NC0003719_Permit (Modification)_20060120

NPDES DOCUMENT 5CANNIN` COVER SHEET
NPDES Permit:
NC0003719
Cedar Creek site WWTP
Document Type:
Permit Issuance
Wasteload Allocation
Authorization to Construct (AtC)
(Permit
Modification
Complete File - Historical
Engineering Alternatives (EAA)
Correspondence
Owner Name Change
Approval
Instream Assessment (67b)
Speculative Limits
Environmental Assessment (EA)
Document Date:
January 20, 2006
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F WATF
��p R Michael F. Easley
.S.)/ pG Governor
Cd r William G. Ross, Jr., Secretary
—I North Carolina Department of Environment and Natural Resources
Alan W. Klimek, P.E., Director
Division of Water Quality
Ms. Elizabeth Martin
DAK Americas
3500 Daniels Rd., N.E.
Leland, North Carolina 28451
Dear Ms. Martin:
January 20, 2006
Subject: NPDES Permit Modification
Permit No. NC0003719
DAK Resins - Cedar Creek
Cumberland County
The Division has reviewed your request for a permit modification at the DAK Resin Cedar
Creek site facility. The modification consists of the rerouting of the non -contact cooling water
from the wastewater treatment plant influent to the stormwater system discharging through
outfall 001. The permit has been modified to allow the discharge of the non -contact cooling
water through outfall 001. The supplement to the permit cover sheet and the monitoring
requirements for outfall 001 were modified. The monitoring requirements reflect the
requirements for the cooling water discharge commingled with stormwater. Due to this permit
modification permit sections A (9.) through A (12.) include changes from your existing permit.
Enclosed find the supplement to permit cover sheet describing the wastewaters tributary to
outfall 001 and the pages containing Sections A (9.) through A (12.) Please replace these pages in
your current permit. A letter shall be submitted to the Division when the modification is
completed.
If you have any questions concerning the draft permit or the other requirements for your
facility, please call me at [phone], extension 553.
Sincerely,
Teresa Rodriguez
NPDES Unit
Cc: NPDES Files
Fayetteville Regional Office
Ms. Peggy Mahoney — DAK Americas
3500 Daniels Rd, N.E.
Leland, North Carolina 28451
Nofie r Carolina
atura!!y
North Carolina Division of Water Quality 1617 Mail Service Center Raleigh, NC 27699-1617 Phone [phone] Customer Service
Internet h2oenr.state.nc.us 512 N. Salisbury St. Raleigh, NC 27604 FAX [phone]
An Equal Opportunity/Affirmative Action Employer — 50% Recycled/10% Post Consumer Paper

Permit NC0003719
SUPPLEMENT TO PERMIT COVER SHEET
DAK Resins, LLC is hereby authorized to:
1. Continue to operate an existing 1.25 MGD wastewater treatment facility consisting
of flow equalization, spill basin, pH adjustment, oil skimming, comminute, dual
aeration basins, clarifier, parshall flume, sludge pump station, dual aerobic
digesters, aerated biosolids holding basin, biosolids drying beds and other
associated equipment located at DAK Resins, LLC, on NC Highway 53, south of
Fayetteville in Cumberland County.
2. Upon closure and clean-up of the Monsanto RoundUp plant, continue to operate
an existing 1.25 MGD wastewater treatment facility with a permitted discharge of
0.5 MGD consisting of flow equalization, spill basin, pH adjustment, oil skimming,
comminute, dual aeration basins, clarifier, parshall flume, sludge pump station,
dual aerobic digesters, aerated biosolids holding basin, biosolids drying beds and
other associated equipment located at DAK Resins, LLC, Fayetteville Plant, on NC
Highway 53, south of Fayetteville in Cumberland County.
3. Discharge water from said treatment works at the location specified on the
attached map into the Cape Fear River which is classified C waters in the Cape
Fear River Basin
4. Upon sale of the Monsanto Fayetteville facility, the new owner shall request a
modification to the NPDES permit and complete a new application for discharge in
accordance with special condition A. (5.) for an ultimate permitted flow of 1.25
MGD.
5. Discharge non -contact cooling water and stormwater from the outfall specified on
the attached map (and stormwater from other outfalls specified in the July 31,
1992 stormwater permit application) into the Cape Fear River which is classified C
waters in the Cape Fear River Basin.
Any other point source discharge to surface waters of the state is prohibited unless covered by
another permit, authorization or approval.
This permit does not relieve the permittee from responsibility for compliance
with any other applicable federal, state, or local law, rule, standard, ordinance,
order, judgement or decree.

Permit NC0003719
A. (9.) EFFLUENT LIMITATIONS AND MONITORING REQIREMENTS
During the period beginning on the effective date of the permit and lasting until connection of the non -contact
cooling water to outfall 001, the Permittee is authorized to discharge stormwater from outfall 001. Such discharges
shall be limited and monitored by the permittee as specified below:
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Total Rainfall4
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Annual
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Event Duration4
Minutes
Annual
SW-1
Total Suspended Solids
mglL
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Annual
Grab
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Nickel
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Lead
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Di-n-butyl phthalate
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Notes:
1. Cutoff Concentration. For each parameter, the arithmetic mean of all analytical sampling results collected during
the first year of the permit shall be calculated for each individual outfall and compared to the cut-off
concentrations listed. If the arithmetic mean is below the specified cut-off concentration for a given parameter,
then the facility is not required to continue annual analytical monitoring for that parameter at the outfall during
the term of the permit unless a significant change in facility operations or configuration occurs. If cut-off
concentration results in discontinued analytical monitoring at an individual discharge outfall, the permittee is
required to maintain facility operations that ensure the continuation of stormwater runoff quality.
2. 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.
3. Sample Location. Samples to be collected at each stormwater discharge outfall (SW-1) located north of the river
water intake pump overflow and south of the sludge drying beds.
4. 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, the amount 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).
For purposes of the stormwater sampling required in this permit, all samples shall be collected from a discharge
resulting from a representative storm event (See Parts A. (13) and A. (14.)).

Permit NC0003719
A. (10.) EFFLUENT LIMITATIONS AND MONITORING REQIREMENTS
During the period beginning upon connection of the cooling water to outfall 001 and lasting until expiration,
the Permittee is authorized to discharge non -contact cooling water and stormwater from outfall 001. Such discharges
shall be limited and monitored by the permittee as specified below:
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Flow
Monthly
Estimate
MH1
Total Suspended Solids
100.00 mglL
Monthly
Grab
MH1
Nickel
789.00 pg/L
Monthly
Grab
MH1
Lead
33.78 pg/L
Monthly
Grab
MH1
Di-n-butyl phthalate
Monthly
Grab
MH1
Temperature2
Monthly
Grab
MH1
Total Residual Chlorine2
28 pg/L
Monthly
Grab
MH1
pH3
Monthly
Grab
MH1
Notes:
1. Sample Location — MH1 - Manhole located north of the river water intake pump overflow and south of the
sludge drying beds.
2. The temperature of the receiving stream shall not be increased more than 2.8 °C above the natural water
temperature and the receiving water temperature shall not exceed a maximum of 32 °C.
3. Monitoring requirements and limit only apply if chlorine is added to the system.
4. The pH shall not be less than 6.0 standard units nor greater than 9.0 standard units.
A. (11.) STORMWATER MONITORING REQUIREMENTS/ Qualitative Monitoring
Qualitative monitoring requires a qualitative inspection of each stormwater outfall, regardless of representative outfall
status, for the purpose of evaluating the effectiveness of the Stormwater Pollution Prevention Plan and assessing new
sources of stormwater pollution. No analytical tests are required. Qualitative monitoring of stormwater outfall does
not need to be performed during a representative storm event.
StormWater Dischargegharacteris lcs F:r , z-r . r:
Meas_ireinont;Frequencm
;mgsafpfe :atcatin:- ,..-
Color
Semi -Annual
See Note 2
Odor
Semi -Annual
See Note 2
Clarity
Semi -Annual
See Note 2
Floating Solids
Semi -Annual
See Note 2
Suspended Solids •
Semi -Annual
See Note 2
Foam
Semi -Annual
See Note 2
0il Sheen
Semi -Annual
See Note 2
Other obvious indicators of stormwater pollution
Semi -Annual
See Note 2
Notes:
1. Measurement Frequency. The first qualitative monitoring event during the term of the permit must be
performed during the initial analytical monitoring event. All subsequent qualitative monitoring will be performed
twice per year, once in the spring (April - June) and once in the fall (September - November).
2. Sample Location: Until connection of the non -contact cooling water to outfall 001 visual monitoring shall be
performed at the manhole located north of the river water intake pump overflow and south of the sludge drying
beds. Upon connection of the non -contact cooling water to outfall 001 visual monitoring may be performed at
each stormwater discharge outfall (SDO) at a point where no additional significant materials could reasonably
enter the system as a result of facility operations.

Permit NC0003719
A. (12.) STORMWATER SPECIAL CONDITION
Representative outfall status has been granted to allow representative stormwater monitoring to be performed at the
manhole located north of the river water intake pump overflow and south of the sludge drying beds. Once the
cooling water is tied into outfall 001 the facility shall monitor as specified in Section A. (10.) and A. (11.)
A. (13.) STORMWATER POLLUTION PREVENTION PLAN
The permittee shall develop a Stormwater Pollution Prevention Plan, herein after referred to as the Plan. The Plan
shall be considered public information in accordance with Part II, Section E.10. of this permit. The Plan shall be
updated on an annual basis. The Plan shall include, at a minimum, the following items:
a. Site Plan: The site plan shall provide a description of the physical facility and the potential pollutant sources
which may be expected to contribute to contamination of regulated stormwater discharges. The site plan
shall contain the following.
(1) A general location map (USGS quadrangle map, or appropriately drafted equivalent map), showing
the facility's location in relation to transportation routes and surface waters, and the name of the
receiving water(s) to which the stormwater outfall(s) discharges. If the discharge is to a municipal
separate storm sewer system, the name of the municipality and the ultimate receiving waters, and
accurate latitude and longitude of the point(s) of discharge must be shown.
(2) A narrative description of storage practices, loading and unloading activities, outdoor process areas,
dust or particulate generating or control processes, and waste disposal practices.
(3) A site map (or series of maps) drawn to scale with the distance legend indicating location of
industrial activities (including storage of materials, disposal areas, process areas, and loading and
unloading areas), drainage structures, drainage areas for each outfall and activities occurring in the
drainage area, building locations and impervious surfaces, the percentage of each drainage area that is
impervious. For each outfall, a narrative description of the potential pollutants which could be
expected to be present in the regulated stormwater discharge.
(4) A list of significant spills or leaks of pollutants that have occurred at the facility during the 3 previous
years and any corrective actions taken to mitigate spill impacts.
(5) Certification that the stormwater outfalls have been evaluated for the presence of non-stormwater
discharges. The certification statement will be signed in accordance with the requirements found in
Part II, Section B.11.
b. Stormwater Management Plan: The stormwater management plan shall contain a narrative description of the
materials management practices employed which control or minimize the exposure of significant materials to
stormwater, including structural and non-structural measures. The stormwater management plan, at a
minimum, shall incorporate the following:
(1) A study addressing the technical and economic feasibility of changing the methods of operations and/or
storage practices to eliminate or reduce exposure of materials and processes to stormwater. Wherever
practicable the permittee should consider covering storage areas, material handling operations,
manufacturing or fueling operations to prevent materials exposure to stormwater. In areas where
elimination of exposure is not practicable, the stormwater management plan shall document the
feasibility of diverting the stormwater runoff away from areas of potential contamination.

DAK Americas
FIBERS, MONOMERS & RESINS
Ms. Teresa Rodreguez
Point Source Branch
North Carolina Division of Water Quality
1617 Mail Service Center
Raleigh, North Carolina 27699-1617
Subject: Request for Minor Permit Modification
DAK Resins, LLC
Cumberland County
NPDES Permit No. NC0003719
Dear Ms. Rodreguez:
Cape Fear Site
3500 Daniels Road, N.E.
Leland, NC 28451
October 31, 2005
DAK Americas requests a minor permit modification to the Cedar Creek site's
NPDES permit to allow non -contact cooling water, currently part of the influent to
the plant's wastewater treatment system and subsequently discharged through
Outfall 002, to be discharged through storm water Outfall 001. This would reduce
the amount of water being treated in the plant's wastewater treatment system by
approximately 50,000-60,000 gallons per day. A schematic of the current flow and
the proposed flow is attached in Figure 1.
If you have any questions or need additional information, please do not hesitate
to contact me at [phone].
Sincerely,
E1iz eth R. Martin
Environmental Engineer
Attachment
cc: Penny Mahoney
Stanley Carter, Cedar Creek
Anthony Hudson, Cedar Creek
Donald Allbright, Cedar Creek
File: Cedar Creek

Figure 1. Proposed discharge of non -contact cooling water to stormwater outfall
October 31, 2005
DAK Resins, LLC
3216 Cedar Creek Road
Fayetteville, NC
Cumberland County
NPDES Permit No. NC0003719
DAK Resins
Influent from process
Non -contact cooling water
Proposed
discharge of
non -contact
cooling water to
stormwater
Outfall 001
I Stormwater 1
Outfall 001
To Cape Fear River
DTF
Spill Basin
I Outfall 002 I
Equalization Tanks
AB1
( ry, - r'' 6' 4
2((-) - II 3 7/ 5L)0
Effluent from wastewater
treatment plant
pH pit
w.O,
ACM` 1i't
Sanitary
Sewer
AB2
1 To sludge storage I
Current Flow
Proposed Change

2005 Monthly CTW Blowdown
January 471,918
February 367,200
March 21,131
April 390,723
May 1,299,438
June 2,514,557
July 996,322
August 1,420,781
September 3,125,095
October 3,959,876
November 614,667
Average 1,380,155

2005 Monthly CTW Blowdown
January 471,918
February 367,200
March 21,131
April 390,723
May 1,299,438
June 2,514,557
July 996,322
August 1,420,781
September 3,125,095
October 3,959,876
November 614,667
Average 1,380,155

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