the permitted activity to maintain compliance with the conditions of this permit. O. Penalties for Falsification of Reports The City of Fayetteville Sewer Use Ordinance and North Carolina General Statute 143-215 provides that any person who knowingly makes any false statement, representation, or certification in any record or other document submitted or required to be maintained under this permit, including monitoring reports or reports of compliance or non-compliance shall, upon conviction, be punished by a fine, or by imprisonment for not more than six (6) months, or by both. P. Transfer of Discharge Permit Wastewater discharge permits are issued to specific industrial users for specific operations. Wastewater discharge permission shall not be re -assigned or transferred or sold to a new owner, new user, different premises, or a new or changed operation. Q. Property Rights This permit does not convey any property rights in either real or personal property, or any exclusive privileges, nor does it authorize any injury to private property or any invasion of personal rights, nor any infringement of Federal, State or City laws or regulations. R. Severability The provisions of this permit are severable and, if any provision of this permit or the application of any provision of this permit to any circumstance is held invalid, the application of such provision to other circumstances and the remainder of this permit shall not be affected thereby. 15 PART II. IU Name: DAK Resins, LLC GENERAL PERMIT Permit#: 2116RF CONDITIONS Pipe#: 01 40 CFR#: 414 S. Permit Modification, Revocation, Termination This permit may be modified, revoked and re -issued or terminated with cause in accordance to the requirements of the City of Fayetteville Sewer Use Ordinance and North Carolina General Statute or implementing regulations. T. Re -Application for Permit Renewal The Permittee is responsible for filing an application with the PWC for re -issuance of this Permit 180 days prior to the expiration date of this Permit. U. Dilution Prohibition The permittee shall not increase the use of potable or process water or in any way attempt to dilute the discharge as a partial or complete substitute for adequate treatment to achieve compliance with the limitations contained in this permit. V. Notification of Production Changes The permittee shall give notice to the PWC at least 90 days prior to any facility expansion, production increase, or process modification which has the potential to result in new or substantially increased discharges or a change in the nature of the discharge. W. Construction No construction of pretreatment facilities or additions thereto shall commence until Final Plans/Specifications have been submitted to the PWC's Pretreatment Program Staff and written approval and an Authorization to Construct have been issued by the PWC. X. Sludge Management Plan Within 90 days prior to the initial disposal of sludge generated by any pretreatment facility, the permittee shall submit a sludge mangement plan to the PWC's Pretreatment Program Office. 16 PART II. IU Name: DAK Resins, LLC GENERAL PERMIT Permit#: 2116RF CONDITIONS Pipe#: 01 40 CFR#: 414 Y. Re -Opener This permit shall be modified or, alternatively, revoked and reissued to comply with any applicable effluent standards or limitation issued or approved by the City, as the Control Authority, for the control of any pollutant not now controlled by this permit or the City Ordinance. Z. Categorical Standard Re -Opener This permit shall be modified, or alternatively, revoked and reissued, to comply with any applicable effluent standard or limitation issued or approved under Sections 302(b) (2) (c), and (d), 304(b) (2), and 307(a) (2) of the Clean Water Act, if the standard or limitation so issued or approved: 1. contains different conditions or is otherwise more stringent than any effluent limitation in this permit, or 2. controls any pollutant not limited in this permit. The permit as modified or reissued under this paragraph shall also contain any other applicable requirements of the Act. AA. Reports of Potential Problems The permittee is responsible for contacting the PWC by telephone immediately of all discharges that could cause problems to the POTW, including any slug loadings as defined by 40 CFR 403.5(b). If the permittee experiences such a discharge, they shall inform PWC immediately upon the first awareness of the commencement of the discharge. Notification shall include location of the discharge, type of waste, concentration and volume, if known, and corrective actions taken by the permittee to prevent future discharges. The permittee shall, within five (5) days of the verbal notification, submit to the PWC Pretreatment Program Office a detailed written report describing the cause of the discharge, and those measures taken to prevent similar future occurrences. Such notification shall not relieve the permittee from any liability that may be incurred as a result of the discharge (see Sewer Use Ordinance, Section 31-53). BB. General Prohibitive Discharge The permittee shall comply with the general prohibition discharge standards in 40 CFR 403.5 (a) of the Federal pretreatment regulations. 17 PART II. IU Name: DAK Resins, LLC GENERAL PERMIT Permit#: 2116RF CONDITIONS Pipe#: 01 40 CFR#: 414 CC. Specific Prohibitions The permittee shall not allow wastewater to be discharged to the Municipal Sewer System that exhibit the following characteristics, as set forth in 40 CFR 403.5(b): 1. Pollutants which create a fire or explosion hazard in the POTW, including but not limited to, wastestreams with a closed cup flashpoint of less than 140 degrees Fahrenheit or 60 degrees Celsius using the test methods specified in 40 CFR 261.21. 2. Pollutants which will cause corrosive structural damage to the POTW, but in no case discharges with pH lower than 5.0, unless the works is specifically designed to accommodate such discharges. 3. Solid or viscous pollutants in amounts which will cause obstruction to the flow in the POTW resulting in interference. 4. Any pollutant, including oxygen demanding pollutants (BOD, etc.) released in a discharge at a flow rate and/or pollutant concentration which will cause interference with the POTW. 5. Heat in amounts which will inhibit biological activity in the POTW resulting in interference, but in no case heat in such quantities that the temperature at the POTW treatment plant exceeds 104 degrees Fahrenheit or 40 degrees Celsius unless the PWC approves alternate temperature limits. 6. Petroleum oil, nonbiodegradable cutting oil, or products of mineral oil origin in amounts that will cause interference or pass through. 7. Pollutants which result in the presence of toxic gases, vapors, or fumes within the POTW in a quantity that may cause acute worker health and safety problems. 8. Any trucked or hauled pollutants, except at discharge points designed by PWC. 18 PART II. IU Name: DAK Resins, LLC GENERAL PERMIT Permit#: 2116RF CONDITIONS Pipe#: 01 40 CFR#: 414 DD. Hazardous Waste Discharge The Public Works Commission prohibits the discharge of hazardous substances (according to 40 CFR 261) or any hazardous wastes as determined by PWC, to the sanitary sewer system. All hazardous wastes should be disposed of in accordance with North Carolina Hazardous Waste Management rules and Solid Waste Management Law (15A NCAC 13A). 19 PART III. IU Name: DAK Resins, LLC SPECIAL PERMIT Permit#: 2116RF CONDITIONS Pipe#: 01 40 CFR#: 414 PART III. SPECIAL PERMIT CONDITIONS A. Biotoxicity Monitoring If it is found that the permittee's effluent has a significant toxic impact upon the municipal wastewater treatment system and/or its receiving stream, the permittee shall be required, upon written notification from the PWC, to conduct Biotoxicity monitoring on the effluent being discharged. The severity of the permittee's effluent toxicity shall determine the frequency of the Biotoxicity monitoring. B. Toxicity Control Upon determination of toxicity in the permittee's effluent, the permittee shall be required to identify and eliminate the source(s) of the toxicity from the final discharge. C. Periodic Reports on Continued Compliance DAK Resins, LLC shall submit to the Public Works Commission a biannual "Periodic Compliance Report" that states whether or not applicable OCPSF standards are being met on a consistent basis, during the months of June and December. The report shall indicate the precise nature and concentrations of the regulated pollutants in its discharge to PWC, the average and maximum daily flow rates of the facility, the methods used by DAK to sample and analyze the data, and a certification that the methods used conform to those methods outlined in the OCPSF regulations. D. Flow Monitoring The Public Works Commission shall use the flows registered on the permittee effluent flow meter for the purpose of flow limit compliance. The permittee will be required to submit records of daily wastewater discharge to PWC no later than the twenty-fifth (25th) of each month. These records shall contain daily wastewater discharge flows for the period of the sixteenth (16th) of one month through the fifteenth (15th) of the following month. E. Relationship Between Dak Americas and Dupont Tejin Films It is recognized that Dak Americas and Dupont Tejin Films have gone to considerable and commendable efforts to foster a good working relationship with each other in light of a potentially precarious situation. It should be noted that Dak Americas being the permit holder is responsible for the quality of effluent from their wastewater treatment facility. Dak Americas and Dupont Tejin Films must continue to work together to ensure that the conditions of this permit are met. 20 PART III. IU Name: DAK Resins, LLC SPECIAL PERMIT Permit#: 2116RF CONDITIONS Pipe#: 01 40 CFR#: 414 To satisfy regulatory conditions, the following conditions must be met: Dupont Tejin Films, as a "user" of the City's sewer system, must be bound by the conditions of this permit including but not limited to Right of Entry, Availability of Records and Reports, Duty to Provide Information, and Re -Application for Permit Renewal. Upon finalization of agreement between Dak Americas and Dupont Tejin Films for use of Dak Americas treatment facility, the Public Works Commission will be provided a copy for review and approval. 21 PART III. IU Name: DAK Resins, LLC SPECIAL PERMIT Permit#: 2116RF CONDITIONS Pipe#: 01 40 CFR#: 414 The flow meter shall be calibrated once during each six-month period and documentation of the calibration event shall be submitted to PWC. Additional calibrations shall be performed by the Pennittee, at the request of PWC, in the event of significant questions concerning the accuracy of the meter, including but not limited to: a. Increase or decrease in sewer flow greater than twenty-five percent (25%) in two consecutive months. b. Increase or decrease in "sewer flow to water consumption" ratio above 10 percent in two consecutive months. PWC shall be notified within 24 hours of any malfunction, damage or repairs to the flow meter. PWC reserves the right to revert to billing for sewer based on water consumption in the event of the failure of the permittee's flow meter to perform properly; or the failure of the permittee to submit the required data and documentation to PWC in a timely fashion. The Public Works Commission shall use flow readings from the dedicated lift station that services the DAK site for sewer billing and surcharge calculation. Compliance with the OCPSF limitations outlined in Part I.B.1. of this permit shall be based on actual process flows recorded at the time of OCPSF sample collection. E. Slug/Spill Control Plan The permittee shall provide protection from accidental discharges of prohibited materials or other substances regulated by this permit. At the request of the permitting authority the permittee shall develop, obtain PWC approval, and implement a written Slug/Spill Control Plan within 120 days of the effective date of this permit. This plan shall include, but is not limited to: • Methods to prevent the discharge of incompatible or prohibited pollutants to the sanitary sewer system. • Description of discharge practices, including non -routine batch discharges. • Description of stored chemicals. 22 PART III. IU Name: DAK Resins, LLC SPECIAL PERMIT Permit#: 2116RF CONDITIONS Pipe#: 01 40 CFR#: 414 • Procedures for immediately notifying the POTW of slug discharges that would cause a violation of 40 CFR 403.5(b) (see General Condition 29, Page 14), with procedures for follow-up notification within 5 days. • If necessary, procedures to prevent adverse impact from accidental spills, including inspection and maintenance of storage areas, handling and transfer of materials, loading and unloading operations, control of plant site run-off, worker training, building of containment structures or equipment, measures for containing toxic organic pollutants (including solvents), and/or measures and equipment for emergency response. 23 PART IV. IU Name: DAK Resins, LLC • PERMIT SYNOPSIS Permit#: 2116RF Pipe#: 01 40 CFR#: 414 City of Fayetteville, North Carolina Public Works Commission Industrial Pretreatment Program Permit PART IV. IUP Synopsis A. IUP Basic Information Receiving POTW name: Rockfish Creek Water Reclamation Facility POTW NPDES#: NC0050105 IUP Name: DAK Resins, LLC IUP Effective Date: [INSERT DATE] IUP Expiration Date: [INSERT DATE] B. IU Survey & Application form Attached is a completed copy of the Industrial User Wastewater Survey & Application Form. C. IU Inspection form Attached is a copy of the most recent Industrial User Inspection. 24 PART IV. PERMIT SYNOPSIS IU Name: DAK Resins, LLC Permit#: 2116RF Pipe#: 01 40 CFR#: 414 D. RATIONALE FOR LIMITATIONS: as listed on the IUP Limits Page(s), PART I, Section B of the IUP. PIPE 01 RATIONALE #1: Categorical Pollutant Limits and Conventional Pollutant Limits, with no Over Allocation situation As listed in 40 CFR 414, Flow, BOD, and pH 25 $35,000.00 $30,000.00 $25,000.00 $20,000.00 $15, 000.00 $10, 000.00 $5,000.00 $- ATTACHMENT NO. 4 Waste Treatment Electrical Costs $29,179.80 $15,699.60 $16,239.60 $26,528.40 $20,935.80 $21,270.60 January February March April May June ATTACHMENT NO. 5 Opinion of Probable Operations and Maintenance Cost DAK Resins - Fayetteville, North Carolina S&W Job No. 40159.10 I Alternative No. 5 - Discharge Treated Wastewater to Fayetteville PWC's System Item Description Quantity Units Unit Cost Cost I 1 POTW Cost for treatment - flow based - normally 100% of time 400 1,000 gpd $ 3.29 - �i $385,000 2 POTW Cost for treatment - BOD based - normally 80% of time 0 lbs/day $ 0.3115 $ - 3 POTW Cost for treatment - BOD based - peak discharge 20% of time 0 lbs/day $ 0.3115 $ - 4 POTW Cost for treatment - TSS based - none normally 0 lbs/day $ 0.1342 $ - 5 POTW Cost for treatment - TSS based - peak discharge 20% of time 0 lbs/day $ 0.1342 $ - 6 Electricity - based on 5 months of billing records prorated for one year 700 kWh $ 0.045 $ 276,000 7 Nutrients 1 LS $ 30,000 8 Chemicals 1 LS $ 195,896 9 Maintenance 1 LS $ 100,000 10 Solids Disposal 1 LS $130,000 11 Lab Expense 1 LS $ 156,000 12 Administrative , 1 LS $ 120,000 Opinion of Probable Operations and Maintenance Cost $1,392,896 1. rgetbr -. om : cm C I Q 12-11 ° ) - rt� pt cta c . pQ_rccrrf-c�es of- -C to w s ` in o w r77,e,c C - O„t..) ,c y .) 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A,a Goy Lfr O) f'L Pie fi P C� Opinion of Probable Operations and Maintenance Cost DAK Resins - Fayetteville, North Carolina S&W Job No. 40159.10 __ ,- Alternative No. 3 - Dischar, e Untreated Wastewater to Fayetteville PWC's System Item I Description Quantity Units I Unit Cost I Cost 1 POTW Cost for treatment - flow based - normally 100% of time 400 1,000 gpd $ 3.29. $ 481,000 �2 3 POTW Cost for treatment - BOD based - normally 80% of' time POTW Cost for treatment - BOD based - peak discharge 20% of time 3,980 10,200 Ibs/day Ib.iday $ 0.31 15v $ 0.31 15i $ 363,000 $ 232,000 4 POTW Cost for treatment - TSS based - none normally 0 Ibs/day $ 0. I342'/ $ - 5 POTW Cost for treatment - TSS based - peak discharge 20% of time 2,500 Ibs/day $ 0.1342'/ $ 25,000 6 Electricity 0 kWh $ 0.045 $ - 7 Labor 0 LS $ - $ - 8 Maintenance 0 LS $ - $ - 9 Lab Expense/� 1 LS $ 156,000 $ 156,000 10 Administrat - 1' ' .n 1 LS $ 120,000 $ 120,000 Opinion of Probable Operations and Maintenance Cost S 1,380,000 ,r3f/ I,00a bra 13GD I r tl LTN6 13 azo pe• x k! q' to I t Stearns & Wheler, PLLC Emconrne,gal Engneas and S,aengsts h-- '-‘fiA) AA.e.tid2-0 1 ttAC14 ,P— Aoes vtarr v-k-}-c, ��.` f,l,540 - 300 = 010-v.) a y �lG�i"" 9 . 3f1‘ = of 1S 0 f1 eti � ii Dzo-) gAgA- Opinion of Probable Operations and Maintenance Cost DAK Resins - Fayetteville, North Carolina S&W Job No. 40159.10 Alternative No. 4 - U� _ rade Cedar Creek WWTP and Dischar_ e to Fa ettevil e stem POTW Cost for treatment - flow based - normally 2 POTW Cost for treatment - BOD based 3 POTW Cost for treatment - TSS based 4 Electricity 5 Chemicals 6 Solids disposal 7 Lab expense 8 Maintenance and materials 9 Nutrients 10 Administrative l00% of time U 't Cost /L..... oo e OOC) p 400 1,000 gpd 5 3.29 $ 0 lbs/day $ 0.3115 $ 0 Ibs/day $ 0.1342 $ 250 kWh $ 0.045 $ 1 LS $ 100,000 $ 1,250 lbs/d $ 0.25 $ 1 LS $ 156,000 $ 1 LS $ 75,000 $ 1 LS $ I LS $ 100,000 $ Opinion of Probable O 1 erations . aintenance Cost 480,340.00 99,000 100,000 115,000 156,000 75,000 30,000 100,000 1,160,000 Ohl A wl Opinion of Probable Operations and Maintenance Cost DAK Resins - Fayetteville, North Carolina . S&W Job No. 40159.10 Alternative No. 5 - Discharje Treated Wastewater to Fayetteville PWC's System Item I Description I Quantity' Units l Unit Cost I Cost 1 POTW Cost for treatment - flow based - normally 100% of time 400 . 1,000 gpd $ 3.291$ 385,000 , 2 POTW Cost for treatment - BOD based - normally 80% of time 0 lbs/day $ 0.3115 $ - 3 POTW Cost for treatment - BOD based - peak discharge 20% of time 0 lbs/day $ 0.3115 $ - 4 POTW Cost for treatment - TSS based - none normally 0 lbs/day $ 0.1342 $ - 5 POTW Cost for treatment - TSS based - peak discharge 20% of time 0 lbs/day $ 0.1342 $ - 6 Electricity - based on 5 tnonths of billing records prorated for one year 0 kWh $ 0.045 $ 276,000 7 Nutrients 1 LS $ 30,000 8 Chemicals 1 LS $ 195,896 9 Maintenance 1 LS $ 100,000 10 Solids Disposal . 1 LS $ 130,000 11 Lab Expense 1 LS $ 156,000 12 Administrative 1 LS $ 120,000 • Opinion of Probable Operations and Maintenance Cost' S 1,392,896 ,i,„„LEA4 1:Z;PJ Po zra,000 6.4--41--w 54,4'01' ',pa,. a/wt.-et/IL-at- -i- tAreaUtuet Stearns & Wheler, RIC o X 3,a9 X 60 r- 3 tia oao , t , mnse 4.4,y)-4 eamla- tack rimpe.A. i riftil (413 /04" Pl&sc aqA±c119 -5141t40144aD) 3 ! --dt44 4001340 fob IC3;i9 =* 1316 4432. ovd itWo