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NC0003719_Permit (Issuance)_19951229
NPDES DOCUMENT SCANNING COVER SHEET NC0003719 Cedar Creek site WWTP NPDES Permit: Document Type: erpit Issuance ' r+REroYr.!'Wrfv i;we:awzpn?•"' 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 29, 1995 This document is printed oiz reuse paper - igzore any content on the reizerse side • State of North Carolina Department of Environment, Health and Natural Resources Division of Environmental Management James B. Hunt, Jr., Governor Jonathan B. Howes, Secretary A. Preston Howard, Jr., P.E., Director Mr. Manhar Patel Monsanto Company , P.O. Box 2307 Fayetteville, North Carolina 28302 Dear Mr. Patel: Al7c*A EDEEI-INJ I December 29, 1995 Subject: NPDES Permit Issuance Permit No. NC0003719 Monsanto Company Cumberland County In accordance with the application for a discharge permit received on March 15, 1995 the Division is forwarding herewith the subject NPDES permit. This permit is issued pursuant to the requirements of North Carolina General Statute 143-215.1 and the Memorandum of Agreement between North Carolina and the U.S. Environmental Protection Agency dated December 6, 1983. In response to the comments submitted by Monsanto on December 7, 1995, the following responses are provided. 1. Part I.A.5. and Part I.A.6: The monthly average and daily maximum tables provided in the comment letter and in this final permit are correct. 2. Part I.A.7 and Part I.A.8: The duplicate compounds listed have been removed and the cumulative allocations are now listed for the appropriate single entry. Since both Monsanto and ICI are currently in expansion start-up with completion scheduled for the first of the year, Part I.A.7. has been deleted as requested. 3. Part II, Section A.1.b.(2): The secondary containment requirements are intended to apply to bulk storage of liquid materials that have the potential to contaminate stormwater runoff. As such, the routing of surface water from these areas to the wastewater treatment plant supersedes the need for secondary containment of structures within these drainage areas. 4. Part II, Section A.3.(b): This section has been changed to read, "...qualitative visual inspection of each stormwater outfall discharging runoff from production and material handling and storage areas..." Footnote 3 has been added as requested. If any parts, measurement frequencies or sampling requirements contained in this permit are unacceptable to you, you have the right to an adjudicatory hearing upon written request within thirty (30) days following receipt of this letter. This request must be in the form of a written petition, P.O. Box 29535, Raleigh, North Carolina 27626-0535 Telephone 919-733-5083 FAX 919-733-0719 An Equal Opportunity Affirmative Action Employer 50'/o recycled/ 10% post -consumer paper • Permit No. NC0003719 Monsanto Company December 29, 1995 conforming to Chapter 150B of the North Carolina General Statutes, and filed with the Office of Administrative Hearings, Post Office Drawer 27447, Raleigh, North Carolina 27611-7447. Unless such demand is made, this decision shall be final and binding. Please take note that this permit is not transferable. Part II, E.4. addresses the requirements to be followed in case of change in ownership or control of this discharge. This permit does not affect the legal requirements to obtain other permits which may be required by the Division of Environmental Management 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 Jeanette Powell at telephone number (919)733-5083, extension 537. Sincerely, c!fled kijl David R. Goodrich A. Preston Howard, Jr., P.E. cc: Central Files Fayetteville Regional Office, Water Quality Section Mr. Roosevelt Childress, EPA Permits and Engineering Unit Facility Assessment Unit Technical Assistance & Certification Group Aquatic Survey and Toxicology Unit STATE OF NORTH CAROLINA DEPARTMENT OF ENVIRONMENT, HEALTH, AND NATURAL RESOURCES DIVISION OF ENVIRONMENTAL MANAGEMENT PERMIT TO DISCHARGE WASTEWATER AND STORMWATER UNDER THE NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM In compliance with the provisions 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, Monsanto Company is hereby authorized to discharge wastewater and stormwater from a facility located at Monsanto Fayetteville Plant NC Highway 53 South of Fayetteville Cumberland County to receiving waters designated as the Cape Fear River in the Cape Fear River Basin in accordance with the disci,:: ge limitations, monitoring requirements, and other conditions set forth in Parts I, II, III, IV, and V hereof. This permit shall become effective January 1, 1996. This permit and the authorization to discharge shall expire at midnight on December 31, 2000. Signed this day December 22, 1995. BY • A. Preston Howard, Jr., P.E., Director Division of Environmental Management By the Authority of the Environmental Management Commission t, Permit No. NC003719 SUPPLEMENT TO PERMIT COVER SHEET Monsanto Company is hereby authorized to: 1. Operate a wastewater,:,treatment facility consisting of flow equalization, spill basin, pH adjustment, oil skimming, comminuter, 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 Monsanto Company, Fayetteville Plant, on NC Highway 53, south of Fayetteville, in Cumberland County. 2. Operate an incinerator scrubber unit and other associated equipment located at Monsanto Company, Fayetteville Plant, on NC Highway 53, south of Fayetteville, in Cumberland County. 3. Discharge wastewater from said treatment works at the locations specified on the attached map into the Cape Fear River which is classified Class C waters in the Cape Fear River Basin. 4. Discharge stormwater from the representative outfall specified on the attached map (and other outfalls specified in the July 31, 1992 stormwater permit application) into the Cape Fear River which is classified Class C waters in the Cape Fear River Basin. 5. After receiving an Authorization to Construct from the Division of Environmental Management, construct treatment facilities as necessary to meet the limits of this permit for wastewater/stdrmwk:.. r discharges. All discharges shall be in accordance with the attached schedules as follows: Part I: Wastewater Monitoring, Controls and Limitations for Permitted Discharges Part II: Stormwater Monitoring, Controls and Limitations for Permitted Discharges Part III: Standard Conditions for NPDES Permits Part IV: Administering and Compliance Monitoring Fee Requirements Part V: Limitations Reopener 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. R Ir. Part I 7. EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS NC0003719 During the period beginning on the effective date of the permit and lasting until expiration, the Permittee is authorized to discharge from outfall serial number 002. Such discharges shall be limited and monitored by the permittee as specified below: Effluent Characteristics AcenaptheneA Acrylonitrile Benzene Carbon Tetrachloride Chlorobenzene 1,2,4-Trichlorobenzene 1,2-Dichloroethane 1,1,1-Trichloroethane Hexachloroethane 1,1-Dichloroethane 1,1,2-Trichloroethane Chloroethane Chloroform 2-Chlorophenol 1,2-Dichlorobenzene 1,3-Dichlorobenzene 1,4-Dichlorobenzene 1,1-Dichloroethylene 1,2-trans-Dichloroethylenc 2,4-Dichlorophenol 1,2-Dichloropropane 1,3-Dichloropropylene 2,4-Dimethylphenol 2,4-Dinitrotoluene 2,6-Dinitrotoluene Ethylbenzene Discharge Limitations Monitoring Monthly Avg. Daily Max. Measurement (lb/day) (lb/day) 0.05 0.13 0.21 0.53 0.35 1.29 0.17 0.36 0.14 0.27 0.15 0.31 0.65 2.01 0.20 0.51 0.05 0.12 0.05 0.13 0.05 0.12 0.23 0.59 0.20 0.44 0.30 0.93 0.73 1.55 0.07 0.10 0.14 0.27 0.15 0.24 0.20 0.51 0.37 1.07 1.46 2.19 0.27 0.42 0.17 0.34 0.25 0.63 0.56 1.42 0.30 1.03 Frequency Quarterly Quarterly Quarterly Quarterly Quarterly Quarterly Quarterly Quarterly Quarterly Quarterly Quarterly Quarterly Quarterly Quarterly Quarterly Quarterly Quarterly Quarterly Quarterly Quarterly Quarterly Quarterly Quarterly Quarterly Quarterly Quarterly Requirements SamSample Typeple Location,1 Composite I or E Grab E Grab E Grab E Grab E Grab E Grab E Grab E Grab E Grab E Grab E Grab E Composite E Grab E Grab E Grab E Grab E Grab E Grab E Grab E Grab E Grab E Grab E Grab E Grab E Grab E Part I NC0003719 7. EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS - CONTINUED Effluent Characteristics Fluoranthene Methylene Chloride Methyl Chloride Hexachlorobutadiene Naphthalene Nitrobenzene 2-Nitrophenol 4-Nitrophenol 2,4-Dintrophenol 4,6-Dintro-o-cresol Phenol B is(2-ethylhexyl)phthalate Di-n-butyl phthalate Diethyl phthalate Dimethyl phthalate Benzo(a)anthracene Benzo(a)pyrene 3,4-Benzofluoranthene Benzo(k)fluoranthene Chrysene Acenaphthylene Anthracene Fluorene Phenanthrene Pyrene Tetrachloroethylene Toluene Trichloroethylene Vinyl Chloride Bromodichloromethane Discharge Limitations Monthly Avg. (Ib/day) 0.06 0.38 0.82 0.04 0.21 0.06 0.09 0.16 0.16 0.17 0.14 0.23 0.06 0.18 0.04 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.06 0.21 0.25 0.05 0.23 1.04 Daily Max. (lb/day) 0.15 0.85 1.81 0.11 0.56 0.15 0.15 0.27 0.27 0.61 0.25 0.62 0.13 0.45 0.10 0.13 0.13 0.13 0.13 0.13 0.13 0.13 0.13 0.13 0.15 0.53 0.76 0.12 0.59 2.77 Monitoring�Requirements Measurement Sample Sample Frequency Quarterly Quarterly Quarterly Quarterly Quarterly Quarterly Quarterly Quarterly Quarterly Quarterly Quarterly Quarterly Quarterly Quarterly Quarterly Quarterly Quarterly Quarterly Quarterly Quarterly Quarterly Quarterly Quarterly Quarterly Quarterly Quarterly Quarterly Quarterly Quarterly Quarterly Type Composite Grab Grab Composite Grab Grab Grab Grab Grab Composite Grab Composite Composite Composite Composite Composite Composite Composite Composite Composite Composite Composite Composite Composite Composite Grab Grab Grab Grab Grab Location E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E i (`. Part I NC0003719 7. EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS - CONTINUED Effluent Characteristics Bromomethane Dibromochloromethane Tribromomethane Total Chromium Total Copper Total Cyanide Total Lead Total Nickel Total Zinc Effluent Characteristics Total PAH's 2 Hexachlorobenzene Discharge Limitations Monitoring Monthly Avg. Daily Max. (lb/day) (lb/day) 1.04 2.77 1.43 5.79 1.43 5.79 2.45 6.12 3.20 7.47 2.53 7.32 3.04 6.56 3.74 8.80 2.32 5.77 Discharge Limitations Monthly Avg. Daily Max. (µgll) (µg/l) 69.70 1.73 Measurement Frequency Quarterly Quarterly Quarterly Quarterly Quarterly Quarterly Quarterly Quarterly Quarterly Monitoring Measurement Frequency Quarterly Quarterly Type Grab Grab Grab Composite Composite Grab Composite Composite Composite Requirements Sample Sample Location 1 E E E E E E E E E Requirements Sample Sample Type Location 1 Composite E Composite E Footnotes: 1 Sample Location: E - Effluent 2 Total PAH's are comprised of Benzo(a)anthracene; Benzo(a)pyrene; 3,4-Benzofluoranthene; Benzo(k)fluoranthene, Chrysene, Dibenz (a,h) anthracene and Indeno (1,2,3-ed) pyrene. Note: Composite samples must be telligerated. Part I a NC0003719 8. EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS - FINAL During the period beginning on the effective date of the permit and lasting until expiration, the Permittee is authorized to discharge from outfall serial number 003. Such discharges shall be limited and monitored by the permittee as sr? _ified below: Effluent Characteristics Flow Total Suspended Solids BOD, 5 Day, 20° C NH3 - N COD Glyphosate pH 2 Discharge Limitations Monitoring Requirements Measurement Sample Sample Monthly An, Daily Max Frequency _Tyne Location 1 0.03 MGD Continuous Recording I or E 67.0 lbs/day 134.0 lbs/day 3/week Composite E 5.0 lbs/day 10.0 lbs/day 3/week Composite E 1.0 lbs/day 2.0 lbs/day 3/week Composite E 40.0 lbs/day 80.0 lbs/day 3/week Composite E 2/month Composite E 2/month Composite E Footnotes: I Sample Locations: E - Effluent, I - Influent 2 The pH shall not be less than 6.0 standard units nor greater than 9.0 standard units. THE PERMITTEE SHALL NOTIFY THE FAYETTEVILLE REGIONAL OFFICE 24 HOURS PRIOR TO DISCHARGE FROM THIS OUTPALL. THERE SHALL BE NO DISCHARGE OF FLOATING SOLIDS OR VISIBLE FOAM IN OTHER THAN TRACE AMOUNTS. Permit No. NC0003719 PART I WASTEWATER MONITORING, CONTROLS, AND LIMITATIONS FOR PERMITTED DISCHARGES SECTION A: FINAL LIMITATIONS AND CONTROLS FOR WASTEWATER DISCHARGES 1. Biocide Approval The permittee is not required to notify the Division of changes in biocide use where said biocides are specifically treated and discharged through the wastewater treatment plant. The permittee shall notify the Director in writing not later than ninety (90) days prior to instituting use of any biocide used in the cooling systems which is not discharged through the wastewater treatment plant and which May be toxic to aquatic life. 2. Detection Levels for Compliance If the discharge limitation of a given parameter is below detection limits, the measured quantity for the purposes of a compliance evaluation is considered to be zero. Values which report below detection level shall be deemed to be in compliance. 3. Acute Toxicity Pass/Fail Permit Limit (Quarterly) The permittee shall conduct acute toxicity tests on a quarterly basis using protocols defined in the North Carolina Procedure Document entitled "Pass/Fail Methodology For Determining Acute Toxicity In A Single Effluent Concentration." The monitoring shall be performed as a Fathead Minnow (Pimephales promelas) 24 hour static test, using effluent collected as a 24 hour composite. The effluent concentration at which there may be at no time significant acute mortality is 90% (defined as treatment two in the North Carolina procedure document). Effluent samples for self -monitoring purposes must be obtained during representative effluent discharge at the combined outfall box located below outfalls 001 and 002. The first test will be performed after thirty days from the effective date of this permit during the months of February, May, August, 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, DEM Form AT-2 (original) is to be sent to the following address: Attention: Environmental Sciences Branch North Carolina Division of Environmental Management 4401 Reedy Creek Road Raleigh, N.C. 27607 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 Part I Permit No. NC0003719 chlorine of the effluent toxicity sample must be measured and reported if chlorine is employed for disinfection of the waste stream. 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 any test data from either these monitoring requirements or tests performed by the North Carolina Division of Environmental Management 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 retesting(within 30 days of initial monitoring event). Failure to submit suitable test results will constitute noncompliance with monitoring requirements. 4. OCPSF and Pesticide Scans The perinittee is required to perform quarterly full range OCPSF pollutant and pesticide scans after start-up of the currently planned ICI expansion. These scans shall include all parameters listed as effluent limitations and monitoring requirements for outfall 002 in Part I.A.7 of this permit. The results of OCPSF and pesticide monitoring shall be submitted to the Division within 30 days of receipt of the analytical results final report. This permit shall be modified, or revoked and reissued to incorporate additional OCPSF and pesticide limitations and monitoring requirements in the event the OCPSF and pesticide pollutant scan indicates that increased monitoring frequencies for all or part of the pollutant list are necessary. After eight monitoring events, the permittee may petition the Division to modify requirements for parameters not found to be of significant concern. Part I 5. EFFLUENT LIMITATIONS AND MONITORING REQUIREMENT` - SUMMER (April 1 - October 31) During the period beginning on the effective date of the permit and lasting until expiration, the Permittee is authorized to discharge from outfall serial number 002. Suchdischarges shall be limited and monitored by the permittee as specified below: Effluent Characteristics Discharge Limitations Flow Total Suspended Solids BOD, 5 Day, 20° C COD NH3 - N Fecal Coliform (geometric mean) Total Nitrogen (NO2+NO3+TKN) Total Phosphorous GIyphosate Residual Chlorine Acute Toxicity 2 pH 3 Dissolved Oxygen 4 Temperature Conductivity Monthly Avg. 1.25 MGD 457.0 lbs/day ** 5000.0 lbs/day 35.0 lbs/day Daily Max. 914.0 lbs/day ** 8000.0 lbs/day 70.0 lbs/day Monitoring Measurement Frequency Continuous 3/week 3/week 3/week 3/week 3/week Quarterly Quarterly 2/month 3/week Quarterly 3/week *** *** *** Requirements Sample Sample Type Location 1 Recording I or E Composite E Composite E Composite E Composite E Grab E Composite E Composite E Composite E drab E Composite E Grab E Grab E,U,D Grab E,U,D Grab U,D Footnotes: 1 Sample Locations: E - Effluent, I - Influent, U - Upstream, two miles from outfall, D - Downstream, 100 yards upstream of Lock and Dam #3. 2 Acute Toxicity (Fathead Minnow) P/F at 90%, February, May, August, November; See Part I.A.4 of this permit. Samples for toxicity testing shall be collected at the combined outfall box located below outfalls 001 and 002. 3 The pH shall not be less than 6.0 standard units nor greater than 9.0 standard units. 4 The daily average dissolved oxygen effluent concentration shall not be less than 5.0 mg/l. Monthly Avg. (lbs/day) 350.0 275.0 200.0 ***Effluent monitoring (if required) shall be conducted three times per week. Upstream and downstream monitoring shall be during June, July, August, and September, and once per week during the rest of the year. ** Summer BOD5 limits shall be phased as follows: Effective Dates April 1,1996 - October 31,1996 April 1, 1997 - October 31, 1997 April 1, 1998 - permit expiration • NC00037 19 Daily Max. (lbs/day') 700.0 550.0 400.0 conducted three times per week THERE SHALL BE NO CHROMIUM, ZINC, OR COPPER ADDED TO THE TREATMENT SYSTEM EXCEPT AS PRE -APPROVED ADDITIVES TO BIOCIDAL COMPOUNDS OR THAT WHICH RESULTS FROM THE NORMAL DEGRADATION OF PIPING AND EQUIPMENT USED IN PROCESS UNITS. THERE SHALL BE NO DISCHARGE OF FLOATING SOLIDS OR VISIBLE FOAM IN OTHER THAN TRACE AMOUNTS. (1' Part I 6. EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS - WINTER (November 1- March 31) During the period beginning on the effective date of the permit and lasting until expiration, the Permittee is authorized to discharge from outfall serial number 002. Such discharges shall be limited and monitored by the permittee as specified below: Effluent Characteristics Flow Total Suspended Solids BOD, 5 Day, 20° C COD NH3 - N Fecal Coliform (geometric mean) Total Nitrogen (NO2+NO3+TKN) Total Phosphorous Glyphosate Residual Chlorine Acute Toxicity 2 pH 3 Dissolved Oxygen 4 Temperature Conductivity Discharge Limitations Monthly Avg. 1.25 MGD 457.0 lbs/day ** 5000.0 lbs/day 70.0 lbs/day Daily Max. 914.0 lbs/day ** 8000.0 lbs/day 140.0 lbs/day Monitoring Measurement Frequency Continuous 3/week 3/week 3/week 3/week 3/week Quarterly Quarterly 2/month 3/week Quarterly 3/week *** *** *** Requirements Sample Sample Type Location Recording I or F_ Composite E Composite E Composite E Composite E Grab E Composite E Composite E Composite E Grab E Composite E drab E 'Grab E,U,D Grab E,U,D Grab U,D i NC0003719 Footnotes: 1 Sample Locations: E - Effluent, I - Influent, U - Upstream, two miles from outfall, D - Downstream, 100 yards upstream of Lock and Dam #3. 2 Acute Toxicity (Fathead Minnow) P/F at 90%, February, May, August, November; See Part I.A.4 of this permit. Samples for toxicity testing shall be collected at the combined outfall box located below outfalls 001 and 002. 3 The pH shall not be less than 6.0 standard units nor greater than 9.0 standard units. 4 The daily average dissolved oxygen effluent concentration shall not be less than 5.0 mg/1. ** Winter BOD5 limits shall be phased as follows: Effective Dates permit issuance - March 31, 1996 November 1, 1996 - March 31, 1997 November 1, 1997 - March 31, 1998 November 1, 1998 - permit expiration Monthly Avg. (lbs/day) 700.0 700.0 550.0 400.0 Daily Max. (lbs/day) 1400.0 1400.0 1100.0 800.0 ***Effluent monitoring (if required) shall be conducted three times per week. Upstream and downstream monitoring shall be conducted three times per week during June, July, August, and September, and once per week during the rest of the year. THERE SHALL BE NO CHROMIUM, ZINC, OR COPPER ADDED TO THE TREATMENT SYSTEM EXCEPT AS PRE -APPROVED ADDITIVES TO BIOCIDAL COMPOUNDS OR THAT WHICH RESULTS FROM THE NORMAL DEGRADATION OF PIPING AND EQUIPMENT USED IN PROCESS UNITS. THERE SHALL BE NO DISCHARGE OF FLOATING SOLIDS OR VISIBLE FOAM IN OTHER THAN TRACE AMOUNTS. 1 Part I Permit No. NC0003719 SECTION B: SCHEDULE OF COMPLIANCE 1. The permittee shall comply with Final Effluent Limitations specified for discharges in accordance with the following schedule: Permittee shall comply with Final Effluent Limitations by the effective date of the permit unless specified below. 2. Permittee shall at all times provide the operation and maintenance necessary to operate the existing facilities at optimum efficiency as required under Part III.C.2. Wastewater/Stormwater PART II STORMWATER MONITORING, CONTROLS, AND LIMITATIONS FOR PERMITTED DISCHARGES SECTION A: FINAL LIMITATIONS AND CONTROLS FOR STORMWATER DISCHARGES During the period beginning on the effective date of the permit and lasting until expiration, the Permittee is authorized to discharge wastewater and stormwater associated with industrial activity. Such discharges shall be controlled, limited and monitored as specified below. 1. Stormwater Pollution Prevention Plan The Permittee shall develop a Stormwater Pollution Prevention Plan, herein after referred to as the Plan. This Plan shall be considered public information in accordance with Part II, Standard Conditions, Section E.8. of this permit. 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 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, the name of the receiving water(s) to which the stormwater outfall(s) discharges, or if the discharg;.:s 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. (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. A site map 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, and 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 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 III, Standard Conditions, Section B.11. (3) Part II Page 2 of 4 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 nonstructural 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 shall cover all 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. (2) A schedule to provide secondary containment for bulk storage of liquid materials (excluding water), storage of Section 313 of Title III of the Superfund Amendments and Reauthorization Act (SARA) water priority chemicals, or storage of hazardous materials to prevent leaks and spills from contaminating stormwater runoff. If the secondary containment devices are connected directly to stormwater conveyance systems, the connection shall be controlled by manually activated valves or other similar devices [which shall be secured with a locking mechanism] and any stormwater that accumulates in the containment area shall be at a minimum visually observed for color, foam, and visible sheens, prior to release of the accumulated stormwater. Accumulated stormwater shall be released if found to be uncontaminated. Records documenting the individual making the observation, the description of the accumulated stormwater and the date and time of the release shall be kept for a period of five years. Releases of accumulated stormwater to wastewater treatment facilities do not need to be documented. (3) A narrative description shall be provided of Best Management Practices (BMPs) to be considered such as, but not limited to, oil and grease separation, debris control, vegetative filter strips, infiltration and stormwater detention or retention, where necessary. The need for structural BMPs shall be based on the assessment of potential of sources to contribute significant quantities of pollutants to stormwater discharges and data collected through monitoring of stormwater discharges. (4) Inspection schedules of stormwater conveyances and controls and measures to be taken to limit or prevent erosion associated with the stormwater systems. c. Spill Prevention and Response Plan. The Spill Prevention and Response Plan shall incorporate a risk assessment of potential pollutant sources based on a materials inventory of the facility. Facility personnel (or team) responsible for implementing the plan shall be identified in the plan. A responsible person shall be on -site at all times during facility operations that have the potential to contaminate stormwater runoff through spills or exposure of materials associated with the facility operations. d. Preventative Maintenance and Good Housekeeping Program. A preventative maintenance program shall be developed. The program shall document schedules of inspections and maintenance activities of stormwater control systems, plant equipment and systems the failure of which will result in stormwater discharges of significant material. Inspection of material handling areas and regular cleaning schedules of these areas shall be incorporated into the program. Part II Page 3 of 4 e. Employee Training. Training schedules shall be developed and training provided at a minimum on a biennial basis on proper spill response and cleanup procedures and preventative maintenance activities for all personnel involved in any of the facility's operations that have the potential to contaminate stormwater runoff. Facility personnel (or team) responsible for implementing the training shall be identified in the Plan. f. Responsible Party. The Stormwater Pollution Prevention Plan shall identify a specific position(s) responsible for the overall coordination, development, implementation, and revision to the Plan. Responsibilities for all components of the Plan shall be documented and position(s) assignments provided. Plan Amendment. The permittee shall amend the Plan whenever there is a change in design, construction, operation, or maintenance which has a significant effect on the potential for the discharge of pollutants to surface waters. The Stormwater Pollution Prevention Plan shall be reviewed and updated, if necessary, on an annual basis. The Director may notify the permittee when the Plan does not meet one or more of the minimum requirements of the permit. Within 30 days of such notice, the permittee shall submit a time schedule to the Director for modifying the Plan to meet minimum requirements. The permittee shall provide certification in writing (in accordance with Part III, Standard Conditions, Section B. 11) to the Director that the changes have been made. h. Facility Inspections. Inspections of the facility and all stormwater systems shall occur at a minimum on a semiannual schedule, once in the fall (September -November) and once during the spring (April - June). The inspection and any subsequent maintenance activities performed shall be documented, recording date and time of inspection, individual(s) making the inspection and a narrative description of the facility's stormwater control systems, plant equipment and systems. Records of these inspections shall be incorporated into the Stormwater Pollution Prevention Plan. g• Visual monitoring as required in II.A.3.(b) shall be performed in addition to facility inspections. Implementation. Implementation of the plan shall include documentation of all monitoring, measurements, inspections and maintenance activities and training provided to employees, including the log of the sampling data and of activities taken to implement BMPs associated with the industrial activities, including vehicle maintenance activities. Such documentation shall be kept on -site for a period of five years and made available to the Director or lus authorized representative immediately upon request. 2. Minimum Monitoring and Reporting Requirements Minimum monitoring and reporting requirements are as follows unless otherwise approved in writing by the Director of the Division of Environmental Management. a. Visual monitoring for color, odor, solids, foam, outfall staining, visible sheens and dry weather flow shall be performed at all stormwater discharge outfall locations. All visual monitoring shall be documented and records maintained with the Stormwater Pollution Prevention Plan. The initial visual monitoring event shall be performed simultaneously with the first analytical monitoring event and documentation of only this initial visual monitoring event shall be submitted along with the required analytical monitoring submittal. Part II Page4of4 b . 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 definitions in Part III, Standard Conditions). Failure to monitor representative storm events in accordance with the specified frequency shall constitute a violation of this permit. If the stormwater runoff is controlled by a detention pond, the following sampling requirements shall apply: (1) If the detention pond detains the runoff generated by one inch of rainfall for 24 hours, visual observations for color, foam, outfall staining, visible sheens, and dry weather flow are required, but analytical sampling shall not be required. (2) If the detention pond discharges only in response to a storm event exceeding a 25- year, 24-hour storm (See Part III, Standard Conditions, Section A), the pond shall be considered a non -discharging stormwater control system and not subject to NPDES requirements, unless the discharge causes a violation of water quality standards. c. Samples analyzed in accordance with the terms of this permit shall be submitted on forms provided by the Director no later than January 31 for the previous year in which sampling was required to be performed. d. Analytical results from sampling during the final year of the permit term shall be submitted with the permit renewal application. e. This permit regulates stormwater discharges. Non-stormwater discharges which shall be allowed in the stormwater conveyance system are: (1) All other discharges that are authorized by an NPDES permit. (2) Uncontaminated groundwater, foundation drains, air -conditioner condensate without added chemicals, springs, discharges of uncontaminated potable water, waterline and fire hydrant flushings, water from footing drains, flows from riparian habitats and wetlands. (3) Discharges resulting from fire -fighting. If the storm event monitored and reported in accordance with this permit coincides with an non-stormwater discharge, the permittee shall separately monitor and report all parameters as required under the non-stormwater portion of this permit and provide this information with the stormwater discharge monitoring report. Part II Permit No. NC0003719 3. STORMWATER MONITORING REQUIREMENTS (a) Analytical Monitoring During the period beginning on the effective date of the permit and lasting until expiration, the Permittee is authorized to discharge stormwater originating from point sources including, but not limited to, bulk storage areas, product transfer areas, loading/unloading areas, etc. Such discharges shall be limited and monitored at outfall serial number 001 by the permittee as specified below: Stormwater Discharge Characteristics Total Flow 4 Total Rainfall ' Event Duration4 Total Suspended Solids Nickel Lead Di-n-butyl phthalate Glyphosate Isopropylamine Surfactants (MBAS) Footnotes: 1 2 3 Units MG inches minute mg/1 µ0 mg/1 mg/1 mg/1 mg/1 Monitoring Requirements Cut-off Measurement Sample Sample Concentration) Frequency2 Type Location3 Annual , ' SW-1 Annual - SW- 1 Annual - SW-1 100.00 Annual Grab SW-1 789.00 Annual Grab SW-1 33.78 Annual Grab SW-1 Annual Grab SW-1 Annual Grab SW-1 Annual Grab SW-1 Annual Grab SW-1 For each parameter, the arithmetic mean of all analytical sampling results collected during the term of the permit shall be calculated for each individual outfall and compared to the cut-off concentrations listed. If the arithmetic mean meets the specified cut-off concentration condition for a given parameter, then th,; facility is not required to continue annual analytical monitoring for that parameter at that outfall during the term of the permit except for the last year of the permit term as stated below unless a significant change in facility operations or configuration occurs. If a cut-off con::.entration 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. The permittee must perform analytical sampling during the first 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. Measurement Frequency: Once per yet r. The facility must perform analytical sampling during the first and last year of the permit term regardless of cut-off concentration conditions. A DMR shall be submitted for the months during which a monitored storm event occurs. Sample locations: All stormwater samples shall be collected at the manhole designated SW-1 located north of the river water intake pump overflow and south of the sludge drying beds. Part II Permit No. NC0003719 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 built -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. 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 Part III.A.16). Failure to monitor storm events in accordance with the specified frequency shall constitute a violation of this permit. (b) Visual Monitoring Visual monitoring requires a qualitative visual inspection of each stormwater outfall discharging runoff from production and material handling and storage areas, regardless of representative outfall status, for the purpose of evaluating the effectiveness of the Stormwater Pollution Prevention Plan (SPPP) and assessing new sources of stormwater pollution. No analytical tests are required. Visual monitoring of stormwater outfalls does not need to be performed during a representative storm event. Footnotes: Stormwater Discharge Characteristics Frequencyl Monitoring Type2 Monitoring Location3 Color Semi -Annual Visual SW-1 Odor Semi -Annual Visual I SW-1 Clarity Semi -Annual Visual SW-1 Floating Solids Semi -Annual Visual SW-1 Suspended Solids Semi -Annual Visual SW-1 Foam Semi -Annual Visual SW-1 Oil Sheen Semi -Annual Visual SW-1 Other obvious indicators of stormwater pollution Semi -Annual Visual SW-1 1 Frequency: The first visual monitoring event during the term of the permit must be performed during the initial analytical monitoring event. All subsequent visual monitoring will he performed twice per year, once in the spring and once in the fall. 2 Monitoring Type: Visual monitoring requires a qualitative visual observation of each stormwater outfall. No analytical testing or sampling is required. 3 Visual monitoring may be performed just inside the perimeter fence at a point where no additional significant materials could reasonably enter the system as a result of facility operations. Part II Permit No. NC0003719 SECTION B: SCHEDULE OF COMPLIANCE 1. The permittee shall comply with stormwater monitoring requirements and controls specified for stormwater discharges in accordance with the following schedule: The Stormwater Pollution Prevention Plan shall be developed and implemented within 12 months of the effective. date of this permit and updated thereafter on an annual basis. Secondary containment, as specified in Part II, Section A.1.b.2. of this permit, shall be accomplished. within 12 months of the effective date of this permit. 2. The permittee shall at all times provide the operation and maintenance necessary to operate the permitted stormwater controls at optimum efficiency. SECTION C: SPECIAL CONDITIONS 1. 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. Should the facility configuration, drainage areas and activities, and/or stormwater ontfalls on -site be significantly altered, the permittee shall notify the Division in writing prior t^ implementation of said changes. Wastewater/Stormwater PART III STANDARD CONDITIONS FOR NPDES PERMITS SECTION A: DEFINITIONS 1. Act or "the Act" The Federal Water Pollution Control Act, also known as the Clean Water Act, as amended, 33 USC 1251, et. seq. 2. Best Management Practices (BMPs) Schedules of activities, prohibitions of practices, maintenance procedures, and other management practices to prevent or reduce the pollution of waters of the United States. BMPs also include treatment requirements, operation procedures, and practices to control plant site runoff, spillage or leaks, sludge or waste disposal, or drainage from raw material storage. 3. Bulk Storage of Liquid Products Liquid raw materials, manufactured products, waste materials or by-products with a single above ground storage container having a capacity of greater than 660 gallons or with multiple above ground storage containers having a total storage capacity of greater than 1,320 gallons. 4. Calculation of Means a Arithmetic Mean: The arithmetic mean of any set of values is the summation of the individual values divided by the number of individual values. b. Geometric Mean: The geometric mean of any set of values is the Nth root of the product of the individual values where N is equal to the number of individual values. The geometric mean is equivalent to the antilog of the arithmetic mean of the logarithms of the individual values. For purposes of calculating the geometric; mean, values of zero (0) shall be considered to be one (1). c. Weighted by Flow Value: Weighted by flow value means the summation of each concentration times its respective flow divided by the summation of the respective flows. 5. Calendar Day A calendar day is defined as the period from midnight of one day until midnight of the next day. However, for purposes of this permit, any consecutive 24-hour period that reasonably represents the calendar day may be used for sampling. 6. Coal Pile Runoff The rainfall runoff from or through any coal storage pile. Part III 7. Concentration Measurement Page 2 of 20 a. The "average monthly concenuation," other than for fecal coliform bacteria, is the sum of the concentrations of all daily discharges sampled and/or measured during a calendar month on which daily discharges are sampled and measured, divided by the number of daily discharges sampled and/or measured during such month (arithmetic mean'of the daily concentration values). The daily concentration value is equal to the concentration of a composite sample or in the case-- of grab samples is the -arithmetic mean (weighted by flow value) of all the samples collected during that calendar day. The average monthly count for fecal coliform bacteria is the geometric mean of the counts for samples collected during a calendar month. This limitation is identified as "Monthly Average" under "Other Limits" in Part I of the permit. b. The "average weekly concentration," other than for fecal coliform bacteria, is the sum of the concentrations of all daily discharges sampled and/or measured during a calendar week (Sunday/Saturday) on which daily discharges are sampled and measured divided by the number of daily discharges sampled and/or measured during such week (arithmetic mean of the daily concentration values). The daily concentration value is equal to the concentration of a composite sample or in the case of grab samples is the arithmetic mean (weighted by flow value) of all the samples collected during that calendar day. The average weekly count for fecal coliform bacteria is the geometric mean of the counts for samples collected during a calendar week. This limitation is identified as "Weekly Average" under "Other Limits" in Part I of the permit. c. The "maximum daily concentration" is the concentration of a pollutant discharge during a calendar day. If only one sample is taken during any calendar day the concentration of pollutant calculated from it is the "Maximum Daily Concentration". It is identified as "Daily Maximum" under "Other Limits" in Part I of permit. d. The "average annual concentration," other than for fecal coliform bacteria, is the sum of the concentrations of all daily discharges sampled and/or measured during a calendar year on which daily discharges are sampled and measured divided by the number of daily discharges sampled and/or measured during such year (arithmetic mean of the daily concentration values). The daily concentration value is equal to the concentration of a composite sample or in the case of grab samples is the arithmetic mean (weighted by flow value) of all the samples collected during that calendar day . The average yearly count for fecal coliform bacteria is the geometric mean of the counts for samples collected during a calendar year. This limitation is identified as "Annual Average" under "Other Limits" in Part I of the permit. e. The "daily average concentration" (for dissolved oxygen) is the minimum allowable amount of dissolved oxygen required to be available in the effluent prior to discharge averaged over a calendar day. If only one dissolved oxygen sample is taken over a calendar day, the sample is considered to be the "daily average concentration" for the discharge. It is identified as "daily average" in the text of Part I. f. The "quarterly average concentration" is the average of all samples taken over a calendar quarter. It is identified as "Quarterly Average Limitation" in the text of Part I of the permit. A calendar quarter is defined as one of the following distinct periods: January through March, April through June, July through September, and October through December. g. Part III 8. DEM or Division, Page 3 of 20 Means the Division of Environmental Management, Department of Environment, Health and Natural Resources. 9. EM Used herein means the North Carolina Environmental Management Commission. 10. Hazardous Substance A hazardous substance means any substance designated under 40 CFR Part 116 pursuant to Section 311 of the Clean Water Act. 11. Landfill A disposal facility or part of a disposal facility where waste is placed in or on land and which is not a land treatment facility, a surface impoundment, an injection well, a hazardous waste long-term storage facility or a surface storage facility. 12. Mass/Day Measurements a. The "monthly average discharge" is defined as the total mass of all daily discharges sampled and/or measured during a calendar month on which daily discharges are sampled and measured, divided by the number of daily discharges sampled and/or measured during such month. It is therefore, an arithmetic mean found by adding the weights of the pollutant found each day of the month and then dividing this sum by the number of days the tests were reported. The limitation is identified as "Mc-nthly Average" in Part I of the permit. b. The "weekly average discharge" is defined as the total mass of all daily discharges sampled and/or measured during the calendar week (Sunday - Saturday) on which daily discharges are sampled and measured, divided by the number of daily discharges sampled and/or measured during such week. It is, therefore, an arithmetic mean found by adding the weights of pollutants found each day of the week and then dividing this sum by the number of days the tests were reported. This limitation is identified as "Weekly Average" in Part I of the permit. c. The "maximum daily discharge" is the total mass (weight) of a pollutant discharged during a calendar day. If only one sample is taken during any calendar day the weight of pollutant calculated from it is the "maximum daily discharge." This limitation is identified as "Daily Maximum," in Part I of the permit. d. The "average annual discharge" is defined as the total mass of all daily discharges sampled and/or measured during the calendar year on which daily discharges are sampled and measured, divided by the number of daily discharges sampled and/or measured during such year. It is, therefore, an arithmetic mean found by adding the weights of pollutants found each day of the year and then dividing this sum by the number of days the tests were reported. This limitation is defined as "Annual Average" in Part I of the permit. Part III 13. Other Measurements Page 4 of 20 a. Flow, (MGD): The flow limit expressed in this permit is the 24 hours average flow, averaged monthly. It is determined as the arithmetic mean of the total daily flows recorded during the calendar month. b. An "instantaneous flow measurement" is a measure of flow taken at the time of sampling, when both the sample and flow will be representative of the total discharge. c. A "continuous flow measurement" is a measure of discharge flow from the facility which occurs continually without interruption throughout the operating hours of the facility. Flow shall be monitored continually except for the infrequent times when there may be no flow or for infrequent maintenance activities on the flow device. 14. Permit Issuing Authority The Director of the Division of Environmental Management. 15. Point Source Discharge Any discernible, confined and discrete conveyance, including but specifically not limited to, any pipe, ditch, channel, tunnel, conduit, well, discrete fissure, container, rolling stock, or concentrated animal feeding operation from which pollutants are or may be discharged to waters of the state. 16. Representative Storm Event A storm- vent that measures greater than 0.1 inches of rainfall and that is preceded by at least 72 hours in which no storm event measuring greater than 0.1 inches has occurred. A single storm event may contain up to 10 consecutive hours of no precipitation. For example, if it rains for 2 hours without producing any collectable discharge, and then stops, a sample may be collected if a rain producing a discharge begins again within the next 10 hours. 17. Runoff Coefficient The fraction of total rainfall that is not infiltrated into or otherwise retained by the soli, concrete, asphalt or other surface upon which it falls that will appear at the conveyance as runoff. 18. Sample Types a. Composite Sample: A composite sample shall consist of: (1) a series of grab samples collected at equal time intervals over a 24 hour period of discharge and combined proportional to the rate of flow measured at the time of individual sample collection, or (2) a series of grab samples of equal volume collected over a 24 hour period with the time intervals between samples determined by a preset number of gallons passing the sampling point. Flow measurement between sample intervals shall be determined by use of a flow recorder and totalizer, and the present gallon interval between sample collection fixed at no greater than 1/24 of the expected total daily flow at the treatment system, or Part III Page 5 of 20 (3) a single, continuous sample collected over a 24 hour period proportional to the rate of flow. (4) a series of grab samples collected at equal time intervals over a 24 hour period at a constant time interval where the grab samples shall be collected at intervals no greater than 20 minutes apart during any 24 hour period and must be of equal size and of no less than 100 milliliters. In accordance with (1) above, the time interval between influent grab samples shall be no greater than once per hour, and the time interval between effluent grab samples shall be no greater than once per hour except at wastewater treatment systems having a detention time of greater than 24 hours. In such cases, effluent grab samples may be collected at time intervals evenly spaced over the 24 hour period which are equal in number of hours to the detention time of the system in number of days. However, in no case may the time interval between effluent grab samples be greater than six (6) hours nor the number of samples less than four (4) during a 24 hour sampling period. b. Grab Sample: Grab samples are individual samples collected over a period of time not exceeding 15 minutes; the grab sample can be taken manually. Grab samples must be representative of the discharge or the receiving waters. 19. Secondary Containment Spill containment for the contents of the single largest tank within the containment structure plus sufficient freeboard to allow for the 25-year, 24-hour storm event. 20. Section 313 Water Priority Chemical A chemical or chemical category which: a. Is listed in 40 CFR 372.65 pursuant to Section 313 of Title III of the Superfund Amendments and Reauthorization Act (SARA) of 1986, also titled the Emergency Planning and Community Right -to -Know Act of 1986; b. Is present at or above threshold levels at a facility subject to SARA title III, Section 313 reporting requirements; and c. That meet at least one of the following criteria: (1) Is listed in appendix D of 40 CFR part 122 on either Table II (organic priority pollutants), Table III (certain metals, cyanides, and phenols) or Table IV (certain toxic pollutants and hazardous substances); (2) Is listed as a hazardous substance pursuant to section 311(b)(2)(A) of the CWA at 40 CFR 116.4; or (3) Is a pollutant for which EPA has published acute or chronic water quality criteria. 21. Significant Materials Includes, but is not limited to: raw materials; fuels; materials such as solvents, detergents, and plastic pellets; finished materials such as metallic products; raw materials used in food processing or production; hazardous substances designated under section 101(14) of CERCLA; any chemical the facility is required to report pursuant to section 313 of Title Part III Page 6 of 20 III of SARA; fertilizers; pesticides; and waste products such as ashes, slag and sludge that have the potential to be released with stormwater discharges. 22. Significant Spills Includes, but is not limited to: releases of oil or hazardous substances in excess of reportable quantities under section 311 of the Clean Water Act (Ref: 40 CFR 110.10 and CFR 117.21) or section 102 of CERCLA (Ref: 40 CFR 302.4). 23. Stormwater Runoff The flow of water which results from precipitation and which occurs immediately following rainfall or as a result of snowmelt. 24. Stormwater Associated with Industrial Activity The discharge from any point source which is used for collecting and conveying stormwater and which is directly related to manufacturing, processing or raw material storage areas at an industrial site. The term does not include discharges from facilities or activities excluded from the NPDES program. The following categories of facilities are considered to be engaging in "industrial activity": a. Facilities subject to stormwater effluent limitations guidelines, new source performance standards, or toxic pollutant effluent standards under 40 CFR Subchapter N Parts 400 - 471 (except facilities which are exempted under (k) of this definition); b. Facilities classified as Standard Industrial Classificapr.ns 24 (except 2434), 26 (except 265 and 267), 28, 29, 30, 311, 32, 33, 3441, 373; c. Facilities classified as Standard Industrial Classifications 10 through 14 (mineral industry) including active or inactive mining operations (except for areas of coal mining operations meeting the definition of a reclamation area under 40 CFR 434.11(1)) and oil and gas exploration, production, processing, or treatment operations, or transmission facilities that discharge stormwater contaminated by contact with or that has come in contact with, any overburden, raw material, intermediate products, finished products, byproducts or waste products located on the site of such operations; inactive mining operations are mining sites that are not being actively mined, but which have an identifiable owner/operator; d. Hazardous waste treatment, storage, or disposal facilities, including those that are operating under interim status or a permit under Subtitle C of RCRA; e. Landfills, land application sites, and open dumps that receive or have received any industrial wastes (waste that is received from any of the facilities described under this definition) including those that are subject to regulation under Subtitle D of RCRA; f. Facilities involved in the recycling of materials, including metal scrapyards, battery reclaimers, salvage yards and automobile junkyards, including but limited to those classified as Standard Industrial Classification 5015 and 5093; g. Steam electric power generating facilities, including coal handling sites; Part III Page 7 of 20 h. Transportation facilities classified as Standard Industrial Classifications 40, 41, 42, 44, and 45 which have vehicle maintenance shops, equipment cleaning operations, or airport deicing operations. Only those portions of the facility that are either involved in vehicle maintenance (including vehicle rehabilitation, mechanical repairs, painting, fueling and lubrication), equipment cleaning operations, airport deicing operations, or which are otherwise identified under (a)-(g) or (i)-(k) of this definition are associated with industrial activity; i. Treatment works treating domestic sewage or any other sewage sludge or wastewater treatment device or system, used in the storage treatment, recycling, and reclamation of municipal or domestic sewage, including lands dedicated to the disposal of sewage sludge that are located within the confines of the facility, with a design flow of 1.0 mgd or more, or required to have an approved pretreatment program under 40 CFR part 403. Not included are farm lands, domestic gardens or lands used for sludge management where sludge is beneficially reused and which are not physically located in the confines of the facility, or areas that are in compliance with section 405 of the CWA; J. Construction activity including clearing, grading and excavation activities except: operations that result in the disturbance of less that five acres of total land area which are not part of a larger common plan of development or sale; k. Facilities under Standard Industrial Classifications 20, 21, 22, 23, 2434, 25, 265, 267, 27, 283, 285, 30, 31 (except 311), 323, 34 (except 3441), 35, 36, 37 (except 373), 38, 39, 4221-25, (and which are not otherwise included within (a)-(j) of this definition). For the categories of industries identified in (a) through (j) of this definition the term includes, but is not limited to, stormwater discharges from industrial plant yards; immediate access roads and rail lines used or traveled by...Triers of raw materials, manufactured products, waste material, or by-products used or created by the facility; material handling sites; refuse sites; sites used for the application or disposal of process wastewaters; sites used for the storage and maintenance of material handling equipment; sites used for residual treatment, storage, or disposal; shipping and receiving areas; manufacturing buildings; storage areas (including tank farms) for raw materials, and intermediate and finished products; and areas where industrial activity has taken place in the past and significant materials remain and are exposed to stormwater. For the categories of industries identified in (k), the term includes only stormwater discharges from all areas listed in the previous sentence (except access roads) where material handling equipment or activities, raw material, intermediate products, final products, waste material, by-products, or industrial machinery are exposed to stormwater. Material handling activities include the: storage, loading and unloading, transportation, or conveyance of any raw material, intermediate product, finished product, by-product or waste product. The term excludes areas located on plant lands separated from the plant's industrial activities, such as office buildings and accompanying parking lots as long as the drainage from the excluded areas is not mixed with stormwater drained from the above described areas. Industrial facilities (including industrial facilities that are Federally or municipally owned or operated that meet the description of the facilities listed in (a)-(k)) include those facilities designated under 40 CFR 122.26(a)(1)(v). Part III Page 8 of 20 25. Ten Year Design Storm The precipitation event of a duration which will produce the maximum peak rate of runoff for the watershed of interest resulting from a rainfall event of an intensity expected to be equaled or exceeded, on the average, once in ten years. 26. Total Flow The flow corresponding to the time period over which the sample collection occurs. The tot4I flow calculated based on the size of the area draining to the outfall, the amount of the built -upon (impervious) surfaces within the drainage area, and the total amount of rainfall occurring during the sampling period. 27. Toxic Pollutant A toxic pollutant is any pollutant listed as toxic under Section 307(a)(1) of the Clean Water Act. 28. vehicle Maintenance Activity Vehicle rehabilitation, mechanical repairs, painting, fueling, lubrication, vehicle cleaning operations, or airport deicing operations. 29. Visible Sedimentation Solid particulate matter, both mineral and organic, that has been or is being transported by water, air, gravity, or ice from its site of origin which can be seen with the unaided eye. 30. Waste Pile Any non -containerized accumulation of solid, non -flowing waste that is used for treatment or storage. SECTION B. GENERAL CONDITIONS 1. Duty to Comply The permittee must comply with all conditions of this permit. Any permit noncompliance constitutes a violation of the Clean Water Act and is grounds for enforcement action; for permit termination, revocation and reissuance, or modification; or denial of a permit renewal application. a. The permittee shall comply with effluent standards or prohibitions established under section 307(a) of the Clean Water Act for toxic pollutants and with standards for sewage sludge use or disposal established under section 405(d) of the Clean Water Act within the time provided in the regulations that establish these standards or prohibitions or standards for sewage sludge use or disposal, even if the permit has not yet been modified to incorporate the requirement. Part III Page 9 of 20 b. The Clean Water Act provides that any person who violates a permit condition is subject to a civil penalty not to exceed $25,000 per day for each violation. Any person who negligently violates any permit condition is subject to criminal penalties of $2,500 to $25,000 per day of violation, or imprisonment for not more than 1 year, or both. Any person who knowingly violates permit conditions is subject to criminal penalties of $5,000 to $50,000 per day of violation, or imprisonment for not more than 3 years, or both. Also, any person who violates a permit condition may be assessed an administrative penalty not to exceed $10,000 per violation with the maximum amount not to exceed $125,000. [Ref: Section 309 of the Federal Act 33 U.S.C. 1319 and 40 CFR 122.41 (a)] c. Under state law, a civil penalty of not more than ten thousand dollars ($10,000) per violation may be assessed against any person who violates or fails to act in accordance with the terms, conditions, or requirements of a permit. [Ref: North Carolina General Statutes § 143-215.6A] d. Any person may be assessed an administrative penalty by the Administrator for violating section 301, 302, 306, 307, 308, 318, or 405 of the Act, or any permit condition or limitation.inplementing any of such sections in a permit issued under section 402 of the Act. Administrative penalties for Class I violations are not to exceed $10,000 per violation, with the maximum amount of any Class I penalty assessed not to exceed $25,000. Penalties for Class II violations are not to exceed $10,000 per day for each day during which the violation continues, with the maximum amount of any Class II penalty not to exceed $125,000. 2. Duty to Mitigate The permittee shall take all reasonable steps to minimize or prevent any discharge or :,ludge use or disposal in violation of this permit which has a reasonable likelihood of adversely affecting human health or the environment. 3. Civil and Criminal Liability Except as provided in permit conditions on "Bypassing" and "Power Failures", nothing in this permit shall be construed to relieve the permittee from any responsibilities, liabilities, or penalties for noncompliance pursuant to NCGS 143-215.3,143-215.6 or Section 309 of the Federal Act, 33 USC 1319. Furthermore, the permittee is responsible for consequential damages, such as fish kills, even though the responsibility for effective compliance may be temporarily suspended. 4. Oil. and Hazardous Substance Liability 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 to which the permittee is or may be subject to under NCGS 143-215.75 et seq. or Section 311 of the Federal Act, 33 USG 1321. Furthermore, the permittee is responsible for consequential damages, such as fish kills, even though the responsibility for effective compliance may be temporarily suspended. 5. Property Rights The issuance of 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 Part III Page 10 of 20 or any invasion of personal rights, nor any infringement of Federal, State or local laws or regulations. 6. Onshore or Offshore Construction This permit does not authorize or approve the construction of any onshore or offshore physical structures or facilities or the undertaking of any work in any navigable waters. 7. 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 circumstances, is held invalid, the application of such provision to other circumstances, and the remainder of this permit, shall not be affected thereby. 8. Duty to Provide Information The permittee shall furnish to the Permit Issuing Authority, within a reasonable time, any information which the Permit Issuing,Authority may request to determine whether cause exists for modifying, revoking and reissuing, or terminating this permit or to determine compliance with this permit. The permittee shall also furnish to the Permit Issuing Authority upon request, copies of records required to be kept by this permit. 9. Duty to Reapply If the permittee wishes to continue an activity regulated by this permit after the expiration date of this permit, the permittee must apply for and obtain a new permit. 10. Expiration of Permit The permittee is not authorized to discharge after the expiration date. In order to receive automatic authorization to discharge beyond the expiration date, the permittee shall submit such information, forms, and fees as are required by the agency authorized to issue permits no later than 180 days prior to the expiration date. Any permittee that has not requested renewal at least 180 days prior to expiration, or any permittee that does not have a permit after the expiration and has not requested renewal at least 180 days prior to expiration, will subject the permittee to enforcement procedures as provided in NCGS 143-215.6 and 33 USC 1251 et. seq. 11. Signatory Requirements All applications, reports, or information submitted to the Permit Issuing Authority shall be signed and certified. a. All permit applications shall be signed as follows: (1) For a corporation: by a responsible corporate officer. For the purpose of this Section, a responsible corporate officer means: (a) a president, secretary, treasurer or vice president of the corporation in charge of a principal business function, or any other person who performs similar policy or decision making functions for the corporation, or (b) the manager of one or more manufacturing production or operating facilities employing more than 250 persons or having gross annual sales or expenditures exceeding 25 million (in second quarter 1980 Part III Page 11 of 20 dollars), if authority to sign documents has been assigned or delegated to the manager in accordance with corporate procedures. (2) For a partnership or sole proprietorship: by a general partner or the proprietor, respectively; or (3) For a municipality, State, Federal, or other public agency: by either a principal executive officer or ranking elected official. b. All reports required by the permit and other information requested by the Permit Issuing Authority shall be signed by a person described above or by a duly authorized representative of that person. A person is a duly authorized representative only if: (1) The authorization is made in writing by a person described above; (2) The authorization specified either an individual or a position having responsibility for the overall operation of the regulated facility or activity, such as the position of plant manager, operator of a well or well field, superintendent, a position of equivalent responsibility, or an individual or position haying overall responsibility for environmental matters for the company. (A duly authorized representative may thus be either a named individual or any individual occupying a named position.); and (3) The written authorization is submitted to the Permit Issuing Authority. c. Certification. Any person signing a document under paragraphs a. or b. of this section shall make the following certification: "I certify, under penalty of law, that this c :cument and all attachments were prepared under my direction or supervision in accordance with a system designed to assure that qualified personnel properly gather and evaluate the information submitted. Based on my inquiry of the person or persons who manage the system, or those persons directly responsible for gathering the information, the information submitted is, to the best of my knowledge and belief, true, accurate, and complete. I am aware that there are significant penalties for submitting false information, including the possibility of fines and imprisonment for knowing violations." 12. Permit Actions This permit may be modified, revoked and reissued, or terminated for cause. The filing of a request by the permittee for a permit modification, revocation and reissuance, or termination, or a notification of planned changes or anticipated noncompliance does not stay any permit condition. 13. Permit Modification. Revocation and Reissuance. or Termination The issuance of this permit does not prohibit the permit issuing authority from reopening and modifying the permit, revoking and reissuing the permit, or terminating the permit as allowed by the laws, rules, and regulations contained in Title 40, Code of Federal Regulations, Parts 122 and 123; Title 15A of the North Carolina Administrative Code, Subchapter 2H .0100; and North Carolina General Statute 143-215.1 et. al. Part III 14. Previous Permits Page 12 of 20 All previous National Pollutant Discharge Elimination System Permits issued to this facility, whether for operation or discharge, are hereby revoked by issuance of this permit. [The exclusive authority to operate this facility arises under this permit. The authority to operate the facility under previously issued permits bearing this number is no longer effective. ] The conditions, requirements, terms, and provisions of this permit authorizing discharge under the National Pollutant Discharge Elimination System govern discharges from this facility. SECTION C. OPERATION AND MAINTENANCE OF POLLUTION CONTROLS 1. Certified Operator Pursuant to Chapter 90A-44 of North Carolina General Statutes, and upon classification of the facility by the Certification Commission, the permittee shall.employ a certified wastewater treatment plant operator in responsible charge (ORC) of the wastewater treatment facilities. Such operator must hold a certification of the grade equivalent to or greater than the classification assigned to the wastewater treatment facilities by the Certification Commission. The permittee must also employ a certified back-up operator of the appropriate type and any grade to comply with the conditions of Title 15A, Chapter 8A .0202. The ORC of the facility must visit each Class I facility at least weekly and each Class II, III, and IV facility at least daily, excluding weekends and holidays, and must properly manage and document daily operation and maintenance of the facility and must comply with all other conditions of Title 15A, Chapter 8A .0202. Once the facility is classified, the permittee shall submit a letter to the Certification Commissi n which designates the operator in responsible charge within thirty days after the wastewater treatment facilities are 50% complete. 2. Proper Operation and Maintenance The permittee shall at all times properly operate and maintain all facilities and systems of treatment and control (and related appurtenances) which are installed or used by the permittee to achieve compliance with the conditions of this permit. Proper operation and maintenance also includes adequate laboratory controls and appropririatc quality a;:burance procedures. This provision requires the operation of back-up or auxiliary facilities or similar systems which are installed by a permittee only when the operation is necessary to achieve compliance with the conditions of the permit. 3. Need to Halt or Reduce not a Defense It shall not be a defense for a permittee in an enforcement action that it would have been necessary to halt or reduce the permitted activity in order to maintain compliance with the condition of this permit. Part III 4. Bypassing of Treatment Facilities a. Definitions Page 13 of 20 (1) "Bypass" means the known diversion of waste streams from any portion of a treatment facility including the collection system, which is not a designed or established or operating mode for the facility. (2) "Severe property damage" means substantial physical damage to property, damage to the treatment facilities which causes them to become inoperable, or substantial and permanent loss of natural resources which can reasonably be expected to occur in the absence of a bypass. Severe property damage does not mean economic loss caused by delays in production. b. Bypass not exceeding limitations. The permittee may allow any bypass to occur which does not cause effluent limitations to be exceeded, but only if it also is for essential maintenance to assure efficient operation. These bypasses are not subject to the provisions of Paragraphs c. and d. of this section. c. Notice (1) Anticipated bypass. If the permittee knows in advance of the need for a bypass, it shall submit prior notice, if possible at least ten days before the date of the bypass; including an evaluation of the anticipated quality and affect of the bypass. (2) Unanticipated bypass. The permittee shall submit notice of an unanticipated bypass as required in Part III, E. 6. of this permit. d. Prohibition of Bypass (1) Bypass is prohibited and the Permit Issuing Authority may take enforcement action against a permittee for bypass, unless: (i) Bypass was unavoidable to prevent loss of life, personal injury or severe property damage; (ii) There were no feasible alternatives to the bypass, such as the use of auxiliary treatment facilities, retention of untreated wastes or maintenance during normal periods of equipment downtime. This condition is not satisfied if adequate backup equipment should have been installed in the exercise of reasonable engineering judgment to prevent a bypass which occurred during normal periods of equipment downtime or preventive maintenance; and (iii) The permittee submitted notices as required under Paragraph c. of this section. (2) The Permit Issuing Authority may approve an anticipated bypass, after considering its adverse affects, if the Permit Issuing Authority determines that it will meet the three conditions listed above in Paragraph d. (1) of this section. Part III 5. Upsets a. Definition. Page 14 of 20 "Upset " means an exceptional incident in which there is unintentional and temporary noncompliance with technology based permit effluent limitations because of factors beyond the reasonable control of the permittee. An upset does not include noncompliance to the extent caused by operational error, improperly designed treatment facilities, inadequate treatment facilities, lack of preventive maintenance, or careless or improper operation. b. Effect of an upset. An upset constitutes an affirmative defense to an action brought for noncompliance with such technology based permit effluent limitations if the requirements of paragraph c. of this condition are met. No determination made during administrative review of claims that noncompliance was caused by upset, and before an action for noncompliance, is final administrative action subject to judicial review. c. Conditions necessary for a demonstration of upset. A permittee who wishes to establish the affirmative defense of upset shall demonstrate, through properly signed, contemporaneous operating logs, or other relevant evidence that: (1) An upset occurred and that the permittee can identify the cause(s) of the upset; (2) The permittee facility was at the time being properly operated; and (3) The permittee submitted notice of the upset as required in Part III, E. 6. (b) of this permit. (4) The permittee complied with any remedial measures required under Part III, B. 2. of this permit. d. Burden of proof. In any enforcement proceeding the pellnitiee seeking to establish ttiG ULL u1ic I1 .G of 11L upset has the burden of proof. 6. Removed Substances Solids, sludges, filter backwash, or other pollutants removed in the course of treatment or control of wastewaters shall be utilized/disposed of in accordance with NCGS 143-215.1 and in a manner such as to prevent any pollutant from such materials from entering waters of the State or navigable waters of the United States. The permittee shall comply with all existing federal regulations governing the disposal of sewage sludge. Upon promulgation of 40 CFR Part 503, any permit issued by the Permit Issuing Authority for the utilization/disposal of sludge may be reopened and modified, or revoked and reissued, to incorporate applicable requirements at 40 CFR Part 503. The permittee shall comply with applicable 40 CFR Part 503 Standards for the Use and Disposal of Sewage Sludge (when promulgated) within the time provided in the regulation, even if the permit is not modified to incorporate the requirement. The permittee shall notify the Permit Issuing Authority of any significant change in its sludge use or disposal practices. Part III Page 15 of 20 7. Power Failures The permittee is responsible for maintaining adequate safeguards as required by DEM Regulation, Title 15A, North Carolina Administrative Code, Subchapter 2H, .0124 Reliability, to prevent the discharge of untreated or inadequately treated wastes during electrical power failures either by means of alternate power sources, standby generators or retention of inadequately treated effluent. SECTION D. MONITORING AND RECORDS 1. Representative Sampling Samples collected and measurements taken, as required herein, shall be characteristic of the volume and nature of the permitted discharge. Samples collected at a frequency less than daily shall be taken on a day and time that is characteristic of the discharge over the entire period which the sample represents. All samples shall be taken at the monitoring points specified in this permit and, unless otherwise specified, before the effluent joins or is diluted by any other wastestream, body of water, or substance. Monitoring points shall not be changed without notification to and the approval of the Permit Issuing Authority. 2. Reporting Monitoring results obtained during the previous month(s) shall be summarized for each month and reported on a monthly Discharge Monitoring Report (DMR) Form (DEM No. MR 1,1.1, 2, or alternative forms approved by the Director, DEM, postmarked no later than the 30th day following the completed reporting period. The first DMR is due on the last day of the month following the issuance of the permit or in the case of a new facility, on the last day of the month following the commencement of discharge. Duplicate signed copies of these, and all other reports required herein, shall be submitted to the following address: Division of Environmental Management Water Quality Section ATTENTION: Central Files Post Office Box 29535 Raleigh, North Carolina 27626-0535 3. Flow Measurements Appropriate flow measurement devices and methods consistent with accepted scientific practices shall be selected and used to ensure the accuracy and reliability of measurements of the volume of monitored discharges. The devices shall be installed, calibrated and maintained to ensure that the accuracy of the measurements are consistent with the accepted capability of that type of device. Devices selected shall be capable of measuring flows with a maximum deviation of less than 10% from the true discharge rates throughout the range of expected discharge volumes. Once -through condenser cooling water flow which is monitored by pump logs, or pump hour meters as specified in Part I of this permit and based on the manufacturer's pump curves shall not be subject to this requirement. LL Part III Page 16 of 20 4. Test Procedures Test procedures for the analysis of pollutants shall conform to the EMC regulations published pursuant to NCGS 143-215.63 et. seq, the Water and Air Quality Reporting Acts, and to regulations published pursuant to Section 304(g), 33 USC 1314, of the Federal Water Pollution Control Act, as Amended, and Regulation 40 CFR 136; or in the case of sludge use or disposal, approved under 40 CFR 136, unless otherwise specified in 40 CFR 503, unless other test procedures have been specified in this permit. To meet the intent of the monitoring required by this permit, all test procedures must produce minimum detection and reporting levels that are below the permit discharge requirements and all data generated must be reported down to the minimum detection or lower reporting level of the procedure. If no approved methods are determined capable of achieving minimum detection and reporting levels below permit discharge requirements, then the most sensitive (method with the lowest possible detection and reporting level) approved method must be used. 5. Penalties for Tampering The Clean Water Act provides that any person who falsifies, tampers with, or knowingly renders inaccurate, any monitoring device or method required to be maintained under this permit shall, upon conviction, be punished by a fine of not more than $10,000 per violation, or by imprisonment for not more than two years per violation, or by both. If a conviction of a person is for a violation committed after a first conviction of such person under this paragraph, punishment is a fine of not more than $20,000 per day of violation, or by imprisonment of not more than 4 years, or both. • 6. Records Retention Except for records of monitoring information required by this permit related to the permittee's sewage sludge use and disposal activities, which shall be retained for a period of at least five years (or longer as required by 40 CFR 503), the permittee shall retain records of all monitoring information, including all calibration and maintenance records and all original strip chart recordings for continuous monitoring instrumentation, copies of all reports required by this permit, for a period of at least 3 years from the date of the sample, measurement, report or application. This period may be extended by request of the Director at any time. 7. Recording Results For each measurement or sample taken pursuant to the requirements of this permit, the permittee shall record the following information: a. The date, exact place, and time of sampling or measurements; b. The individual(s) who performed the sampling or measurements; c. The date(s) analyses were performed; d. The individual(s) who performed the analyses; e. The analytical techniques or methods used; and f. The results of such analyses. Part III 8. Inspection and Entry Page 17 of 20 The permittee shall allow the Director, or an authorized representative (including an authorized contractor acting as a representative of the Director), upon the presentation of credentials and other documents as may be required by law, to; a. Enter upon the permittee's premises where a regulated facility or activity is located or conducted, or where records must be kept under the conditions of this permit; b. Have access to and copy, at reasonable times, any records that must be kept under the conditions of this permit; c. Inspect at reasonable times any facilities, equipment (including monitoring and control equipment), practices, or operations regulated or required under this permit; and d. Sample or monitor at reasonable times, for the purposes of assuring permit compliance or as otherwise authorized by the Clean Water Act, any substances or parameters at any location. SECTION E. REPORTING REQUIREMENTS 1. Change in Discharge All discharges authorized herein shall be consistent with the terms and conditions of this permit. The discharge of any pollutant identified D. this permit more frequently than or at a level in excess of that authorized shall constitute a violation of the permit. 2. Planned Changes The permittee shall give notice to the Director as soon as possible of any planned physical alterations or additions to the permitted facility. Notice is required only when: a. The alteration or addition to a permitted facility may meet one of the criteria for determ.n;^g whether a facility is a new source in 40 CFR Part 122.29 (b), b. The alteration or addition could significantly change the nature or increase the quantity of pollutants discharged. This notification applies to pollutants which are subject neither to effluent limitations in the permit, nor to notification requirements under 40 CFR Part 122.42 (a) (1). c. The alteration or addition results in a significant change in the permittee's sludge use or disposal practices, and such alternation, addition or change may justify the application of permit conditions that are different from or absent in the existing permit, including notification of additional use or disposal sites not reported during the permit application process or not reported pursuant to an approved land application plan. Part III Page 18 of 20 3. Anticipated Noncompliance The permittee shall give advance notice to the Director of any planned changes in the permitted facility or activity which may result in noncompliance with permit requirements. 4. Transfers This permit is not transferable to any person except after notice to the Director. The Director may require modification or revocation and reissuance of the permittee and incorporate such other requirements as may be necessary under the Clean Water Act. 5. Monitoring Reports Monitoring results shall be reported at the intervals specified elsewhere in this permit. a. Monitoring results must be reported on a Discharge Monitoring Report (DMR) (See Part III. D. 2 of this permit) or forms provided by the Director for reporting results of monitoring of sludge use or disposal practices. b. If the permittee monitors any pollutant more frequently than required by the permit, using test procedures specified in Part III, D. 4. of this permit or in the case of sludge use or disposal, approved under 40 CFR 503, or as specified in this permit, the results of this monitoring shall be included in the calculation and reporting of the data submitted in the DMR. c. Calculations for all limitations which require averaging of measurements shall utilize an arithmetic mean unless otherwise specified by the Director in the permit. 6. Twenty-four Hour Reporting a. The permittee shall report to the central office or the appropriate regional office any noncompliance which may endanger health or the environment. Any information shall be provided orally within 24 hours from the time the permittee became aware of the circumstances. A written submission shall also be provided within 5 days of the time the permittee becomes aware of the circumstances. The written submission shall contain a description of the noncompliance, and its cause; the period of noncompliance, including exact dates and Imes, and if the noncompiianrr has not been corrected, the anticipated time it is expected to continue; and steps taken or planned to reduce, eliminate, and prevent reoccurrence of the noncompliance. b. The following shall be included as information which must be reported within 24 hours under this paragraph: (1) Any unanticipated bypass which exceeds any effluent limitation in the permit. (2) Any upset which exceeds any effluent limitation in the permit. (3) Violation of a maximum daily discharge limitation for any of the pollutants listed by the Director in the permit to be reported within 24 hours. c. The Director may waive the written report on a case -by -case basis for reports under paragraph b. above of this condition if the oral report has been received within 24 hours. Part III Page 19 of 20 7. Other Noncompliance The permittee shall report all instances of noncompliance not reported under Part III. E. 5 and 6. of this permit at the time monitoring reports are submitted. The reports shall contain the information listed in Part III. E. 6. of this permit. 8. Other Information, Where the permittee becomes aware that it failed to submit any relevant facts in a permit application, or submitted incorrect information in a permit application or in any report to the Director, it shall promptly submit such facts or information. 9. Noncompliance Notification The permittee shall report by telephone to either the central office or the appropriate regional office of the Division as soon as possible, but in no case more than 24 hours or on the next working day following the occurrence or first knowledge of the occurrence of any of the following: a. Any occurrence at the water pollution control facility which results in the discharge of significant amounts of wastes which are abnormal in quantity or characteristic, such as the dumping of the contents of a sludge digester; the known passage of a slug of hazardous substance through the facility; or any other unusual circumstances. b. Any process unit failure, due to known or unknown reasons, that render the facility incapable of adequate wastewater treatment such as mechanical or electrical failures of pumps, aerators, compressors, etc. c. Any failure of a pumping station, sewer line, or treatment facility resulting in a by- pass directly to receiving waters without treatment of all or any portion of the influent to such station or facility. Persons reporting such occurrences by telephone shall also file a written report in letter form within 5 days following first knowledge of the occurrence. 10. Availability of Reports Except for data determined to be confidential under NCGS 143-215.3(a)(2) or Section 308 of the Federal Act, 33 USC 1318, all reports prepared in accordance with the terms shall be available for public inspection at the offices of the Division of Environmental Management. As required by the Act, effluent data shall not be considered confidential. Knowingly making any false statement on any such report may result in the imposition of criminal penalties as provided for in NCGS 143-215.1(b)(2) or in Section 309 of the Federal Act. 11. Penalties for Falsification of Reports The Clean Water Act 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 noncompliance shall, upon conviction, be punished by a fine of not more than $10,000 per violation, or by imprisonment for not more than two years per violation, or by both. • Part III Page 20 of 20 SECTION F. OTHER REQUIREMENTS A. Construction No construction of wastewater treatment facilities or additions to add to the plant's treatment capacity or to change the type of process utilized at the treatment plant shall be begun until Final Plans and Specifications have been submitted to the Division of Environmental Management and written approval and Authorization to Construct has been issued. B. Groundwater Monitoring The permittee shall, upon written notice from the Director of the Division of Environmental Management, conduct groundwater monitoring as may be required to determine the compliance of this NPDES permitted facility with the current groundwater standards. C. Changes in Discharges of Toxic Substances The permittee shall notify the Permit Issuing Authority as soon as it knows or has reason to believe: a. That any activity has occurred or will occur which would result in the discharge, on a routine or frequent basis, of any toxic pollutant which is not limited in the permit, if that discharge will exceed the highest of the following "notification levels"; (1) One hundred micrograms per liter (100 ug/1); (2)Two hundrea micrograms per liter (200 ug/1) for acrolein and acrylonitrile; five hundred micrograms per liter (500 ug/1) for 2.4-dinitrophenol and for 2- methyl-4.6-dinitrophenol; and one milligram per liter (1 mg/1) for antimony; (3) Five (5) times the maximum concentration value reported for that pollutant in the permit application. b. That any activity has occurred or will occur which would result in any discharge, on a non-routinP or infrequent basis, of a toxic pollutant which not limited in the permit, .. r .�- pollutant which is .. ♦ limited ♦v L. a Vaasa .., if that discharge will exceed the highest of the following "notification levels"; (1) Five hundred micrograms per liter (500 ug/l); (2) One milligram per liter (1 mg/1) for antimony; (3) Ten (10) times the maximum concentration value reported for that pollutant in the permit application. D. Requirement to Continually Evaluate Alternatives to Wastewater Discharges The permittee shall continually evaluate all wastewater disposal alternatives and pursue the most environmentally sound alternative of the reasonably cost effective alternatives. If the facility is in substantial non-compliance with the terms and conditions of the NPDES permit or governing rules, regulations or laws, the permittee shall submit a report in such form and detail as required by the Division evaluating these alternatives and a plan of action within sixty (60) days of notification by the Division. c �* PART IV ANNUAL ADMINISTERING AND COMPLIANCE MONITORING FEE REQUIREMENTS The permittee must pay the annual administering and compliance monitoring fee within 30 (thirty) days after being billed by the Division. Failure to pay the fee in a timely manner in accordance with 15A NCAC 2H .0105(b)(4) may cause this Division to initiate action to revoke the permit. PART V LIMITATIONS REOPENER This permit shall be modified or alternatively, revoked and reissued, to comply with any applicable effluent guideline or water quality standard issued or approved under Sections 302(b) (2) (c), and (d), 304(b) (2) and 307(a) of the Clean Water Act, if the effluent guideline or water quality standard so issued or approved: a. contains different conditions or is otherwise more stringent than any effluent limitation in the permit; or b. controls any pollutant noc limited in the permit. The permit as modified or reissued under this paragraph shall also contain any other requirements in the Act then applicable. MEMO DATE• TO: k(ro /L(i514,J17' F71, SUBJECT: PEki iV f I7 (N ( LtAMI I (r-tzbM 1i ',c TV- METED Al ew A-r . ZFx 1i61 L4 MA -Cc gc 3 EFF. 6i-7745 x (� Z> titi'6 NL 'f D fr-wvo ict -7 Z. -1) �GL Wsu,i,t A-N `S O G 4 4 ,4,Jc- (5z 7 7) Z•cc, PAV r.")kIU{ M" ' /sa ()CPS cA-Lc . 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O. Box23O7 Fayetteville, NC 28302 'DOTAL QUALITY: E COSTOItER REQUIZENENTS jilwa. ;Kozo FAX Transmittal. Form Date: z ,Z'\ � � `r No. Of Pages, Including Cover. O.0 To: Lj. 14, SutmkIS•- PE. Fax No. (9 Ij)—%33'3919 Firm Or Department 1::)G-M N L"" 4)evivaks 414c,Ad"� Sender 'qa/v"( P _ Monsanto, Fayetteville, NC Human Resources FAX Phone (910) 433-4240 Sender Telephone: (910) Ali- 4-2.0,5" Note: _ Pei eria e;i&v.4 t ke_oredv-4- 40 omit' IfYou Do Not Receive AllOi The Pages, Please . sE The pesticides guidelines as well as the OCPSF guidelines allow us to discharge up to 346 lbs.%day. However, we are being regulated well below that at the proposed 200 lbs,%day for 4 out of the 5 years of permit duration. > While Monsanto's present and past treatment system has continued to perform at an "impressive" efficiency in SOD removal we are, with the proposed expansion, embarking upon "new grounds" that will require additional time and costs to maintain close to similar treatment standards. DIVISION OF ENVIRONMENTAL MANAGEMENT WATER QUALITY SECTION NPDES GROUP March 20,1995 MEMORANDUM To: Steve Tedder Water Quality Section Chief Through: Don Sa Technical Support Branch Assistant Chief Coleen Sullins Permits and Engineering Unit Supervisor From: Dave Goodrich\ NPDES Group upervisor Subject: Proposed Limits for Monsanto WWTP Expansion NPDES Permit #NC0003719 Cumberland County After reviewing the preliminary information provided by TRC Enivronmental Corporation (Monsanto's consultant) and discussing permitting issues with you and Water Quality Section staff, I would offer the following comments regarding the development of limits for this facility. There are three general methods of developing limits for permits: 1) Base limits on model results. 2) Base limits on BPJ. 3) Base limits on BAT. The existing permit limit of 350 lbs/day for BOD5 (summertime limit) was derived through a combination of #1 and #3, although it was primarily the BAT limits which were suggested by Monsanto. EXISTING WATER QUALITY. CONCERNS Ambient monitoring data are collected by the Division in the mainstem of the Cape Fear River on a monthly basis. These data indicate that dissolved oxygen levels are depressed in the area of Monsanto's discharge to levels below 6 mg/1 under summertime conditions. Instream BOD5 concentrations are also much higher in the Cape Fear River mainstem when compared to nearby rivers like the Black and South Rivers which do not have significant point source impacts. It should be noted that the ambient data reflect existing loading from point and non -point sources as opposed to permitted loading to this system. Facility instream data are also collected which show levels of DO below the standard on the mainstem of the river (see attachment). It is possible that these data don't corroborate the information collected by the Division as a result of differences in the time of day in which samples are collected and/or the effect of algal activity upstream of the lock and dams. QUAL2E MODEL RESULTS Although model results are not finalized, Monsanto discharges to the beginning of a DO sag which is predicted to depress levels of oxygen below the standard (see attachment). Monsanto is one of many discharges which contributes to this sag. The significance of this finding is that existing permitted loading is not predicted to protect the dissolved oxygen levels in the Cape Fear River basin. BPJ CONSIDERATIONS Over the past few years, the Division has been assigning limits no less stringent than 12 mg/1 (summertime BOD5) and 2 mg/1(summertime NH3) to all expanding domestic facilities upstream of Lock and Dam #1 on the Cape Fear River. Although these limits were derived from preliminary modeling evaluations, the 12 and 2 limits are considered "BPJ" since they have been applied to virtually every expanding discharger without regard to total loading to the system. It was the concensus of Water Quality Section staff that these limits are appropriately applied to municipal and domestic wastewater discharges only. Another consideration was to examine what the Division was requiring other similar industrial discharges to meet in this area. DuPont is anOCPSF discharger in the proximity of the Monsanto discharge with a flow limit of 2 MGD and a BOD5 summertime limit of 175 lbs/day <equivalent allowable concentration of 10.5 mg/1 at design flow). After reviewing information about the specific operation of this plant and type of wastestream being treated, it was decided by staff not to recommend equivalent loading be given to Monsanto based purely on this type of "BPJ". DETERMINATION OF BAT The simplest way to predict mass limits based on BAT would be to calculate average concentrations of BOD5 which are currently being discharged and extrapolate this concentration to the requested permitted flow limit. Based on the data provided by Monsanto, the average concentration of BOD5 in the effluent is 5.8 mg/1 (summer) and 10.3 (winter - excluding March 1994). This would equate to mass effluent limits of 63 lbs/day (summer) and 112 lbs/day (winter). However, is this an appropriate method.to use when determining a BAT limit? In this case, it is probably not. Since production and wastewater flow are not increasing proportionately, Monsanto will most likely experience an increase concentration of influent BOD5. The idea of averaging effluent concentrations also does not provide for operational variations at the facility. Therefore, in order to calculate limits based on BAT, two factors were determined: • Removal efficiency of treatment system • Relationship between production and resultant :predicted influent BOD5 loading The assumption of a removal efficiency of the treatment system is an important element in determining what type of treatment is reasonably achieved at a. given WWTP. Although a difference of one or two percentage points would appear to be inconsequential, this is not the case. For example, in considering a BPJ limit of 120 lbs/day, removal efficiencies of 98% and 99% were assumed in order to calculate the mass of influent BOD5 which could be treated by the WWTP. The results were: Effluent Limit % Removal Assumed Max. Influent Mass which could be accepted by the WWTP 120 lbs/day 120 lbs/day 98% 99% 6000 lbs/day 12000 lbs/day This determination, then, is extremely important, and was a focus of the analysis to recommend BAT limits. Based on information supplied by the company, the removal efficiencies for Monsanto's WWTP are listed in the following table: Date Observed Removal Efficiency Apr 1993 99.6% May 1993 99.7% Jun 1993 99.8% Ju11993 99.8% Aug 1993 99.8% Sep 1993 99.6% Oct 1993 99.7% Nov 1993 99.7% Dec 1993 99.6% Jan 1994 99.3% Feb 1994 99.0% Mar 1994 89.9% Apr 1994 99.4% May 1994 99.4% This period of time was presented to the Division by Monsanto as representing a typical production period and was also assumed to represent the range of treatment capability. Also, note that the March 1994 removal efficiency was a result of a major plant upset which was corrected by the company and not represented in the data collected during the following month. It was not considered a representative removal efficiency in this analysis. Monsanto has committed to increasing treatment of BOD5 at their Fayetteville facility and should be able to do so with the proposed changes to the wastewater treatment system (see attachments). Summertime removal efficiencies range from 99.4 - 99.8%. However, again realizing the potential for operational variation, a removal efficiency of 99% was assumed in this analysis. This matches the lowest removal efficiency documented in the representative months above and is also quoted as the removal efficiency in all four of the treatment methods performed during the company's treatability study. Since ICI and Wellman are both OCPSF facilities, allowable BOD5 limits are determined using the Federal Guidelines (40 CFR 414). Based on predicted wasteflow and the highest monthly average flow observed during the representative time period, 52.8 lbs/day should be allowed for these wastestreams. Measured influent values for Monsanto were increased by a ratio of lbs/day of BOD5 to lbs/day of product produced multiplied by the maximum predicted production rate in a single month. The resulting influent values ranged from 5664 lbs/day to 14733 lbs/day. Assuming the highestpredicted monthly mass (14733 lbs/day) and a 99% removal efficiency, the BAT limit for Monsanto's contribution to the treatinent system would be 147.3 lbs/day. Therefore, when added to the allowance from the OCPSF facilities (52.8 lbs/day), the Division should require Monsanto to meet a limit of 200 lbs/day. These values were checked by ignoring the OCPSF requirements and increasing the influent loading from ICI by 30%. Effluent values from the resulting worst -case month-(i.e., BAT limit) was 208 lbs/day which is comparable to the 200 lbs/day limit recommended. Fig. xx. Self -monitoring data (April - October, 1993 & 1994) Cape Fear Diver: Buckhorii Dam to Lock & Dam #3 0 72 chiles — standard Facilities with self -monitoring; Lillington WWTP Efwvifi Mills Fayetteville - Cross Creek WWTP Fayetteville - stockfish Creek WWI? Monsanto 9 8 7 2 1 Permitted Toads under summer condtlons Upper Little Ri (1.7 ds) Lower Little River (39 ifs) Rockfish k (109 cis) slope change (from 2.5 fpm to 43.5 fpm) 0 10 20 30 40 �E' 50 miles below Buckhom Dam 70 Buckhom Dam to Lock Dam 3 MONSANTO: EXISTING TREATMENT WORKS The existing Monsanto treatment system consists of a spill basin .(1 MG - seldom used), an equalization basin (4 MG), oil/water separator, pH adjustment, two aeration basins (0.4 MG, 1 MG), two clarifiers (90 ft - in use, 50 ft - not in use), sandfilters (not in use), chlorine contact chamber (not in use), an aerobic sludge digestor, a sludge storage basin and sludge drying beds. Additionally, Monsanto has side -stream treatment systems for some of their more highly concentrated waste stream (centrifuge spent wash wastewater) that are not in use, including two sequencing batch reactors and an incinerator. Currently, waste streams from different production areas and sanitary contribution are brought into the treatment system at different points. For example, the centrifuge spent wash is added to the treatment system after the equalization basin and the sanitary contribution is added at the second aeration basin MONSANTO RECONFIGURATION: Monsanto is proposing to re -pipe the existing influent waste streams to the head of the wastewater treatment plant and modify the existing in -ground components to obtain better levels of treatment. The reconfiguration of the system still does not propose to use all of the treatment components that are on - site, specifically, the sequencing batch reactors, the 50 ft clarifier, the sandfilters, the chlorine contact basin and the incinerator are not proposed to be used. Additionally, the function of the existing remaining units will -be modified: Oil/water separator (same function, propose to modify slightly) Spill Basin - converted to equalization basin (1 MG - permitted flow requested is 1.3 MGD, therefore, size as an equalization basin is more than sufficient) Equalization basin - converted to primary aeration basin-(4 MG capacity) eration basin - proposing to convert one of the existing two aeration basins into a sludge digestor, the initial proposal is to convert the larger (1 MG) to a sludge digestor and use the smaller aeration basin (0.4 MG) in series with the new primary aeration basin (4 MG). Proposal also includes piping to bypass the secondary aeration basin and potentially not use it in the treatment scheme. Clarifiers - continue to use the 90 ft diameter clarifier, not proposing to use the smaller clarifier. This reconfiguration will consist of relocating the pH adjustment to the lift station at the head of the treatment plant, adding four 7.5 HP mixers to the new equalization basin, relocating existing aerators to the new equalization basin and adding six additional aerators to the primary aeration basin. TREATMENT DESIGN CONSIDERATIONS A comparison of theexistingdesign parameters to the reconfigured system supports the determination that the system will provide equal or slightly better levels of treatment. The current system is providing a detention time of 74 hours in the aeration system, producing average effluent concentrations of 8 mg/1 BOD5 and 1 mg/1 NH3. Under the expansion and reconfiguration the aeration detention time will be 80 hours. The 90 ft. clarifier is also adequately sized to handle the loading rate that is projected to occur. Therefore, it appears that the system will provide similar levels of BOD5/Ni-i3 removal as those currently being achieved. Proposed permit limits (GODS = 200 #/day, or —18 mg/1) should provide an adequate window for compliance. • Monsanto Wellman ICI bypass C. Spill Basin 1 A. Chem Lift `Dry beds L7X5 not 5hokt) G`t14m6 SOH- dGvihlr) 51u1n4 4-[ACfbr5) and /f// r, Date. 03/09/1995 TI ne. 117013 a. n. <Effluent I. Sludge Stor. B. pH Pit 4M D. EQ Basin G. Clarifier 10 H. Digester Decant 4 E. AB #1 Sanitary l•Ow6 F. AB #2 btrich r. EXISTING FAYETTEVILLE WASTE TREATMENT SYSTtM Monsanto Agriculture Company 4Fayetteville, NC Page 1 of 1 Sanitary Monsanto Wellman ICI GSW J. Oil/Water Sep. Elmm=41'l A. Chem Lift < Dry beds I Mb C. EQ Basin bypass <Effluent emergency bypass D. B. pH Pit Primary Aeration I. Sludge Stor. G. Clarifier q0' E. Secondary Aeration H. Secondary Digester Decant F. Primary Digester * Bold lines indicate changes in system routing Date+ 03/09/1995 TI nee+ 9+ 49 a. n. Draw! no File+ ' N I SCPROJ\N50010A KA6 PROPOSED FAYETTEVILLE WASTE TREATMENT SYSTEM y Monsanto Agriculture Company Fayetteville, NC Page 1 of 1 Monsanto Process and CSW ► ICI Septic Waste Treatment Block Flow Diagram of Proposed Modifications (164 CU,e CU 1 J cis l oKyra (.0 F lb 6R Equalization Wellman Bio-solids Drying ► Lift Station Ex r) Digester #2 p1I Adjustment 4Mb Aeration Basin #1 A-6 (.2 xdL� Aeration Basin # 2 Digester # 1 Clarifier 9o' ► Effluent 4/19/95 I.,„vkc.1 n-bbi gk.. 7.6,3(,„ fakyckc.,c(c.f k-AA rttk, Atm(d5w), • &Au/ blyesiev (voIA:), NOS ',e) /e) /1441/p0 Wel (fruziA,-) PFve.1,91ii( d rev re5&Lo oks cold slaft, Wm-1- -7 (ies. inficti; --fitt brAs faA,d is bac kfr4exsi j 6 imait 1)//da-4,, bAn-IS (7.14ks Pgr- 6700 ( 1)1/ iriA 4_ Me/ .(0/ ck(6 (A7y) ) tas4-y)1-k--0; p/vi /"y/ 4kkis15 go/e///7•04s (amaneyrottimi rium541 lok41712-h-ice41; IA444) nieMaA401 is 6 Nvviviati-uvCi add evees3 y(o/ ir‘-eteoeter,4 eily& (OI -e edac-/-- 'wiz._ p< eec Owl -7.;GAyls PIM W.ghwA4-r- (oliolined ,e),orce.J 7ertc:fro;7 (fracauni ded le4(4/1 6:ectrc pki-s/t4,4_,1-07 kmite stizo1 _AC;a, if-eep rKS.,Sa v/ 4114v,1 Of.a/ ei F/41 P (A-4 ma/ r (66 kvklev (sed - Adti-ne fraess -J21v/re retake - wiy1 be a (6'whodur pralss (00 pi+ r(p_h acid procosS Cry/40) SO/ /51)/7/4-11 Ati.d/Ora‘S' kialed kivi C67 :77 frta-4)- CdrWs sC kill/ /V C-6 (0/.67rnina#1 /1/ iyate_ /dell FVeresc . . 7ake -I, /renlylf-Fle-7 ?rcLs Ad( h/ivoltiv ge_ 00141 ejecbr - is Qt44,-/ ArU et- COI-um/7 b7 )et410-/ (,->' 11/ Or ;6s .--- p ‘ Iv ,74Alirio /6;ki,y1.4 bkoie elor - Alk,(;)iers ____141/11V Res'im - _eitkviti‘ _5._ idlymos _ 4;:lvviS Projk.:401 tv,k0 s Y4- 4.4- N f-crz- 15 -«Ast— \,,,a-tV 1' er(ot� to �IN+ )1 s1&a4 - aS O ,La ii,±-6„6,w,„,,,A, of cordecim.)riez-6- Nina r�a� ni/i)l�m4zcf lUv pelers,h� 1n.6s creakkj prkivo from 4- Swig 0.to+0b.ICM6.D ola C 11 &f a 030 y 116D P 51nivts MtfytAndz) I. 6„ 0/Ln y = lrtpkva y,,,rm >n'a S I IleMia" Cam cmi ATisoAsfr Mill load 1, 4-/a6 4-a/Vt �-, r�►wa- t! J a ■ a a ■ a a Summer April 1 - Oct 31 Flow -.7MGD DA IL Y A VG LBS BOD 350 TSS 660 NH3 23 COD 3470 D.O MIN - 5.0 MG/L PH-6.0-9.0 DAILY MAX LBS 700 1264 46 5608 in Winter ® Nov -March31 ■ Flow - .7 MGD ■ Daily AVG ■ LBS ■ BOD 700 ■ TSS 678 ■ NH3 46 ■ COD 4715 ■ D.O. MIN - 5.O MG/L ■ PH-6.0-9.0 Daily MAX LBS 1400 1298 92 7624 3/11/95 Monsanto Agricultural Group/MWB/95 4 I A DbI€ IPME T SCRIPTIONS is ■ is DETENTION TIME - Approximately 35 minutes. ® Controls ph and removes oil. a STAGE I AERATION O SIZE - 4.3 gallons - Present working level - 3.5 mg. s DETENTION TIME - Presently 7 to 8 days. 3/11/95 Monsanto Agricultural Group/MWB/95 5 SPILL BASIN SIZE - 1.0 MG. Spills can be diverted from either Monsanto/Wellman chemical streams or ICI streams to this basin Simultaneously or separately by a remote control valve that is located in the Utility room. Removing the spilled material from the spill basin is currently accomplished by a portable sump pump which pumps directly to the second stage aeration system. PH CONTROUOIL SKIMMER BASIN SIZE -96,000 Gallons - working level - 82,000 gallons. Al) IP STAGE 11 AERATION BASIN NO. 1 SIZE - .3 Million gallons DETENTION TIME - Depends on stage split. Aerated by two 40 hp surface mechanical aerators and two 15 hp floating vortex aerators. ® This basin receives 25% to 30% of the waste from stage l ® BASIN NO. II ® SIZE - 1.2 Million gallons. ■ DETENTION TIME - Depends on stage split. (Overall DT for second stage is 3.3 days) ■ Aerated by two 50 hp surface turbine aerators, one 75 hp surface mechanical aerator, two 40 hp surface aerators and one simi-sub surface aerator. ® This basin receives 70% to 75% of the waste from stage I 3/11/95 Monsanto Agricultural Group/MWB/95 6 INS ANI) EQUIP CONT- NINETY FOOT CLARIFIER SIZE - .7 Million gallons DETENTION TIME - Approximately 1.5 days for incoming waste. (13 hours considering RAS.) Settles solids and skims surface. n AEROBIC DIGESTOR ® SIZE - .5 Million gallons. Aerated by three 25 hp floating surface aerators. n Digest solids and prepares them for drying and or liquid land application. ® BIOSOLIDS STORAGE BASIN ■ SIZE- 1.0 Million gallons. Stores solids for drying and or Liquid land application. 3/11/95 Monsanto Agricultural Group/MWB/95 7 JNSAND EQUIP GONT- SOLIDS DRYING BEDS. Three drying beds. (30 x 200 ft. = 6, 000 sq. ft ea.). Drys solids for land cake application. DRYED SOLID CAKE STORAGE SIZE - 30' X 60' x 2' Stores dryed cake until it can be land applied 3/11/95 Monsanto Agricultural Group/MWB/95 8 OCESS FLOW DIAGRAM PLANATION M�1+,merit cistforMirr?r!c+�x..1.4.';r.2pR pprzFavri snr�+ � 7rynymil o IVEP!IRT, , • , Major Sources Of Waste. ICI Americas - Basically a polyester product waste Wellman Inc. - Also basically polyester product waste. Monsanto Co. - Glyphosate product Waste. PROCESS. ▪ Ph is adjusted and oil is removed in the Ph/oil skimmer basin. ■ Waste flows are split between stage I and stage 11 as determined by load and dissolved oxygen available in stage 1. Sometimes this is dictated by odor due to insufficient levels of oxygen in stage 1. ■ Both the waste bypassing stage I and the partially treated waste exiting stage I join together just downstream of stage 1 before entering stage 11. ■ At this point the waste are again split to give a 30/70 loading to second stage aeration basins no. 1 (.3 mg) and 11 (1.2 mg) respectively. ■ Waste is aerated in these basins with ras in proportion to basin size, dissolved oxygen capacity and solids under aeration analyses by the aerators described in equipment descriptions. 3/11/95 Monsanto Agricultural Group/MWB/95 9 OCESS FLOW CONT- '1"'''�COOLiuiiLl2T�llYJlSiiii�P�^�YL`l+i�£l3"d+'+'Rr wi:10YaY P: Oh t4.lelClL�Ylii#lY:tiLn (e��. Waste flows from second stage aeration basins through a common mixing box to the 90' clarifier where they settle out and are either returned to the aeration basins or wasted to the aerobic digestor. y'a Effluent from the 90' clarifier gravity feeds to a lift station pit where it is lifted by pumps to an original chlorine contact chamber(no longer used for that purpose) after which it gravity flows through a parshall flume, is sampled by a composite sampler, its flow recorded and totalized before it continues through a pipeline running along the bottom to the center of the Cape Fear River where it is discharged. s Sanitary wastes from Monsanto and Wellman Inc. enter the system through a comminutor pit and into the 1.2 mg aeration no. II. ® ICI sanitary wastes enter along with their chemical waste. 3/11/95 Monsanto Agricultural Group/MWB/95 10 Oa:SS FLOW CONT- Deactivated solids from the digestor are pumped to the biosolids storage basin by a digestor level control where they are held for drying before applying to the farm land as a cake or applied directly to the farm land as a liquid. Biosolids that are dried are removed from the drying beds to the dry storage basin until they can be applied to the farm. 3/11/95 Monsanto Agricultural Group/MWB/95 11 PRA TION AND CONTROL SAMPLING LOCATIONS AND ANALYSES See sampling Schedule CONTROL INDICATORS F/M Ratio - Current Target - .2 - .3 Ibs COD/Ibs MLVSS (Depends on split between stage 1 and Stage 11). ® RAS - 700 - 850 GPM. a WAS - 4000 - 5000 Ibs/day ■ Sample analyses Report (See attachment) 3/11/95 Monsanto Agricultural Group/MWB/95 12 YPHOSATE SPENT WASH All spent wash is currently treated biologically in the second stage aeration basins at a rate of 1500 to 2000 gallons/day. 3/11/95 Monsanto Agricultural Group/MWB/95 13 ND APPLICATION PERMIT Permit was renewed in November for another five years. We are currently permited to apply liquid or cake biosolids to land. Liquid enables us to move solids when weather does not permit drying. One hundred and seventy-two acres under permit. ▪ Consists of both grass (pasture) land and set aside land. ® Solids can be applied without incorporating on grass. ® All land application plots are supplied with monitoring wells before applying any solids to them as mandated by Monsanto Corporate procedures. 3/11/95 Monsanto Agricultural Group/MWB/95 14 Waste Treatment Block Flow Diagram of Proposed Modifications Monsanto Process and CSW ► ICI r,, `>` 4- septic" s<4c. % Wellman (90S FV eIc +API k Equalization ttlt ► Bio-solids Drying Lift Station pH Adjustment Digester #2 ZP;ft.. Aeration Basin # 2 I•ZM Aeration Basin #1 if, /4 4641 Digester # 1 - Me D 90 • Clarifier ► Effluent 4/19/95 ,--,izkiti(t_k x y144,ty L1-ao /5//4 ',87„ ()- xg�� /5f d ( f i�5 IL < <, 772) " /, /bocowixl / 7Yc) 41Yci P E`?Z i! IN)E COJ/, 'L.4 Tl01J Cam•'_' Itit-p /5 A5ay. /i&ctcs,47ey (T �s mRei27 N'r- , J Masi /11,,vc.4A,7p). ord,A2 4-41-6e. 11 X / 7 " >Aft 04T-77- (nY /110,4M-f) 4 MIA/4410 7 r) > rifriilt:15 { 3 r16 f nun 33197 Lt877 rc/3��97� 7o0 87,././77 3;()1 ply 7 1 bs Ai 51- 4-c-/i4f3. nib ks ///f/9 7 - (.6-.1/ *al 11444414-4 (9rq)- 57/ -3535- Dc,&A,%)_ 1,& �uf /Z75- A 41 vvv it Iu/i -- owl ov- .� NE r--ty- .r,t- 17 1/4 1/4 A/02 -PAILy MX . li r gK. VkA \c9 lq 4.1 00 <-1\01.1. /W61 oA *,#u4 //38'. S 4 /� l 53-% (6/ olio( WY. ;X ,Mod, AA. OG�N cAlt-Y i1M'X . 661I Mot, 417. A-Clqat 3 rLocdesr i<c. 78.7z-A, 5-7 /ydai 4-r qs`70 gz/ fig, c-i /b/� !ff_V_I_474 ,4r-'1g;9(S9q fittiff (3' E'9d) tr3 it-70 (b/ p7cu1 rr Cd1y ) 5500 I Ol d svoo 1fr'lj- of 1 /ra'Al-S/MM, 47- ‘;1.':' 1 et5/d46 1/427 y. e., TV4I'ig/-M'ctr.v: 077/fie rmiltki ii-Aierri7A)5 oc? t."-A4,----'.-. /9 7/ IturiAjokr lAVAE. e-,-,1: Vw.5 _ ---T-• ",_._e_s2_,3.,.. ..---__;tetv-:::- ),, 1-10 ,Llei 6'.F, Ale k.,71 A Pie- pu c ,-.:7. . al 1 1 f d Mr at c T-s-- - 00- - av WI. &I:vow_ . .17 4 - 273 1 . 4 +..... ; ; ( ( ..----- ,,. Al k / . .-.. C-0 19V .4 r- rfr. 7 if. AA. (qc . C.1-14,14092644.7 1,\(/) 3 6 7 /1.1e:.; I( - 1‘.• 7-5- ._./7/116, A m.5._ (1E, ) AkcCL Cory c-) ") or-Jfl(1411 NI1?:7`.7, A? ,errxst Se=-`15, r706.471-f e; - LAI -."-c•_.ek 6 04 c it4-3/4 7-7) C e ( I G, ere,;7re t r - 1;7 rilrek4ibitIC-Aant. ,.-6( 76y)( f r ior-oe e .7 - 4c4/470Aewt.." /- — ,iro Co dill' e (ani /fri.a 4(:5 (cc/i/c)e, e (17 vOz#,Ier s- roc' —c 4,1(e,ryr impapy I) (14 fi --11/-b-0 54 --d;-11-_-VELP144,ir,'/V_ • horrid $() -c44-6e /40/ry) ow' /4:4 /1.17itis-WA/70 p-hrzz- • flAT,e/WL sik./4 r- 44opmey e 9-, (I) serf4 ( mkfr --14 7()_/_o —701 /4_44ebefrpe _ arc c (eye, cyci orejl 7171d/ex-lie _e4 4 /erephe ive/ • 4 yc e ,f1 ,ht ity / y 7,e/e AP- l6nn/g)734e4//- 1/.2 4e tf1/1 /44 v- /it 11/Yr he/4c! r, Et 111/C. Ziikt:±11gyi "Att hitt_ 3 3 '- j /iy4.beal z/ 7 /�r� ) Ae_crYam. 41u/ _ C of h c--- ri cc #/1/579iv70 !G' iye• r //VcUf Mi4 FiPi • /- 4lf-vr ,74-a4sr; Clithh!mAy_41.t-- - p kierr4 ��"' . � r 1 hzc l f0/0_0/ _ qc- y-re,/re{C-44Yte yikk .l �du^'P rrt be-0 ' lf (.41104-yrn Jog 11 /1/f.0i1 v'et z.(- 16; / Gl's 4 iew/S 4-4'1G '6't' Lilt we M r_ it/1r z.-t./1•1A-Al i M, i. r '-' Thy ' - _LC T 4/PEA ,C42 c- (3/4 / ? 2,) kik .4 (--.e.) a) Jic4'lC1'( 17) .Lf '° -fig �� � Zi e l/.s Y 1e— F�f I�Gf/ f� //ill/ :, mil/ uG �_ � . 5 A r �x,,, 1 . amnua � a � cii �:6f,i, 6.e. � �z�� r: � 7c ),<- • � ��'�� �f L"/71 d ! /4 J r y(: • / / L'✓ r �. i �i �� ' I � � �+ �"' / / we (5/f—'/9e) /5'O /Z'/- y, 2 ifei . / 1- •ACC j i? ��€. Cal . o �- P�Uh�1� Uc. c R # °4 An �- C i erg) A t' Pl /1/1). ; (� 4 4 J /ek1 (4 .r G7Ee( //'? -!/4g ^c /: GY_ ' K ..c'e'unti.?) 414 'c 'G'CE 5" d�� .�_: 7 ADO w / ✓ n/"L J/ ?. 4 ylir56fie, 5-75/067 7 (47 . • UGC// eta et%- �% / C,rna/ mid r‘/!t f lt". 4.i4;o ..e.??, 7 if'",ft? ,.; • ./1( _m: _444) /4..). 4. e ".4.7`;-•,-; • eec_- _1:1/14-0 f / /My) a -p_ - MAR-28-95 TUE 16:29 MAC FAYETTEUILLE FAX NO, 9104334210 P. 02 Monsanto THE AGRICULTURAL GROUP P.O. BOX 2307 FAYETTEVILLE, NORTH CAROLINA 28302 PHONE (910) 328.3300 March 27, 1995 Ref; Monsanto's Expansion Plans NPDES #NC0003719 Coleen H. Sullins, P.B. Supervisor - Permits & Engineering Division of Environmental Management Water Quality Section P. O. Box 29535 Raleigh, NC 27626-0535 Dear Ms. Sullins: As a follow-up to our telephone conversations on 3/21/95, Monsanto personnel have had an opportunity to review your preliminary proposal to limit the BOD discharge level which we understand to be as follows. YEAR AVG. BOD (LBS./DAY) SUMMER AVG. BOD (LBS./DAY) WINTER 1996 350 700 1997 200 400 1998 200 400 1999 200 400 2000 200 400 Having evaluated the above limitations and timing factors involved in meeting the above criteria, the following comments are offered for your information and further consideration. > The pesticides guidelines as well as the OCPSF guidelines allow us to discharge up to 346 lbs. f day. However, we are being regulated well below that at the proposed 200 lbs./day for 4 out of the 5 years of permit duration. While Monsanto's present and past treatment system has continued to perform at an "impressive" efficiency in. BOD removal we are, with the proposed expansion, embarking upon "new grounds" that will require additional time and costs to maintain close to similar treatment standards. MAR-28-95 TUE 16:29 MAC FAYETTEUILLE FAX NO. 9104334210 P. 03 Coleen H. Sullins, F.E. 3/27/95 Page 2 of 4 > The lab scale bio-Rx studies were done to provide indicators to operating windows and not to determine performance from bench to field. It is evident that simple linear extrapolation of controlled bench scale performance to field cannot be assumed, nor expected, due to variabilities. > The goal of the bio-Rx studies, therefore, provided critical information such as Oz requirement, net solids generation, and the impact of hydraulic residence times (I-IRPs). • The 02 demand for the stage 1 aeration under the proposed configuration and loadings indicated 40 mg/liter/hr. or 1.98 lbs. 02/lb. BOD in the influent. > As mentioned and shared with you earlier, Monsanto has already designed into this expansion a reduction in the proportionate amount of waste generation utilizing internalized techniques of stream recycling to a rate of greater than 30% less waste per pound of product (less load to the bio-system per unit of production). • Also shared with you previously was a description of discharge allocation of BOD per unit of Monsanto production. As summarized in the table below, significant reductions in discharge allocations are indicated. RATIOS: LBS, OF DISCHARGE PER 'M' LBS. OF PRODUCTION r PRODUCTION' FACTOR BOD COD TSS NH3 •N Base Case (Curren» 17 169 32 1.1 *Expansion (Case) 2,24 4.9 79 % Change 241 -71 -53 -80 -64 *NOTE: Production Factor = 2.24 (Flow Weighted Basis: ICU/Monsanto) MAR-28-95 TUE 16:30 MAC FAYETTEUILLE FAX 140. 9104334210 P. 04 Coleen H. Sullins, P.E. 3/27j95 Page 3 of 4 > Comparing Monsanto's bio-system performance with the conventional systems indicates the following: MONSANTO (EXPANDED SYSTEM PROPOSED) CONVENTIONAL SYSTEM(S) Avg,Days HRT BOD - Removal Y� 5-6 s 98+% 4-8 Hours 85-95% The above i tables indicate Monsanto's ongoing intentions of maximizing Ito ft."0ts-ssr:a c�'r%.:.'=:t.-rs3r :it +!:: r r' 1......1.. .... . . .. rra _ f ciIi LACS (LLG1 L.thn , LVW. aiia, �J1�L116) kaCuuly,ub'b'GSLS Una the nit i's longer than 1.21 days it .vC nu appreciaoie gain in EOD removal--i.e. most of the benefits in a fully acclimated system are within the five (5) days of HRT. .. i _ S: . u .s. : • . x • •• •••ww-••v.•••a •v •.•YVM..V\• .•r v...... 110 •t•• ' •1!S•a■ 161V43?c4LI 6Y SiiiL3 i.iii w••--w AM Ale • ter•..:... .-� .. .�11 .. - . .1 1 1.•' 1 •. ti• . • - ili Taaribt.ui V UAW, JAI iii.i i L. T. •4 . .. . ..• •. •4 I.I.•SIP • •�-��--r •.-...- w•ry r.v•.4.a-M.•• 1.•V ►sa ••rabv wus W 1,6rwi■IV•V AV11VL iv r via Va 1J JJ./ Vll a i ha.Sed-in a1)T?Tna.C.. iS A. reasnnnh1P• TP.nmmPAt Mnncantn aarPPc that the nvarall r+nr.+aT♦t of L. .... .-..-...-.- ..Q.--- •..- •..- ..• MP. ..•. VV+•VV••• V•• a basin -wide approach to Cape Fear River quality has merits. Therefore, Monsanto proposes and sincerely expects that you will consider the following approach to meeting our MAR-28-95 TUE 16:33 MAC FAYETTEUILLE FAX NO, 9104334210 P. 01 Coleen H, Sullins, P,E, 3/27/95 Page 4of4 The above proposal is considered by Monsanto to be challenging but reasonable, since it allows The necessary time to address the waste treatment technology, while allowing the start-up factors involving both ICIA's and Monsanto's projects to be fully integrated into the current system. The gradual reduction approach to BOD discharge limits over the subsequent period additionally assists Monsanto to channel appropriate technological resources in defining and implementing the bio-treatment schemes. We trust that you will consider this request to be reasonable and allow us to proceed along these lines. Please note that, should we be able to reach our target limits ahead of the stated timing, Monsanto will not hold back resources to implement actions to fulfill that goal ahead of schedule. Sincerel Manhar N. Patel tw 70-pp M./metes Affibig ,4*/ K4Pvi Gll /s ov ac✓Qs (gAg �IQ/'�IG1Gil�' Cu�LvlDI DceGpr �uetiu«t'e/has. �a5 weis-/e/lot4is kr/csf.— ~et K-9v�r6ifs a/� luxe- 4c,W. fiat yvccs_c sloes /ns-rr yr Aim/ h cemb D0( D0� .5ef4Arzrk 517YrY104-fr- J6»1 6eC%J n/dec: U5t /qti Fps T- is 11/4`KeS7 nail rotir 1tw �gcfurg k;l/c/bi N 4!» L ca' I G 7I /M477J' 6.70 -Torrc itiv4 Ls, J 5444,1/ ..c• {tins ' • Cher 6a I ,%Dill/, diffils,.--) . s imyy • r / d (5I49j4'i us w otz►-Nt(44 Rry;vd4m07/A` 7�' chiyr,� .6(Y6 !Aide l�z� c)c s 4- /(1034 . 114Aitc. m4"I M7 r«r4J2 /S - /4,4410 I . 1(`)0 - 1 /hyl- 44y1o1 . z '7D ' Iltehldth7d& . 6 3470 f1 gr I ° o'24,tt ell 4adf 5 M 44,&t, ftz € S 1 / vac kii,vr d 11074 w ils . (ii/A 13 , GOYI h G7 �2�) 0 f/.�/fit p X 17 y::;e(47 11k.' Sd;c�us= �,,��iSlid01�n5� nSLS G - �•c /slr3- ipi 1pkrAft, fi;rlJ(4J/y flo al ytWi Cor/ A< 54110a0 rYIL .-/1417A/ 4 c000r JTC /-?'ever /W.se-g--c L . 9 acw s Soo 5i/wsiolz Ais fD 02,24? 4cra ! U ( fin/ ITT f��✓T (re.z-) -avietY Po�vsr�. P471/4/7. &oft/ /A/ /776 ov 4.4g /-A4 -r° ZG1 fr.) /i86. fret-Lefrie (06(7,145L/4/,ninh,i0 k,S 44.764 - 4 V ttot yjgtc `4,1writ70 A r? PA17- P11746tAy 1-1-€/tArAp4111,)-7; m9441/141i 76g47) /- vy/! 4?i Aft C.6917 d, I 0/i%4i's 7i . kichi 4,7 rzzonyaL- g1)PR/ills 8)1 .51:12,- ypoldoze. 2 7ze- 64os t tise/L frfrith- rocfi pie/. ift!rzitf. > IV 4,0 A IblVr 1191-v45'113M1b1y1/. rtil7 ih try $ / ttMJ Vi (/,; Gwc-s) /ft Al 4 as (5a c.(4.) MP/54446 (.4'r• aGet$ ,2z-/--htuf/c/bi 7-4Atiti7eya4 ,(56 r 6-141, i,J Iry C.:ei faks//2s (yt57v *15 ate' (u,t,f,de,Y /if ) 14F bArrray ztliau/s;4 f c/� j�.s .mot cooV e,1 prz,5s.te(- �ictyls 1:9 (1 a e ilk Ao/ 5 Yten5 ;e4jyaittt/;6(4(.% 1"-trt/Aitkol Piri.foikkaMatitYv4)644,0 4/4d, 4v7,74 y d1 0-44- . 4c ' l e--- ,1/414krce PA'om miirrAtO ,16-xeiTc'o catd5 af7,c) 5t-1 Cad,ito Irii-,471414itice( r5 L th yys5l C4Ii')1t y I,z, ;Wei M 4p5 corx. /-72 s//1/0 �- 7/td-tee%A6. 1 14//11----- —7‘ pan, may. A47111L1fr C6 "a 5 % / tM /J 4: ill Arv5,7 lLl ,12, efrilitov.. 006 Pivit' 4011 #1*5 (Jlit) (z-ci) \o/Jr veit/nbeE /776.. P4oeci-f4%,E _L pdy_01-ev miyAcii_ator friYyt r<,i, iwifizetA7 effiefi r , ai, Rebpir iv/-- M(5.1-4k) 7p an,* _Ieti--- TG.f '14 gf 4ao( ,A/11/tfeir piitiO v= 4erke7P' 1-‘ii 1--- ' fiecif #7_ O. (#0,0„„,/,," ., , / pi&kif k: /g. /me 5 „ i%vi‘ec,:is-iii is- le4 'rev/ C h / ell 5tt - , /Item 56/ DA41-7tfkiornc)/ \V /1 , ( fihmilivt„ aftlithfri)_ 14 _.............. z cA 6a1,7 i , Dfir Mit-pittfric 1, ,,,e ( 104. 0,elAk Ocuktw; G)itte(i 14V 4-7-74 t 0,44, 77;44. "Z7 I /;,#er illee,f/ s P40 .1, hnt 1 irt‹t . 0) Ale adhcq• I t,(7 u96( 150pOictit ttrr 1(( tftliy . re0171,1 otid 5hkfl- L7 tt - Pvi /1 \ 12:ktrati cot , in15" Ne/C 41 05 ('7,2 114Ai pfM C Y/1,a44 ..04a y te6 -rliflic4Mieff 7 bet:: 4 - .C1/0 /42,0fireS24 1//)/ 11/76 ea.(,) le.)27/ CIO 14'r/ V7-fYe du' 5;1.016.1y - Milt"( 1,414.07). . 24, qifilt6I.K ktv Ali( I itu • t:it- Ale 7- 1.7. /11,4/41Wn, DIVISION OF ENVIRONMENTAL MANAGEMENT WATER QUALITY SECTION August 11, 1995 MEMORANDUM TO: Carla Sanderson FROM: Jeanette Powell 19 SUBJECT: NC0003719 Monsanto Company Waste Load Allocation Revisions Monsanto has submitted a letter revising their requested flow for the in-house permit modification currently under staff review. They have re-evaluated their flow estimates and now request that their maximum permitted flow be reduced to 1.25 MGD. This request will be incorporated into the draft permit. Please advise if this flow revision will affect the permit limits specified in the current WLA. cc: Jason Doll -�C FACILITY Monsanto OCPSF Flow 0.265 MGD Flow is based on processes only 7010s 791 ds Qavg 4340 cis PF 1.25 MGD Human Hlth Human Hlth Allowable Allowable Limit Limit Fedl Standard Standard Allowable Allowable Aquatic Life Human Hlth Limit Daily Monthly Daily Monthly Daily Monthly State Aquatic Organisms conc. Aquatic cone Organisms Based Max Avg. max avg max avg Life Life Organisms on: Parameter ug/i ugA #Id #Id stdrd µfill µg/l µg/i µg/1 #/day #/day #/day Acenaphthene 59 22 0.130 0.049 FC no stdrd 2700.00 no stdrd 1104996.77 no stdrd 11510.383 OCPSF 0.130 #/day 0.049 Acrylonitriie (c) 242 96 0.535 0.212 FC no stdrd 0.66 no stdrd 1479.06 no stdrd 15.407 OCPSF 0.535 #/day 0.212 Benzene (c) 136 37 0.301 0.082 SS no stdrd 71.40 no stdrd 160007.40 no stdrd 1666.744 OCPSF 0.301 #/day 0.082 Carbon Tetrachloride (c) 38 18 0.084 0.040 SS no stdrd 4.42 no stdrd 9905.22 no stdrd 103.179 OCPSF 0.084 #/day 0.040 Chbrcbenzene 28 15 0.062 0.033 FC no stdrd 21000.00 no stdrd 8594419.35 no stdrd 89525.202 OCPSF 0.062 #/day 0.033 1,2,4-Tnchbrobonzene 140 68 0.309 0.150 FC no stdrd no stdrd no stdrd no stdrd no stdrd no stdrd OCPSF 0.309 #/day 0.150 Hexachlorobenzene (c) 28 15 0.062 0.033 FC no stdrd 7.70E-04 no stdrd 1.726 no stdrd 1.80E-02 CHRONIC 1.726 µg/I 1,2-Dichbroethane (c) 211 68 0.466 0.150 FC no stdrd 99.00 no stdrd 221859.00 no stdrd 2311.031 OCPSF 0.466 #/day 0.150 1,1,1-Trichloroethane 54 21 0.119 0.046 FC no stdrd no stdrd no stdrd no stdrd no stdrd no stdrd OCPSF 0.119 #/day 0.046 Hexachloroethane (c) 54 21 0.119 0.046 FC no stdrd 8.90 no stdrd 19944.90 no stdrd 207.759 OCPSF 0.1 19 #/day 0.046 1,1-Dichloroethane (c) 59 22 0.130 0.049 FC no stdrd no stdrd no stdrd no stdrd no stdrd no stdrd OCPSF 0.130 #/day 0.049 1,1,2-trichloroethane (c) 54 21 0.119 0.046 FC no stdrd 42.00 no stdrd 94122.00 no stdrd 980.438 OCPSF 0.1 19 #/day 0.046 Chloroethane 268 104 0.592 0.230 FC no stdrd no stdrd no stdrd no stdrd no stdrd no stdrd OCPSF 0.592 #/day 0.230 Chloroform (c) 46 21 0.102 0.046 FC no stdrd 470.00 no stdrd 1053270.00 no stdrd 10971.563 OCPSF 0.102 #/day 0.046 2-Chlorophenol 98 31 0.217 0.069 FC no stdrd 400.00 no stdrd 163703.23 no stdrd 1705.242 OCPSF 0.217 #/day 0.069 1,2-Dichlorobenzeno 163 77 0.360 0.170 FC no stdrd 17000.00 no stdrd 6957387.10 no stdrd 72472782 OCPSF 0.360 #/day 0.170 1,3-Dichbrobenzene 44 31 0.097 0.069 FC no stdrd 2600.00 no stdrd 1064070.97 no stdrd 11084.073 OCPSF 0.097 #/day 0.069 1,4-DIchbrobenzene 28 15 0.062 0.033 FC no stdrd 2600.00 no stdrd 1064070.97 no stdrd 11084.073 OCPSF 0.062 #/day 0.033 1,1-Dichloroethyiene (c) 25 16 0.055 0.035 FC no stdrd 3.20 no stdrd 7171.20 no stdrd 74.700 OCPSF 0.055 #/day 0.035 1,2-trans-Dichloroethylene 54 21 0.119 0.046 FC no stdrd no stdrd no stdrd no stdrd no stdrd no stdrd OCPSF 0.119 #/day 0.046 2,4-Dichlorophenol 112 39 0.248 0.086 FC no stdrd 790.00 no stdrd 323313.87 no stdrd 3367.853 OCPSF 0.248 #/day 0.086 1,2-Dichloropropane 230 153 0.508 0.338 FC no stdrd 39.00 no stdrd 15961.06 no stdrd 166.261 OCPSF 0.508 #/day 0.338 1,3-Dichloropropylene (c) 44 29 0.097 0.064 FC no stdrd 1700.00 no stdrd 3809700.00 no stdrd 39684.375 OCPSF 0.097 #/day 0.064 2,4-Dimethylphenol 36 18 0.080 0.040 FC no stdrd 2300.00 no stdrd 941293.55 no stdrd 9805.141 OCPSF 0.080 #/day 0.040 2,4-Dinitrotoluene (c) 285 113 0.630 0.250 FC no stdrd 9.10 no stdrd 20393.10 no stdrd 212.428 OCPSF 0.630 #/day 0.250 2,6-Dinitrotoluene (c) 641 255 1.417 0.564 FC no stdrd no stdrd no stdrd no stdrd no stdrd no stdrd OCPSF 1.417 #/day 0.564 Ethylbenzene 108 32 0.239 0.0711Q/NOE( 325.000 29000.00 133008.87 11868483.87 1385.509 123630.040 OCPSF 0.239 #/day 0.071 Flouranthene 68 25 0.150 0.055 FC no stdrd 370.00 no stdrd 151425.48 no stdrd 1577.349 OCPSF 0.150 #/day 0.055 Methylene Chloride (c) 89 40 0.197 0.088 FC no stdrd 1600.00 no stdrd 3585600.00 no stdrd 37350.000 OCPSF 0.197 #/day 0.088 Methyl Chloride 190 86 0.420 0.190 FC no stdrd no stdrd no stdrd no stdrd no stdrd no stdrd OCPSF 0.420 #/day 0.190 Hexachlorobutadiene (c) 49 20 0.108 0.044 FC no stdrd 49.70 no stdrd 111377.70 no stdrd 1160.184 OCPSF 0.108 #/day 0.044 Naphthalene 59 22 0.130 0.049 FC no stdrd no stdrd no stdrd no stdrd no stdrd no stdrd OCPSF 0.130 #/day 0.049 Nitrobenzene 68 27 0.150 0.060 FC no stdrd 1900.00 no stdrd 777590.32 no stdrd 8099.899 OCPSF 0.150 #/day 0.060 2 Nitrophenol 69 41 0.152 0.091 FC no stdrd no stdrd no stdrd no stdrd no stdrd no stdrd OCPSF 0.152 #/day 0.091 4-Nitrophenol 124 72 0.274 0.159 FC no stdrd no stdrd ' no stdrd no stdrd no stdrd no stdrd OCPSF 0.274 #/day 0.159 2,4-Dinitrophenol 123 71 0.272 0.157 FC no stdrd 14000.00 no stdrd 6729612.90 no stdrd 59683.468 OCPSF 0.272 #/day 0.157 4,6-Dinitro-o-cresol 277 78 0.612 0.172 FC no stdrd 765.00 no stdrd 313082.42 no stdrd 3261.275 OCPSF 0.612 #/day 0.172 Phenol 26 15 0.057 0.033 FC no stdrd 4600000.00 no stdrd ############ no stdrd 19610282.268 OCPSF 0.057 #/day 0.033 8/11/95 1 CCPSF Parameter FACILITY Monsanto OCPSF Flow 0.265 MGD Flow is based on processes only 7Q10s 791 ds Qavg 4340 ds PF 1.25 MGD Human Hlth Human Filth Allowable Allowable Limit Limit Fedl Standard Standard Allowable Allowable Aquatic Life Human Hlth Limit Daily Monthly Daily Monthly Daily Monthly State Aquatic Organisms conc. Aquatic conc Organisms Based Max Avg. max avg max avg Lite Life Organisms on: ug/i ug/l #/d #/d stdrd µg/l µg/l µg/l µgll #/day #Iday #/day Bis(2-ethylhexyl) phthalate (c) Dbutyl phthalate Diethyl phthalate Dimethyl phthalate Benzo(a)anthracene (c, PAH) Benzo(a)pyrene (c, PAH) 3,4-Benzolluoranthene (c, PAH) Benzo(k)fluoranthene (c,PAH) Chtysene (c, PAH) Acenaphthylene Anthracene Fluorene Phenanthrene Pyrene Tetrachloroethylene (c) Toluene Trichlororethylene (c) Vinyl Chloride (c) PAH (total -µg/I) (c) "Total Chromium " Total Copper " Total Cyanide " Total Lead " Total Nickel " Total Erne 279 103 0.617 0.228 FC no stdrd 5.90 no stdrd 13221.90 no stdrd 137.728 OCPSF 0.617 #/day 0.228 57 27 0.126 0.060 FC no stdrd 12000.00 no stdrd 4911096.77 no stdrd 51157.258 OCPSF 0.126 #/day 0.060 203 81 0.449 0.179 FC no stdrd 120000.00 no stdrd 49110967.74 no stdrd 511572.581 OCPSF 0.449 #Iday 0.179 47 19 0.104 0.042 FC no stdrd 2900000.00 no stdrd ############ no stdrd 12363004.032 OCPSF 0.104 #Iday 0.042 59 22 0.130 0.049 FC no stdrd 0.05 no stdrd 109.81 no stdrd 1.144 OCPSF 0.130 #/day 0.049 61 23 0.135 0.051 FC no stdrd 0.05 no stdrd 109.81 no stdrd 1.144 OCPSF 0.135 #/day 0.051 61 23 0.135 0.051 FC no stdrd 0.05 no stdrd 109.81 no stdrd 1.144 OCPSF 0.135 #/day 0.051 59 22 0.130 0.049 FC no stdrd 0.05 no stdrd 109.81 no stdrd 1.144 OCPSF 0.130 #/day 0.049 59 22 0.130 0.049 FC no stdrd 0.05 no stdrd 109.81 no stdrd 1.144 OCPSF 0.130 #Iday 0.049 59 22 0.130 0.049 FC no stdrd no stdrd no stdrd no stdrd no stdrd no stdrd OCPSF 0.130 #/day 0.049 59 22 0.130 0.049 FC no stdrd 110000.00 no stdrd 45018387.10 no stdrd 468941.532 OCPSF 0.130 #/day 0.049 59 22 0.130 0.049 FC no stdrd 14000.00 no stdrd 5729612.90 no stdrd 59683.468 OCPSF 0.130 #/day 0.049 59 22 0.130 0.049 FC no stdrd no stdrd no stdrd no sidrd no stdrd no stdrd OCPSF 0.130 #Iday 0.049 67 25 0.148 0.055 FC no stdrd 11000.00 no stdrd 4501838.71 no stdrd 46894.153 OCPSF 0.148 #/day 0.055 56 22 0.124 0.049 FC no stdrd 8.85 no stdrd 19832.85 no stdrd 206.592 OCPSF 0.124 #/day 0.049 80 26 0.177 0.057 SSIAQ 11.000 200000.00 4501.84 81851612.90 46.894 852620.968 OCPSF 0.177 #Iday 0.057 54 21 0.119 0.046 SS no stdrd 92.40 no stdrd 207068.40 no stdrd 2156.963 OCPSF 0.1 19 #/day 0.046 268 104 0.592 0.230 SS no stdrd 525.00 no stdrd 1176525.00 no stdrd 12255.469 OCPSF 0.592 #/day 0.230 aromatic hydrocarbons SS no stdrd 0.0311 no stdrd 69.70 no stdrd 0.726 CHRONIC 69.695 µg/I 2770 1110 0.000 0.000 SS 50.000 no stdrd 20462.90 no stdrd 213.155 no stdrd OCPSF 0.000 #/day 0.000 3380 1450 0.000 0.000 SS -AL 7.000 no stdrd 2864.81 no stdrd 29.842 no stdrd OCPSF 0.000 #/day 0.000 1200 420 0.000 0.000 SS 5.000 no stdrd 2046.29 no stdrd 21.316 no sidrd OCPSF 0.000 #/day 0.000 690 320 0.000 0.000 SS 25.000 no stdrd 10231.45 no stdrd 106.578 no stdrd OCPSF 0.000 #/day 0.000 3980 1690 0.000 0.000 SS 88.000 no stdrd 36014.71 no stdrd 375.153 no sidrd OCPSF 0.000 #/day 0.000 2610 1050 0.000 0.000 SS -AL 50.000 50.00 20462.90 2046290 213.155 213.155 OCPSF 0.000 #/day 0.000 "Total Zlnc for Rayon Fber Manufacture that uses the viscose process and Acrylic Fber Manufacture that uses zinc chloride/solvent process is 6,796 ug/L and 3,325 ug/L for maximum for any one day and maximum for monthly average, respectively. " Metal should only be limited if Total metal bearing wasteflow: process contains metal bearing wasteflow. Cyanide should only be limited if Total cyanide bearing wasteflow: process contains cyanide bearing wasteflow. 8/11/95 2 A/0 z LJLfts 47'.+'tcPfc2S NPDES WASTE LOAD ALLOCATION PERMIT NO.: NC0003719 PERM! 1"l'hE NAME: FACILITY NAME: Monsanto Company Fayetteville Plant Facility Status: Existing Permit Status: Major Pipe No.: 002 Renewal with Modification Minor Design Capacity: 1.3 MGD Domestic (% of Flow): (r10,006 9 iF do►r4911.6 Industrial (% of Flow): 100 Comments: waste treatment effluent AJ04-e.: List of ou06� 4.4-she_ RECEIVING STREAM: Cape Fear River Class: C ,64 LmetS , G itay.h 4 t Sub -Basin: 03-06-15 Reference USGS Quad: H 23 NE County: Cumberland Regional Office: Fayetteville Regional Office (please attach) Previous Exp. Date: 05/31/96 Treatment Plant Class: III Classification changes within three miles: No class change Requested by: Prepared by: Reviewed by: Jeanette Powell QA Ma-ry D, L ) to6,c) ib61,6 y (5) 33Z0 Ib S/o1,1 „Act_ (3/i7- Date: 0.3/30/95 Flow (MGD): GODS abs/day): TSS (lbs/day): DO (mg/1): pH (SU): COD (lbs/day): • NH3-N Fecal Coliform (/100m1): Residual Chlorine (ttg/1): Glyphosate (mg/1): TN (mg/I): TP (mg/1): Modeler Date Rec. # Drainage Area (mi2 ) L/39s Avg. Streamflow (cfs): 13LL() 7Q10 (cfs) 7C / Winter 7Q10 (cfs) AJ14- 30Q2 (cfs) AJA Toxicity Limits: IWC GIO % Instream Monitoring: Parameters 're-m/ / r-Dia u c-i'1► Upstream ye-6 Downstream ye5 Recommended Limits (Outfall 002): Summer in Monthly Avg. Daily Max. Monthly Avg. Daily Max. 1.3 200 457 5.0 6.0-9.0 5000 35 monitor monitor monitor monitor monitor hronic Location rn:. 0/0&-ittam maw. .l( Location foo yds f s e..•r11 PL_043 460 914 8000 70 (quarterly) (quarterly) 1.3 400 920 457 914 5.0 6.0-9.0 5000 8000 70 140 monitor monitor monitor monitor (quarterly) monitor (quarterly) OCPSF Parameters: The existing permit requires Monsanto to monitor quarterly for Methylene Chloride, Phenol, Bis(2-ethylhexyl)phthalate, Chloroform, 2-Chlorophenol, Chromium, Copper, Cyanide, Lead, Nickel, Zinc, and Total PAH's and monitor annually for all remaining OCPSF parameters as listed in 40 C I R 414, Subpart I. The parameters monitored quarterly were detected in an earlier battery of effluent sampling done by Monsanto. ICI, Inc. is undergoing a major increase in production along with a significant change in production methods. The monitoring frequency should be raised again for all parameters at least until sufficient data for a toxicant analysis is obtained. The data should be collected at a frequency no more than monthly and no less than quarterly during a period in which all production expansions (Monsanto and ICI) are : complete and all planned treatment components are operational until at least 12 data points have been accumulated. It should be communicated to the permittee that, once the necesAary data are obtained, a permit modification may be requested, and upon analysis of the data, monitoring may be reduced to an annual frequency again for the appropriate parameters. Monsanto will likely do sampling for OCPSF parameters over and above permit requirements on various influent and treatment system waste streams. The permit cover letter should contain a request that the permittee provide the results of any additional sampling to DEM for our evaluation. NPDES WASTE LOAD ALLOCATION PERMIT NO.: NC0003719 PERMI1"FEE NAME: FACILITY NAME: Monsanto Company Fayetteville Plant Facility Status: Existing Permit Status: Major .1 Pipe No.: 003 Renewal with Modification Minor Design Capacity: 0.03 MGD Domestic (% of Flow): Industrial (% of Flow): 100 % Comments: Discharge associated with incinerator. Applies only when incinerator is operational. Special condition requiring notification of regional office prior to discharge from this outfall. da*L 3 : /5/q5 RECEIVING STREAM: Cape Fear River Class: C Sub -Basin: 03-06-15 Reference USGS Quad: H 23 NE (please attach) County: Cumberland Regional Office: Fayetteville Regional Office Previous Exp. Date: 05/31/96 Treatment Plant Class: III Classification changes within three miles: No class change Requested by: Jeanette Powell Date: Prepared by: Ldi Date: Reviewed by: Date: --130D,_ ktgisidoy (s) 36 Iba/day Co) fez el - Modeler Date Rec. # Drainage Area (m.2 )'<3'S Avg. Streamflow (cfs): (43 LID 7Q10 (cfs) 7rj / Winter 7Q10 (cfs) 30Q2 (cfs) ,J4 Toxicity Limits: IWC % Acute/Chronic Instream Monitoring: (erect br opa f-e�ol`cm�►fS Parameters I (� Upstream Location Downstream Location IEffluent chnrarteristirs ISummer Recommended Limits (Outfall 003): Winter NOTE: Outfall 003 is for an incinerator at the Monsanto facility that would be used in emergency to dispose of contaminated or impure product. The incinerator has never been used since Monsanto began operations at this plant. The permittee has stated repeatedly that they never intend to use the incinerator because it would constitute a loss of highly valuable raw glyphosate product. The permit should continue to stipulate that Monsanto notify the Fayetteville Regional Office 24 hours prior to any discharge from this outfall. Flow (MGD): BOD5 (lbs/day): TSS (lbs/day): DO (mg/1): pH (SU): COD (lbs/day): NH3-N (mg/l): Glyphosate (mg/1): Monthly Avg. Daily Max. 0.03 5 10 67 134 6.0-9.0 40 1.0 monitor 6.0-9.0 80 2.0 monitor Comments: Facility Name: NPDES No.: Type of Waste: Facility Status: Permit Status: Receiving Stream: Stream Classification: Subbasin: County: Regional Office: Requestor: Date of Request: Topo Quad: FACT SHEET FOR WASTELOAD ALLOCATION Request # nn Monsanto Company NC0003719 100% Industrial Existing Modification (expansion to 1.3 MGD) Cape Fear River C 03-06-15 Cumberland Fayetteville Jeanette Powell 4/20/95 H23NE JUN 15 1995 - ENV. MANAGEMENT Stream Characterir:TTW fatMG. OFFICE' USGS # Minimum Release ' Date: 1985 Drainage Area (mi2): 4395 Summer 7Q10 (cfs): 791 Winter 7Q10 (cfs): Average Flow (cfs): 4340 30Q2 (cfs): IWC (002): 0.25% IWC (003): 0.006% Wasteload Allocation Summary (approach taken, correspondence with region, EPA, etc.) This WLA recommends a reduction of BOD5 from 350 lbs/day to 200 lbs/day, because modeling analysis of Cape Fear mainstem (with field calibrated QUAL2E) has indicated that cumulative loading of oxygen demanding wastes from point sources is a significant factor contributing to low dissolved oxygen levels in the lower half of the river. The Cape Fear Basin Plan recommends tertiary limits for all new and expanding major domestic discharges and BAT limits for major industries to be evaluated on a case by case basis. Analysis (by P&E) of removal efficiencies for Monsanto's treatment system has shown it to be consistently capable of achieving 99% removal of BOD5, which will allow the facility to meet the lower limit. NBOD loading is not a significant factor in this discharge so NH3N limit should remain unchanged. Monitoring frequency for OCPSF parameters has increased due to production increase with process change at ICI, Inc. Design flow increase for Monsanto will increase IWC slightly, but not enough to change toxicity test requirement. Sp al Schedule Requirements and additional comments from Reviewers: • / OA R-alrn ,/uLsr5 l ,,d gc- Ail> Tr /. Z S/1x, ieg C coitf/nfoo. Recommended by: Reviewed by Instream Assessment /1cc� c. i_,���� Regional Supervisor: Permits & Engineering: RETURN TO TECHNICAL SUPPORT BY: e / Date: (� ./%S JUL 1 1995 t4orc-- 1f tbtRS nit Leteiite r:r.YAK 2 Flow (MGD): BOD5 (lbs/day): TSS (lbs/day): DO (mg/1): pH (SU): COD (lbs/day): NH3-N (fygy�):(16s/day Fecal Coliform l ) Residual Chlorine (1.1g/1): Glyphosate (mg/1): TN (mg/1): TP (mg/1): OCPSF Parameters: TOXICS/METALS/CONVENTIONAL PARAMETERS Toxicity Test Requirements (Outfall 002): Existing Limit: Recommended Limit: Monitoring Schedule: Quarterly Acute (Fathead), 24 hr., NSM, P/F @ 90% Renew with existing limit. Feb., May, Aug., Nov. Existing Limits (Outfall 002): Flow (MGD): BOD5 (lbs/day): TSS (lbs/day): DO (mg/1): pH (SU): COD (lbs/day): NH3-N (J.1): !Js Fecal Coliform 10 Residual Chlorine (14/1): Glyphosate (mg/1): TN (mg/1): TP (mg/1): OCPSF Parameters: Summer Monthly Avg. Daily Max. 0.859 350 700 660 1264 5.0 6.0-9.0 3470 5608 23 46 monitor monitor monitor monitor (quarterly) monitor (quarterly) See Special Instructions or Conditions section. OCPSF parameters with limits is attached. Recommended Limits (Outfall 002): Summer Monthly Avg. Daily Max. 1.3 200 457 5.0 6.0-9.0 5000 35 monitor monitor monitor monitor (quarter monitor (quarter Winter Monthly Avg. Daily Max. 0.859 700 1400 678 1298 5.0 6.0-9.0 4715 7624 46 92 monitor monitor monitor monitor (quarterly) monitor (quarterly) List of Winter Monthly Avg. Daily Max. 1.3 460 400 920 914 457 914 5.0 6.0-9.0 8000 5000 8000 70 70 140 monitor monitor monitor ly) monitor (quarterly) ly) monitor (quarterly) See Special Instructions or Conditions section. List of OCPSF parameters with limits is attached. Limits Changes Due To: Change in 7Q10 data Change in stream classification Relocation of discharge Change in wasteflow New pretreatment information Other (onsite toxicity study, interaction, etc.) Parameter(s) Affected X BOD5, NH3N, COD, TSS WQ or EL WQ EL EL EL EL EL 3 X Parameter(s) are water quality limited. For some parameters, the available load capacity of the immediate receiving water will be consumed. This may affect future water quality based effluent limitations for additional dischargers within this portion of the watershed. OR No parameters are water quality limited, but this discharge may affect future allocations. Existing Limits (Outfall 003): NOTE: Outfall 003 is for an incinerator at the Monsanto facility that would be used in emergency to dispose of contaminated or impure product. The incinerator has never been used since Monsanto began operations at this plant. The permittee has stated repeatedly that they never intend to use the incinerator because it would constitute a loss of highly valuable raw glyphosate product. The permit stipulates that Monsanto notify the Fayetteville Regional Office 24 hours prior to any discharge from this outfall. Monthly Avg. Daily Max. Flow (MGD): 0.03 BODS abs/day): 5 10 TSS (lbs/day): 67 134 DO (mg/1): pH (SU): 6.0-9.0 6.0-9.0 COD (lbs/day): 40 80 NH3-N (mg/1): 1.0 2.0 Glyphosate (mg/1): monitor monitor Recommended Limits (Outfall 003): RENEW WITH EXISTING LIMITS (including 24 hr. notice provision). INSTREAM MONITORING REQUIREMENTS Upstream Location: Two miles upstream from outfall Downstream Location: 100 yards upstream of US Army Corps Lock & Dam #3 Parameters: Temperature, Dissolved Oxygen, Conductivity Special instream monitoring locations or monitoring frequencies: It should be noted that Monsanto's instream data is somewhat su ect, becausa Fayetteville PWC takes downstream samples for the Rockfish Creek at the exact same si and when samples are taken on the same days and near the same time, Monsanto's reported DO levels are consistently 1-2 mg/1 higher than PWC's. C A.0 cLe 1, u,��� � o zQ �s ��-�tS S C it w C. 0 S , ..-�o y p -� ��.w ' k ``P aF 1l� k -ek. sts ♦ u � C. 0.f ski S ! t 11__ ` l � 4 MISCELLANEOUS INFORMATION & SPECIAL CONDITIONS Adequacy of Existing Treatment Has the facility demonstrated he ability to meet the proposed new limits with existing treatment facilities? Yes No ✓ If no, which parameters cannot be met? MoNS kN-co -eLcv aac - e_ s� Would a "phasing in" of the new limits be appropriate? Yes ✓ No If yes, please provide a schedule (and basis for that schedule) with the regional office recommendations: rh oS - 1 N -J��: �,% ...L�=,t • c.t M- 6 4` l'o V o . If no, why not? Special Instructions or Conditions OCPSF Limits and Monitoring: The existing permit requires Monsanto to monitor quarterly for Methylene Chloride, Phenol, Bis(2-ethylhexyl)phthalate, Chloroform, 2-Chlorophenol, Chromium, Copper, Cyanide, Lead, Nickel, Zinc, and Total PAH's and monitor annually for all remaining OCPSF parameters as listed in 40 CFR 414, Subpart I. The parameters monitored quarterly were detected in the effluent in an earlier battery of sampling done by Monsanto. Since ICI, Inc. is undergoing a major increase in production along with a significant change in production methods, the monitoring frequency f s v should be raised to quarterly for all parameters until sufficient data for a toxicant analysis is �.� ��`� obtained (12 or more data points). It should be communicated to the permittee that, once the necessary data are obtained, monitoring will be reduced to an annual frequency again for the appropriate parameters. Monsanto will likely do sampling for OCPSF parameters over and above permit requirements on various influent and treatment system waste streams. The permit cover letter should contain a request that the permittee provide the results of any additional sampling to DEM for our evaluation. Wasteload sent to EPA? (Major) Y (Y or N) (If yes, then attach updated evaluation of facility, including toxics analysis, modeling analysis if modeled at renewal, and description of how it fits into basinwide plan) Additional Information attached? Y (Y or N) If yes, explain with attachments. 1. Full list of OCPSF toxicant parameters as given in 40 CFR 414, Subpart I with monthly average and daily maximum limits. 2. Toxicity test requirement form. Monsanto OCPSF Parameter FACILITY Monsanto OCPSF Flow 0.265 MGD Flow is based on processes waters only 70103 791 cfs Qavg 4340 cfs PF 1.3 MGD Limit Limit Recommended Federal Daily Monthly Daily Monthly monitoring or max avg max avg frequency State ug/I ug/I #/d #/d standard Acenaphthene 59 22 0.130 0.049 quarterly FC Acrylonitrile (c) 242 96 0.535 0.212 quarterly FC Benzene (c) 136 37 0.301 0.082 quarterly SS Carbon Tetrachloride (c) 38 18 0.084 0.040 quarterly SS Chlorobenzene 28 15 0.062 0.033 quarterly FC 1,2,4-Trichlorobenzene 140 68 0.309 0.150 quarterly FC Hexachlorobenzene (c) 28 15 0.062 0.033 quarterly FC 1,2-Dichioroethane (c) 211 68 0.466 0.150 quarterly FC 1,1,1-Trichloroethane 54 21 0.119 0.046 quarterly FC Hexachloroethane (c) 54 21 0.119 0.046 quarterly FC 1,1-Dichloroethane (c) 59 22 0.130 0.049 quarterly FC 1,1,2 trichloroethane (c) 54 21 0.119 0.046 quarterly FC Chloroethane 268 104 0.592 0.230 quarterly FC Chloroform (c) 46 21 0.102 0.046 quarterly FC 2-Chlorophenol 98 31 0.217 0.069 quarterly FC 1,2-Dichlorobenzene 163 77 0.360 0.170 quarterly FC 1,3-Dichlorobenzene 44 31 0.097 0.069 quarterly FC 1,4-Dichlorobenzene 28 15 0.062 0.033 quarterly FC 1,1-Dichloroethylene (c) 25 16 0.055 0.035 quarterly FC 1,2trans-Dichloroethylene 54 21 0.119 0.046 quarterly FC 2,4-Dlchlorophenol 112 39 0.248 0.086 quarterly FC 1,2-Dichloropropane 230 153 0.508 0.338 quarterly FC 1,3-Dichloropropylene (c) 44 29 0.097 0.064 quarterly FC 2,4-Dimethylphenol 36 18 0.080 0.040 quarterly FC 2,4-Dinitrotoluene (c) 285 113 0.630 0.250 quarterly FC 2,6-Dinitroto!uene (c) 641 255 1.417 0.564 quarterly FC Ethylbenzene 108 32 0.239 0.071 quarterly AQ/NOEC Flouranthene 68 25 0.150 0.055 quarterly FC Methylene Chloride (c) 89 40 0.197 0.088 quarterly FC Methyl Chloride 190 86 0.420 0.190 quarterly FC Hexachiorobutadiene (c) 49 20 0.108 0.044 quarterly SS Naphthalene 59 22 0.130 0.049 quarterly FC Nitrobenzene 68 27 0.150 0.060 quarterly FC 2-Nitrophenol 69 41 0.152 0.091 quarterly FC 4-Nitrophenol 124 72 0.274 0.159 quarterly FC 2,4-Dinitrophenol 123 71 0.272 0.157 quarterly FC Page 1 Monsanto OCPSF 4,6-Dinitro-o-cresol 277 78 0.612 0.172 quarterly FC Phenol 26 15 0.057 0.033 quarterly FC Bis(2-ethylhexyl) phthalate (c) 279 103 0.617 0.228 quarterly FC Dibutyl phthalate 57 27 0.126 0.060 quarterly FC Diethyl phthalate 203 81 0.449 0.179 quarterly FC Dimethyl phthalate 47 19 0.104 0.042 quarterly FC Benzo(a)anthracene (c, PAH) 59 22 0.130 0.049 quarterly FC Benzo(a)pyrene (c, PAH) 61 23 0.135 0.051 quarterly FC 3,4-Benzofluoranthene (c, PAH) 61 23 0.135 0.051 quarterly FC Benzo(k)fluoranthene (c,PAH) 59 22 0.130 0.049 quarterly FC Chrysene (c, PAH) 59 22 0.130 0.049 quarterly FC Acenaphthylene 59 22 0.130 0.049 quarterly FC Anthracene 59 22 0.130 0.049 quarterly FC Fluorene 59 22 0.130 0.049 quarterly FC Phenanthrene 59 22 0.130 0.049 quarterly FC Pyrene 67 25 0.148 0.055 quarterly FC Tetrachloroethylene (c) 56 22 0.124 0.049 quarterly FC Toluene 80 26 0.177 0.057 quarterly SS/AO Trichlororethylene (c) 54 21 0.119 0.046 quarterly SS Vinyl Chloride (c) 268 104 0.592 0.230 quarterly SS PAH (total -µg/l) (c) aromatic hydrocarbons quarterly SS ** Total Chromium 2770 1110 0.000 0.000 quarterly SS ** Total Copper 3380 1450 0.000 0.000 quarterly SS AL **Total Cyanide 1200 420 0.000 0.000 quarterly SS **Total Lead 690 320 0.000 0.000 quarterly SS ** Total Nickel 3980 1690 0.000 0.000 quarterly SS ** Total Zinc* 2610 1050 0.000 0.000 quarterly SS -AL Page 2 Facility Name Alb-Ala/4o l 6,,1,4y G Permit # dtcoo37)q Pipe # 00.2, ACUTE TOXICITY PASS/FAIL PERMIT LIMIT (QRTRLY) The permittee shall conduct acute toxicity tests on a quarterly basis using protocols defined in the North Carolina Procedure Document entitled "Pass/Fail Methodology For Determining Acute Toxicity In A Single Effluent Concentration." The monitoring shall be performed as a Fathead Minnow (pimephalea promelas) 24 hour static test, using effluent collected as a 24 hour composite. The effluent concentration at which there may be at no time significant acute mortality is 90% (defined as treatment two in the North Carolina procedure document). Effluent samples for self -monitoring purposes must be obtained during representative effluent discharge below all waste treatment. The first test will be pert ed after thirty days from the effective date of this permit during the months of f A/1a y� 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, DEM Form AT-2 (original) is to be sent to the following address: Attention: Environmental Sciences Branch North Carolina Division of Environmental Management 4401 Reedy Creek Road Raleigh, N.C. 27607 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 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 any test data from either these monitoring requirements or tests performed by the North Carolina Division of Environmental Management 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 retesting(within 30 days of initial monitoring event). Failure to submit suitable test results will constitute noncompliance with monitoring requirements. 7Q10 79 I cfs Permitted Flow / . 3 MGD IWC Basin & Sub -basin 63 --D(0 - 16 Receiving Stream cape_ J r (de r County �.t)m el/,q.i Recommended by: QAL P/F Fathead 24 Version 9/91 MEMO TO: M_0716ael A) L 4 h 5 6e- DATE• SUBJECT: :51.S�rG4if 117)ri 11G� 16oke- 0;M M, a€l LA) (F o) r 4 !`dart �ornWnCMIS b (+ p�ul/rGCcf� f,-161-rea,si n1071, re !'�`il /4oi16flfo, PC- (6yelfet,1J p,1d IOu4M4. .z e.x/1 aei ,,cue- were - the c rSctrc. Gf ,e c- (,346 plug/iGG��II� JU 1- ye. s74i (a/c *3j was 4e- tin ac.c,e,55(61po.%1i- oolfrA ctrld (oes.e.14 Surc it USe- bJ-e-re, ready /a dry Moern,n'fos ►`6D0r45f6/'/ri -JrD!/1�iScAfkt /hall/ior:il . ..17n o fV'ioil lie- boo Coil �� rL' fn o..J :% as ll y DP -tj e t <4 ,5 rA`IfrL in ern r�v r r 43 171 ° "1d jm;1 -- fhe- 114cei ✓e— 716 iog4c.rr0a.i4 - ?e, n'1Ern, -71o<</'-C/ r o� lr ,eort Al u) 7klY/1 i1G r i 4- it el- Cid c. /ac,, 5` 1 tz 1,'dk aid t'i�rrnJ1Ale) `Ae. 4,4, pcx1 , 6 holt Li ile- reIle, uJe (,n5i 1 al( ,ns%e,a.n mtrn, c';1) Tar Wftic, ,6efr Xfl.) rF cog(' Y.tpl01.G( ncpz Di,�Ltr5s Olu,f1 `d 64_4 Ae. 6l4-cc 0From 10()-1C 5e l(I exa 01 e\ 1 �d �� 4- (4-I :,; STATF North Carolina Department of Environment, Q Health, and Natural Resources g9 Printed on Recycled Paper COMPARITIVE LOADING UPPER CAPE FEAR RIVER FACILITY Lillington WWTP Buies Creek WWTP Swift Textiles Erwin WWTP Dunn WWTP PERMITTED NPDES# FLOW BOD5 MGD mg/I NC0021636 0.6 12.0 NC0030091 0.5 30.0 NC0001406 2.5 40.8 NC0064521 1.2 30.0 NC0043176 3.0 30.0 Cross Creek WWTP NC0023957 Rockfish Creek WWTP NC0050105 Monsanto NC0003719 Dupont -Fayetteville NC0003573 Carolina Foods NC0078344 West Point Pepperell NC0003522 Elizabethtown WWTP NC0026671 BOD5 MULT Ibs/day ratio 60.0 2.7 125.1 4.4 850.0 11.4 300.2 3.3 750.6 2.3 CBODu mg/I 32.4 132.0 464.7 99.0 69.0 CBODu Ibs/day 162.1 550.4 9690.0 990.8 1726.4 NH3N mg/1 2.0 20.0 NL 20.0 20.0 22.0 8.0 1467.8 2.5 20.0 3669.6 2.0 12.0 6.0 600.5 4.6 27.6 2762.2 1.0 0.86 48.8 350.0 8.3 405.0 2905.0 3.2 2.0 10.5 175.4 7.7 81.0 1350.6 1.4 3.0 5.0 125.1 5.6 28.0 700.6 5.0 2.5 10.9 227.0 6.8 74.0 1543.6 NL 0.7 30.0 175.1 2.0 60.0 350.3 20.0 Fuquay-Varina WWTP NC0028118 1.2 16.0 160.1 1.6 25.6 256.2 5.0 Fort Bragg WWTP NC0003964 8.0 16.0 1067.5 2.0 32.0 2135.0 11.0 Spring Lake WWTP NC0030970 1.5 28.0 350.3 2.2 61.6 770.6 8.0 Raeford WWTP NC0026514 3.0 30.0 750.6 6.9 207.0 5179.1 20.0 TOTAL LOAD 64.6 7535.5 34742.6 NH3N Ibs/day 10.0 83.4 0.0 200.2 500.4 367.0 100.1 23.0 24.0 125.1 0.0 116.8 50.0 733.9 100,1 500.4 NBOD Ibs/day 45.0 375.3 0.0 900.7 2251.8 1651.3 450.4 103.5 108.0 563.0 0.0 525.4 225.2 3302.6 450.4 2251.8 BODu %TOT Ibs/day 207.2 1.2 925.7 5.5 9690.0 58.0 1891.5 11.3 3978.2 23.8 16692.6 5320.9 3212.6 3008.5 1458.6 1263.5 1543.6 875.7 16683.4 481.4 5437.7 1221.0 7430.9 2934.3 13204.4 47947.0 31.9 19.3 18.0 8.7 7.6 9.3 5.2 FACILITY Lillington WWTP Buies Creek WWTP Swift Textiles Erwin WWTP Dunn WWTP Cross Creek WWTP Rockfish Creek WWTP Monsanto Dupont - Fayetteville Carolina Foods West Point Pepperell Elizabethtown WWTP Fuquay-Varina WWTP Fort Bragg WWTP Spring Lake WWTP Raeford WWTP TOTAL LOAD FLOW MGD 0.45 0.36 1.5 0.78 2.4 12.9 7.2 0.49 0.95 2.1 1.20 0.53 BOD5 mg/I 13.5 15.0 5.6 6.1 5.0 3.8 3.4 17.6 5.7 6.2 2.0 13.3 ACTUAL BOD5 Ibs/day 50.7 45.0 70.5 39.7 100.1 408.8 204.2 71.8 45.1 109.4 20.1 58.8 0.83 7.6 52.5 5.0 3.5 146.0 0.89 5.5 40.8 1.65 24.3 334.4 39.2 1797.9 CBODu CBODu mg/I Ibs/day 36.5 136.8 66.0 198.2 64.2 803.7 20.1 11.5 9.5 15.6 145.8 43.8 35.0 13.7 26.6 130.9 230.2 1022.1 939.2 595.9 346.9 612.6 136.7 117.6 NH3N mg/I 3.6 1.1 0.2 0.5 1.4 0.3 0.1 0.6 1.8 0.1 1.1 5.8 NH3N Ibs/day 13.5 3.3 2.3 3.3 28.0 32.3 8.4 2.4 14.3 2.1 11.0 25.6 NBOD Ibs/day 60.8 14.9 10.4 14.6 126.1 145.2 37.8 10.8 64.2 9.5 49.5 115.4 12.2 84.2 0.7 4.5 20.2 7.0 291.9 0.2 7.1 31.9 12.1 89.8 0.2 1.3 5.7 167.7 2307.3 10.5 144.5 650.2 8043.9 303.8 1367.2 species. A Poor bioclassification was assigned to Little Rockfish Creek and the data indicate that the Stevecoknit facility is stressing benthic fauna and is a possible contributor to the degraded water quality of Rockfish Creek below Wallace. The writer observed discolored water on the Northeast Cape Fear River near SR 1318 on June 5 and complaints were received by this office on June 6 and 8 regarding colored waters in this same area. One of the complaintants said he had caught fish which had leisons. SR 1318 is located roughly 14 miles downstream from the Stevecoknit discharge point. Colored waters were also apparent at the writers house, located roughly 19 miles downstream. Discolored waters have been observed in Rockfish Creek at I-40 on several occassions, but were fairly constant during May and June of this year due to dry weather conditions, and consequently low flows in the creeks. A color sample collected at I-40 on May 3 measured 390 (ADMI at pH 7.8). A sample collected the same day from Little Rockfish Creek at NC 11 measured 1100 (ADMI at pH 7.6). It is the writers understanding that the State is working towards a color standard. In an effort to provide supportive documentation, this office will be collecting color and copper samples twice a month for a period of six months from the effluent, at the confluence of Little and "big" Rockfish Creeks, upstream from Little Rockfish on Rockfish Creek at Highway 17, and downstream from Little Rockfish at the I-40 ambient station. At the end of six months it will be determined if further data is required. Although color monitoring was recommended by Instream Assessment and copper limits were advocated by the WIRO Regional Supervisor during permit modification in December 1991/January 1992, these recommendations were not included in the final permit. It is the intent of this memo to reemphasize the problem of elevated levels of copper, as well as the increased detection of highly colored waters in Rockfish Creek. While it is known that the color impacts are from Stevecoknit, it is suspected that the elevated copper levels are a result of this facilities' discharge as well. Placement of limits on effluent copper levels and color monitoring are recommended when Stevcoknits' NPDES permit is reviewed/renewed in 1996 (if not before). cc: Coleen Sullins Ken Eagleson Carla Sanderson Dianne Reid Julia Storm Mike Williams Fat: 5 199 Figure A.32 Box Plots for Dissolved Oxygen (rig/1) for Cape Fear River Mainstem, 1988-1993 0 0 0 Station # Station Name 02102178 Cape Fear River At NC Hwy 42 Near Corinth, NC 02102500 Cape Fear River At US Hwy 401 At Lillington, NC 02102696 Cape Fear River At NC Hwy 217 Near Erwin, NC 02104000 Cape Fear River At NC Hwy 24 At Fayetteville, NC 02105500 Cape Fear River @ William O. Huske Lock Nr Tar Heel, NC 02105512 Cape Fear River At SR 1316 Near Tarheel, NC 02105544 Cape Fear River At Lock And Dam #2 Near Elizabethtown, NC 02105769 Cape Fear River At Lock #1 Near Kelly, NC 02105771 Cape Fear River At NC Hwy 11 Near Kelly, NC 02105825 Cape Fear River Above Neils Eddy Landing Near Acme, NC 02107570' Cape Fear River Below Hale Point Landing Nr Phoenix, NC 02107576 Cape Fear River At Navassa NC 02I08736 Cape Fear River @ Channel Marker 1155 @ Wilutinbton, NC 02108757 Cape Fear River @ Channel Marker#50 Near Wilmington NC 0 0 O. .1111 8 § _1) : J( 13 i I (� O OTv.° -?�Via.sq� " ° '1.c dk`3w-411- CN vihama- YQ c•�qi3•V Yq , 1J J 8 I( 1'plr Ili►,I 3' CTO '-+ [� O in vs)▪ (` 00 ▪ r- N ▪ ,--i kr) kr) V) V-1 v V) t--- r-- 00 CD 0) CD CD CD CDO O CD CD - - - ' , -4'Cl-� ,---- - ,-- N N N N N N N N N N N 0 0 0 0 0 0 0 0 O 0 0 0 0 I HWY401. 1.3 miles down @ boat ramp Erwin Mills • HWY217 • Hoffer WTP • Riverside Landing • HWY87 • DuPont Fayetteville water intake • above Carolina Foods Tarheel Landing Federal Paper water intake • DuPont Wilmington water intake ' 1 DO (MG/L) I m aco I po co I Hal -Para 0 I I om (ffi—DICI-I4 cre--Ca—ca o 0 0 00 :omo. oI ao Io 0 o I oo--Damt0 0 I tliCH I o .4 00 I prepuces aavionA Amp Chemical Monitoring Summary Report CAPE FEAR RIVER @ WILLIAM O. HUS KE LOCK NR TAR HEEL; iNC Page 1 of 2 Station Number: 02105500 • STORET Number: 88300000 Water Quality Class: C Regional Office: Fayetteville Topographic Map: County: Bladen Subbasin: 030616 Drainage Area (sq nu): 4852 Average Flow (cfs): 4957 • Summer 7Q10 (cfs): 385 Winter 7Q10 (cfs): 679 30Q2 (cfs): 925 Gage: Gage Site ® Stream [] Estuary El Lake ® Fish Tissue El Fish Community ▪ Benthic Parameter Name Units STORET NC State Code Criterion Min Med Max Beginning Ending n > Det > Crit Date Date Dissolved Oxygen mg/1 00300 4 5.8 8.4 11.4 63 63 0 1/22/88 7/28/93 pH SU 00400 6 - 9 5.6 6.7 8.1 63 63 1 1/22/88 7/28/93 Conductivity µMho 00094 N/C 63 101 400. `- ,, 63 63 0 1/22/88 7/28/93 Chlorophyll a (Corr) µg/1 32209 N/C 1 2.5 4 2 2 0 10/13/92 6/2/93 Fecal Coliform, MF #/100 ml 31616 200 10 58.79 660 18 18 3 3/19/92 7/28/93 Total Phosphorus mg/1 00665 N/C 0.11 0.14 0.91 18 18 0 3/19/92 7/28/93 Ammonia -Nitrogen mg/1 00610 N/C 0.02 0.08 0.32 *18 18 0 3/19/92 7/28/93 Nitrate/Nitrite-N mg/1 00630 N/C 0.28 0.64 0.91 18 18 0 3/19/92 7/28/93 Total Nitrogen mg/1 00600 N/C N/S_4 .. Turbidity " ' NTU 00076 50 3.6 16 40 ::"3'1f r`'" 31 0 3/15/88 7/28/93 Hardness mg/1 00900 N/C 17 22 36 31 31 0 3/15/88 7/28/93 Total Residue mg/1 00500 N/C 79 120 160 17 17 0 3/15/88 6/2/93 Total Suspended Res mg/1 00530 N/C 4 13 64 33 33 0 3/15/88 7/28/93 Aluminum • µg/1 01105 N/C 5 380 2100 17 16 0 12/6/89 7/28/93 Arsenic µg/I 01002 50 10 31 0 3/15/88 7/28/93 Cadmium µg/1 01027 2 2. 33 0 3/15/88 7/28/93 Chromium µg/1 01034 50 25 33 0 3/15/88 7/28/93 Copper (AL) µg/1 01042 7 2 5 10 33 26 4 3/15/88 7/28/93 Iron (AL) µg/1 01045 1000 300 790 2800 16 16 6 3/19/92 7/28/93 Lead µg/1 01051 25 10 33 0 3/15/88 7/28/93 Mercury µg/1 71900 0.012 0.02 0.2 0.8 33 1 1 3/15/88 7/28/93 Manganese µg/1 01055 N/C 28 61.5 91 12 .1 12 0 3/19/92 7/28/93 Nickel µg/1 01067 88 10 10 50 33 2 0 3/15/88 7/28/93 Zinc (AL) µg/1 01092 50 10 10 , 37 33 8 0 3/15/88 7/28/93 Abbreviations: n=number of observations; > Det=number of observations greater than the detection limit; > Crit=number of observations greater than the criterion; N/S=No sample; N/C=No Criteria; AL=Action Level Notes: Median values are calculated using the detection level for samples classified as below detection. The Median value for Fecal Coliform is actually the Geometric Mean value. Data includes only surface samples. Samples recorded at less than detection are considered at the detection level for this summary. Station Comments: CAPE FEAR RIVER @ WILLIAM O. HUSKE LOCK NR TAR HEEL, NC Page 2of2 Summer Summary (April -October): Dissolved Oxygen (mg/1): pH (SU): Total Phosphorus (mg/1): Ammonia -Nitrogen (mg/1): Nitrate/Nitrite-Nitrogen (mg/1): Conductivity (µMho): Chlorophyll a (Corr) (ug/1): Total Suspended Residue (mg/1): ations Observs > Det Median Maximum Minimum 39 39 7.1 9.4 5.8 39 39 6.7 8.1 6 13 13 0.14 0.91 0.11 13 13 0.08 _ 0.32 0.04 13_ 13 • 0.62 0.91 0.28 39 39 109 400 65 2 2 2.5 4 1 21 21 13 38 4 Summer Summary (June -September): Dissolved Oxygen (mg/1): pH (SU): Total Phosphorus (mgll): Ammonia -Nitrogen (mg/1): Nitrate/Nitrite-Nitrogen (mg/1): Conductivity (p.Mho): Chlorophyll a (Corr) (µg/l): Total Suspended Residue (mg/1): Yearly Summary : Dissolved Oxygen ervations Observs > Det Median Maximum Minimum 22 22 6.6 9.4 5.8 22� 22 6.7 8.1 6 7. • 7 0.14 0.23 0.11 7 7 0.08 0.12 0.04 7 _ 7 0.62 0.72 0.28 22 22 128 400 65 1 1 4 4 4 15 15 13 38 4 Year Obs Obs>Det Median Max Min 1988 12 12 8.45 11.2 5.8 1989 12 . 12 8.05 11.2 6.2 1990 12 12 8.85 10.2 6.3 1991 9 9 7.6 10.4 6 1992 12 12 7.45 11.4 6.2- 1993 6 6 8.65 11.2 6.4 • Conductivity 1988 12 12 94.5 400 68 1989 12 12 90.5 129 _ 70 1990 12 12 108 189 91 1991 9 9 124 161 71 1992 12 12 109.5 160 65 1993 6 6 107 140 63 Total Suspended Residue 1988 - 4 4 8.5 64 8 1989 4 4 12.5 38 7 _ 1990 4 4 . 13 31 7 1991 3 3 10 18 5 1992 _ 11 11 14 23 6 i 1993 7 7 15. 34 4 pH Year Obs Obs>Det Median Max Min 1988 12 12 6.45 7.2 6 1989 12 12 6.8 7.3 6.5 1990 12 12 7 8.1 6.6 1991 9 9 6.7 7 6.2 1992 12 12 6.65 7.2 6.2 1993 6 6 6.25 6.6 5.6 Total Phosphorus 1988 N/S 1989 N/S 1990 N/S 1991 • N/S 1992 11 11 0.13 0.91 0.11 1993 7 7 0.17 0.17 0.11 Ammonia -Nitrogen 1988 N/S . 1989 N/S 199'0 N/S 1991 N/S 1992 11 ' 11 0.07 0.32 0.04 1993 , -7 7 0.09 0.12 0.02 Monsanto NC0003719 AIBICIDIE FIGIHII 1 date temp UPSTREAM DO DO sat % sat temp DOWNSTREAM DO DO sat % sat 2 3 5/4/94 21.0 7.3 8.9 0.82 20.0 7.2 9.1 0.79 4 5/11/94 18.0 7.8 9.5 0.82 18.0 7.6 9.5 0.80 5 5/18/94 18.0 7.0 9.5 0.74 19.0 7.9 9.3 0.85 6 5/25/94 22.0 6.8 8.7 0.78 23.0 8.8 8.6 1.03 7 6/1/94 22.0 7.0 8.7 0.80 22.6 7.9 8.6 0.91 8 6/8/94 26.0 7.3 8.1 0.90 25.5 7.8 8.2 0.95 9 6/15/94 25.3 8.2 25.5 6.4 8.2 0.78 10 6/22/94 25.2 5.8 8.2 0.70 25.4 6.1 8.2 0.74 11 6/29/94 27.8 7.0 7.9 0.89 27.8 6.8 7.9 0.87 12 7/6/94 29.6 6.4 7.6 0.84 28.4 6.5 7.8 0.84 13 7/13/94 28.7 6.2 7.7 0.80 29.4 6.2 7.6 0.81 14 7/20/94 29.8 6.7 7.6 0.88 29.6 6.7 7.6 0.88 15 7/27/94 26.8 6.2 8.0 0.78 28.0 6.4 7.8 0.82 16 8/3/94 26.6 6.8 8.0 0.85 23.6 6.9 8.5 0.81 17 8/10/94 25.8 7.2 8.1 0.88 23.5 7.0 8.5 0.82 18 8/17/94 26.1 6.1 8.1 0.75 24.4 6.2 8.4 0.74 19 8/24/94 25.6 7.1 8.2 0.87 25.3 7.1 8.2 0.86 20 8/31/94 25.2 7.2 8.2 0.87 24.1 6.9 8.4 0.82 21 9/7/94 21.1 7.8 8.9 0.88 21.9 8.1 8.8 0.92 22 9/14/94 24.9 6.6 8.3 0.80 24.8 6.3 8.3 0.76 23 9/21/94 23.2 7.1 8.5 0.83 23.2 6.8 8.5 0.80 24 9/28/94 22.8 7.4 8.6 0.86 22.7 7.4 8.6 0.86 25 10/5/94 19.8 7.4 9.1 0.81 20.4 7.0 9.0 0.78 26 10/12/94 18.1 8.0 9.4 0.85 18.4 7.9 9.4 0.84 27 10/19/94 15.6 8.7 10.0 0.87 16.1 8.4 9.8 0.85 28 10/26/94 17.3 7.8 9.6 0.81 17.4 7.7 9.6 0.80 29 30 31 32 33 34 35 Page 1 Ai /US 7. . 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A 7,4 A - 0.740'fre-' AA/it /.0- 04Z, %dad (41( diZOPIA3-el 12g.OUL 'fg4/LtieLL Lk ›f2,ci 9:WC. 1,-0 OC/6, t • cvi(A-aAi zfitia,--- /Row 2 _(`1/7 ,04 _ye-i,e6.---14 /0,4 0JL1 003 023 Ott„1111142.6 44 !! l , iCa il�n f zwtox 2 .c? ( /e A.L o vc- n,(4-4 , l ( No (is lercoot 61 68 /1 •._ (44 S-1d'cG ivt. �) �c3 r,J /I ,� f%ems /� -� lI . . �`� 444704- 120 /°l� 0/-,..z cif(e -z,. 7 o 640.:, , 0 . jwi frko 1.4_,. 1,S ST (e, G07 ti z 4,, S ,t , irk• -7, 6..1 i,3,/71=- (a, o� -'. q /J5 -7/[ 5a , .1 7,7 , 3 7 hj-) (. I iiiiiik 5. q -7✓4,7. 5-5 (,7 5. �- 7/ . 7,3 5.0 6_5 7fr62- 5, q 6 , 3 ids flOs S 5 -7 ,? A3 'W,IPA-J 5.5 -7, Li /Js //1,1fr-L 6,,C) (e . i (p ,5 *.e:7 G .1y _ Co ,'7 ". V 105 -/a/sa 7, -7, C 6, I q y y� 51 7,1 �, 3 � (9,6 1, y C , c'///-3 (t/ i I co, (e' /05 7/3°//2- 9 , I -7, ,5 Inf ./9? �,( -7.( ii5 rf bv- o �-7, 5 i, s /I 5 !0/21 ra- 7 7 7. I( ii, z -7r ( /ll s G. 41 S �r3 ,Os r3 jV J 6, S� S 7a ik1S bra o S, S 1 �15 GJ .S kJ S 1dS 6,44z eAfiteL (. a/vim Sd -7b0 (pS0 3, �a 75 /60 -7(0 -/a 5, a�ag�5 Sid6, 3A/56 aoc) (A/v, 4eYe5L,) p� M f'cI cAeI LiIe/r DIVISION OF ENVIRONMENTAL MANAGEMENT Water Quality Planning Branch Tue, Apr 16,1996 MEMORANDUM TO: Lisa Tabor, Groundwater Section FROM: Dianne Reid RE: Monsanto, ICI Films, Wellman Natural Attenuation CAP ervykotA Per your request I have reviewed the information on the Monsanto, IQ Films, and Wellman groundwater discharge. Surface water quality standards must be met in the seepage from the bank. This statement is based on the definition of groundwater (15A NCAC 2L .0100). I also looked at the data you provided to see if surface water quality standards are being exceeded. The portion of the Cape Fear River into which the seep runs is classified C waters. The following table presents the highest concentrations found in the seepage from 1994 (memorandum from Environmental Sciences to Fayetteville Regional Office dated February 15,1994) and 1995 (Monsanto monitoring data) and the applicable water quality standards. Contaminant Seepage** 2/15/94 11/15/95 (uall) NC Surface Water Quality Standard (ug/1) Arsenic 7.8 - 50 Chlorobenzene 1.9 - 488 Chloroethane 230.0 220 860* Chloroethyl vinyl ether, 2- 40.0 - 17,500 Chromium 20.0 - 50 Cyanide 12.0 • 5 Dichloroethylene, 1,2- 11.0 - 7.0* DichIoroethane, 1,1- 560 2.9 19.8* Tetrachloroethylene 17 66 8.85t Trichloroethane, 1,1,1- 140 - 2,453 Trichloroethylene 8.2 4.1 92.4 j zinc 100.0 _ 50 * Developed per 15A NCAC 2B .0208 based on limited data set and acute/chronic ratio of 0.05. ** Data from February 15,1994 DEM memo and Monsanto sampling November 15,1995. t NC standard for water supplies is 0.8 ug/1. Since this portion of the Cape Fear is not water supply, this criteria was developed per 15A NCAC 2B .020& Division of Environmental Management Page 1 Water Quality Planning Branch Monsanto Natural Attenuation CAP April 16,1996 Lisa Tabor There are five contaminants which exceed the applicable.water quality standards. Those contaminants are listed below. • cyanide • 1,2-dichloroethylene • 1,1-dichloroethane • tetrachloroethylene • zinc Several of these concentrations are close to the applicable standard and may be not be significantly different from the standard. Of the contaminants listed for 1995, only tetrachloroethylene concentrations (66 ug/1) were above the surface water quality criteria of 8.85 ug/l. The Fayetteville Regional Office water quality staff should be consulted regarding any further actions necessary to protect surface water quality. If you have questions, then please call me at 733- 5083 extension 568. cc: Jimmie Overton Phil Bethea Paul Rawls, FRO Division of Environmental Management Page 2 Water Quality Planning Branch State of North Carolina Department of Environment, Health and Natural Resources JamesB. Hunt,Jr., Govemor Jonathan B. I-bwes, Secretary Seven J. Levitas, Deputy Secretary FAX TO: AvICC'rA �EHNR Division of Environmental Management Water Quality Planning P.O. Box 29535 Raleigh, N.C. 27626-0535 FAX:(919) 715-5637 FAX NUMBER: quLcsrA-I ca_ 6 FROM: (2 Q PHONE: (919) 733-5083 x (Q e NO. OF PAGES INCLUDING THIS SHEET: 3 Zu-<ak- c,, c, \.„,,o__ ,LA, -7- 4-- -6, 2,--3c-L-Y ,;,-- c;r6„,,QL,,. eajo LI -IL 2_Q/ff.s Lft_hyt u)(JJ,ys f) iej, ji,,_ ,,,_„0 a <(,,,,(c_csL uictgc ,L)-;,-k\-\\ 4-&-rsiv u.;ilt_ an t,e,,e,._ a,-J Y 3,(-:d Lr . / -45- 66.4))7,-- cl,r- La.,)A- LiJ)1r----> c/f) '-j iict- 1,1,1-TCA PCE 1,1-DCA A • 1,1-DCE TCE c-1,2-DC E [AN. t-1,2-DCE 1 ,2-DCA VINYL CHLORIDE CHLORO- ETHANE Source: Adopted from Dragun, 1988 A WGERAGHTY /i r& MILLER, INC: Aid Environmental Services Transformation of Chlorinated Aliphatic Hydrocarbons Monsanto Agricultural Company Fayetteville, North Carolina FIGURE 2-2 l G, G Table 2-1. Surface -Water Quality Data Summary, November 15, 695,_Monsanto Agricultural Company, Fayetteville, North Carolina. COMP-1 SP-2A SP-3A SP-3B SP-3C COMP-4 COMP-5 REP-001 VOCs (USEPA 601) lig/L Trichloroethene <1.0 <1.0 <5.0 <1.0 4.1 2.7 <1.0 <1.0 Tetrachloroethcnc <1.0 66 <5.0 <1.0 <1.0 1.3 <1.0 <1.0 Chloroethane 18 28 220 6.4J <1.0 <1.0 <1.0 3.5J 1,1-Dichlorocthane <1.0 <1.0 <5.0 1.9 <1.0 <1.0 <1.0 2.9 SVOCs (SW-846 8270) lig/L Diphenyl Ether 22 41 15 <10 120 <10 <10 <10 ll� Micrograms per liter. NA Not analyzed. J Compound concentrations did not meet the field duplicate sample criteria and are qualified as estimated. The sample data for SP-3B and Rep-001 are less than 5 times the quantization limit and the difference between the two concentrations is greater than the quantization limit. sprojecONC0315.00112.1 LAN.XLSW26196 GERAGHTY & MILLER, INC. 0 Page 1 of 2 Table 3-1. Groundwater Quality Data Summary, November 16, 1995, Monsanto Agricultural Company, Fayetteville, North Carolina. MW-1 MW-2 MW-3 MW-6 MW-7 MW-10 MW-11 MW-12 MW-13 VOCs (USEPA 601) tig/L Chloroethane <1.0 <1.0 <1.0 <1.0 <1.0 <1.0 <1.0 <1.0 <1.0 1,1-Dichlorocthane <1.0 <1.0 <1.0 <1.0 <1.0 <1.0 <1.0 <1.0 <1.0 Tetrachloroethene <1.0 <1.0 <1.0 <1.0 <1.0 1 9.3 <1.0 <1.0 1,1,1-Trichloroethane <1.0 <1.0 <1.0 <1.0 <1.0 <1.0 19 <1.0 <1.0 Trichloroethene <1.0 <1.0 <1.0 <1.0 <1.0 <1.0 <1.0 <1.0 <1.0 SVOCs (SW-846 8270) ug/L Diphenyl Ether NA NA NA <10 <10 NA <10 150 <10 lag& NA J* J** Micrograms per liter. Not analyzed. Compound concentrations did not meet the field duplicate sample criteria and are qualified as estimated (J). The sample concentrations for MW-20 and Rep-002 exceed 5x the quantitation limit and the relative percent difference between the two concentrations is greater than 20%. Compound concentrations did not meet the field duplicate sample criteria and are qualified as estimated (J). The sample concentrations detected in Rep-002 is below 5x the quantitation limit and the difference between the concentration detected in MW-20 and Rep-002 is greater than the quantitation limit. sprojccf NC034S.001O.1 LAN.XLS►Y26/96 GERAGHTY & MILLER, INC. Ci Page 2 of 2 Table 3-1. Groundwater Quality Data Summary, November 16, 1995, Monsanto Agricultural Company, Fayetteville, North Carolina. MW-14 MW-15 MW-16 MW-17 MW-18 MW-19 MW-20 REP-002 VOCs (USEPA 601) ug/L Cltloroethane <1.0 <1.0 <1.0 <1.0 <1.0 120 9.0J* 12J* 1,1-Dichloroethane <1.0 <1.0 <1.0 <1.0 <1.0 <5.0 5.7J* 7.9J* '1'etrtcitloroetltenc <1.0 <1.0 <1.0 <1.0 <1.0 <5.0 17J** <1.0J** 1,1,1-Trichlorocthane <1.0 <1.0 <1.0 <1.0 <1.0 <5.0 <1.0 <1.0 Tricltlorocthcne <1.0 <1.0 <1.0 <1.0 <1.0 <5.0 <1.0 1.6 SVOCs (SW-846 8270) ttg/L Diphcnyl Ether <10 <10 <10 2300 <10 32 <10 <10 µg/L Micrograms per liter. NA Not analyzed. J* Compound concentrations did not meet the field duplicate sample criteria and are qualified as estimated (J). The sample concentrations for MW-20 and Rep-002 exceed 5x the quantitation limit and the relative percent difference between the two concentrations is greater than 20%. J** Compound concentrations did not meet the field duplicate sample criteria and arc qualified as estimated (J). The sample concentrations detected in Rep-002 is below 5x the quantitation limit and the difference between the concentration detected in MW-20 and Rep-002 is greater than the quantitation limit. sprojecANC0343.00113-1 LAN.XLSWl6/96 GERAGHTY & MILLER, INC. La A. WARREN o- ct 0 W Y 0 W 3 m O W 0 C a A O 0 < z 0 z < O 0 z to z 0 2 O z W ..J L. 0 tri Q r'9 0 U z 0 Z 1- - C. In tT tvt O Q1 W 1- O 3 0 - r 1 1 I 1 1 1 i v 0 N a W S t- W J Z W W 2 I -a 1 i i O j in Z ` m to tx m V) CO to r N tO 'd 00 N N a La La Z 2 < W 2 ~ .-IW � 0 OZ W = J d 00 CL 4. w GROUND -WATER SEEP 1.1-DICHLOROETHANE TETRACHLOROETHENE TRICHLOROETHENE ESTIMATED CONCENTRATION cc W 3 Oat N W a H to z20 h z� 0 Z J W cr. Q % v W 0 Z 8 O w CC r" D 1 1 N `14 d e-i-< Table 1. Summary of Seeps Analytical Results November 29, 1994, Monsanto Agricultural Chemicals Company, Fayetteville, North Caroli Compound [1] SE1 2A(SE) 3A(SE) 3B(SE) 3C(SE) 13A(SE) 13B(SE) 13C(SE) SE4 SE5 [3A(SE) [3B(SE) [3C(SE) Replicate] Replicate] Replicate] Chloroethane 0.029 0.074 0.069J 0.100J 0.0018 0.093J 0.170J 0.0021 BDL BDL cis/trans-1,2-Dichloroethene BDL BDL BDL BDL 0.0050 BDL BDL 0.0056 0.0021 . BDL 1,1-Dichloroethane BDL BDL BDL 0.020J 0.0030 0.019 0.027J 0.0035 0.0024 0.0012 Tetrachloroethene BDL BDL BDL BDL BDL BDL BDL BDL 0.014 0.0051 1,1,1-Trichloroethane BDL BDL BDL BDL BDL BDL BDL BDL BDL 0.0025 Trichloroethene BDL BDL BDL BDL BDL BDL BDL BDL 0.0028 BDL All Other USEPA Method BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL 601 Compounds [1] All results expressed in milligrams per liter (mg/L). BDL Below detection limit. J Estimated concentration. Duplicate sample QC criteria were not met. NCO27$.00112160ncm ..urnmablx1Av17ros GERAGHTY & MILLER, INC. 0 FIGURE NCO275.00I/Doc.2I60maos2160.itr/17Fcb95 MONSANTO PROPERTY 1 l � _ _ V V �/ , jCI AKERICAS • • PROPERTY / S-ZR / S017 ACRES 1 /• S-12 SEEP NUMBER ELEVATION IA e5 19 70 1C 70 1D 73 1E 75 2A 83 s 72 3C 75 4A 67 4B 83 5A 71 58 85 5C 67 0 400 FT. o. VEWIAN PROPERTY 1819 ACRES 1 1 98.38 APPROXIMATE ABANDONED AREA D-3 rnitu • S-13 1 1 MEI 100 MW--6 MW-17 IEREEN • 61W-20 EMU Uw -13 98 • MW-11 108 104 100 88 80�` 120 D E 3C 38 . 5- C STREAM 1 2A STREAM 27 3 STREAM 5 STREAM 4 RIVER /4f GERAGHTY 4r & MILLER, INC. siiir EnviTvnmentaj Services - - • MW-1 ' Awm PROPERTY 228.42 ACRES MW-4 MEC • MW-10 / / / LEGEND • MONITOR WELL 96 WATER TABLE ( —� GENERAUZED C FLOW DIRECTIO. O GROUND—WATEF GENERALIZED GROUND -WATER FLOW PATTERNS WITHIN THE LOWER SAND AOUIFER 8EFTE 28,1992 MONSANTO AGRICULTURAL CHEMICALS COMPANY. FAYETTEVILL E. NORTH CAROUNA 1 v- . 1 { LQINSANTO 11 PROPERTY 1 1 1 1 SEEP NUMBER ELEVATION 1A 65 18 70 1C 70 10 73 1E 75 2A 63 3A 69 38 72 3C 75• 4A 67 48 63 5A 71 58 65 5C 67 0 IMMO 400 FT. { 1 1 1- 1 1 1 1 1 1 1 T d1140.08� • WELLMAN PROPERTY 1819 ACRES ICI AMERICAS PROPERTY 5017 ACRES • - - • - • ESII-11 MW-7 1136.771 EIEMEr • S-5 1124.331 Lj._ • APPROXIMATE I ABANDONED LANDFILL 'A • MW-14 1132.631 OE 3C 38 2A STREAM 1 GO - STREAM 2 132 128 124 120 116� 112 5: C SIREA14 5 STREAM 4 RIB MW-2 • 14W-5 MONSANTO PROPERTY 228.42 ACRES L / / LEGEND • MONITOR WELL —120— WATER TABLE CC GENERALIZED GS FLOW DIRECTION O GROUND -WATER Its GERAGHTY /fir Fs? MILLER, INC. Abr Envirvnmentai Services GENERALIZED GROUND -WATER FLOW PATTERNS WITHIN THE UPPER SAND AOUIFER EEP113.13ER 28,1ee2 MONSANTO AGRICULTURAL CHEMICALS COMPANY FAYETTEVILLE. NORTH CAROUNA unnrn Nu: NCI 54CIK NSANT 1111 PROPERTY 1 1 1 rc_rcr AIRS PROP RT 50.17 ACRES • • S-12 _ J /..--- . .-- .,—.... • M-6 n IVELLNAN PROPERTY ESM-10I I1 & 19 ACRES !IW-7 I • I• ESM-11 M- : MW-8 ESM-12 • • MW-9• ESM-13• • ESM-9 P ..._t ESM-3••M-3 • S-11 M-1 M-2 • S-6 • S-5 •0-3 S-2R . S-9 •S-13 0-2 APPROXIMATE ABANDONED AAREA�LL L--:_J 11 o j — 1 2A STREAM 1 STREAM 2 FEAR MW- 13 s MW-14 NA MW-15 rai MW-16 NO MW-18 NA MW-20 CHLOROETHANE 9 J 1.1 PCE DCA 5.7 J 17J MW-19 MW-1 ~ 3C 39 A4 5 MW-12 STREAM 5 STREAM 4 RIVER 400 FT. 1 MW-2 NA •• MW-1 ND NONSANTO PROPERTY 221142 ACRES MW-5 MW-4 MW-10 MW-3 ND • / • 1 L / / MW-8 . / MW-9 . / / / / 1 LEGEND • MONffOR WELL 0 GROUND -WATER SEEP 1.1-DCA 1.1-01CHLOROETIIANE PCE TE►RACHLOROETHENE 1.1.1-TCA 1.1.1-TRICHLOROETHANE ESTIMATED CONCEuTRATION NOTE; ALL CONCENTRATIONS SHOWN ARE IN MICROGRAMS PER LITER (UQ/L). ANALYTICAL METHOD BY EPA ME1H00 601. GROUNDWATER QUALITY DATA SUMMARY NOVEMBER 1e, 1995 MON ;ANTO AGRICULTURAL COMPANY FAYEiTEVILLE. NORTH CAROLINA I DWG DATE: 18JAN95 PRJCT NO.: NCO275.001 I FILE. NO.: MONSANTO I DRAWING: MAC-001 ( CHECKED: L. MORETZ APPROXIMATE ABANDONED LANDFILL AREA CHLOROETHANE 170 J 1,1—DCA 27 J 1C ID 1E 18 1A CHLOROETHANE 29 0 SCALE IN FEET 200 CHLOROETHANE 93.1 1,1—DCA 19 CHLOROETHANE 74 STREAM 2 STREAM 1 400 2A CHLOROETHANE 21 CIS/TRANS-1,2-0CE 5.6 1.1—DCA 3.5 3C 38 3A n 4A STREAM 3 48 5A 58 5C RIVER APPROVED: M. RADECKE I DRAFTER: A. WARREN 1,1—DCA 1.2 PCE 5.1 1,1,1—TCA 2.5 1 ---' .l STREAM 5 l CIS/TRANS-1.2-0CE 2.1 1,1—DCA 2.4 PCE 14 TCE 2.8 1 LEGEND 0 GROUND -WATER SEEP 1.1-DCA 1.1-DICHLOROETFAN£ PCE TETRACHLOROETHENE TCE TRICHLOROETHENE 1.1.1-TCA •1.1.1-TRICHLOROETHANE CIS/TRANS-1.2-DCE CIS/TRANS-1.2-0ICHLOR- ETHENE ESTIMATED CONCENTRATION NOTES: ALL CONCENTRATIONS SHOWN ARE IN MICROGRAMS PER LITER (ug/L). ANALYTICAL METHOD BY EPA METHOD 601. Alf GERAGHTY Alf & MILLER, INC. AllYEnvironmental Services SUMMARY OF CHLORINATED VOLATILE COMPOUNDS DETECTED IN THE SEEPS - NOVEMBER 29, 1994 MONSANTO AGRICULTURAL COMPANY FAYETTEVILLE, NORTH CAROLINA FIGURE 1. (9&,te_) cLt.c.-k ar-1 bc,r)-10.44- !( QU-�f�✓J c2- vim" � 1ti,�.,�,C w�1 CLci,_c-lt, a )115 /UaL( n �. �..-��•� ) L vi De— Le,,a1 Gip._ £7I / '/I V (l L1Tf cr . 2- \ .Pc-t\-\ .411110. /6_ �aTT.u�1�7"� JG P7z/!�s eJe,r( --054 -A (2Mi ate. _' vn#asidoL` �(f(f/ '. -done_,( 9,51-cri /, d/ c »tAi5de. fen ) cc44,r" klx57(e- 54C-1;j/er /laylt, CT /C`S V 7.1.0-/er Aaft zwzr ua 'rotes J - Q -14 % ,2-- ' et.) ,Of Gvrt 71a,111rdll-1, d( • k , S 0 /Vl ei4 446 ( /!I etA) 1 o Ge-c s c �Q�'oc.Gss el a-4 / k �,� Q ie, tc ( /4 c-i'cA& Ls G 5 A l.�s p.15 o ,G,1 7i o • '8'O /�0 C/ e. of/Ga( j J qr. ( pow, ,n5 is-c.4n0( 1,L( 446 oe S an, 7y peA !l of / ;�. Pn. at 302 5s /) (> A - V") u - efu, 2X, .11 gal -414 41. d1,17` /Y71- 040- - -90 2)6, - -ram. .6)640,/ 7:7itxi/AvY- Zo,d /-4>z- 014, delt./6 4id Cle I t epd ///4774.1- mot 4.4 c' ,6(,e, *6- 7,644Y- 1.6 c-it/zo Vz.„_____Azza4; 7z/bit- oide4 �� 2 9t714-a4at sit,4ker7u (600 1 il'/41) „ 6CA's-fr" --bduck &he. 02, 745-Y- Apied 664, 735 /c< /5-2/ A,(24-- agk.61.14(24 afizrAleteec .44tke7L-' /C) "0, c7Isto-74-j-GPf-er-fiL „Fj) AlifiLtfot 'oda ,i)c) 75' 4Ler-ea, hta &-uree. e izzoLe_ .eAcezadtd i>diov,) Ls: 0 ypti 711-0 ,r/6926,ha-vve. 17 ?Ili 14 -5 itJ. ,,% ram 4,atii A.- ,c,iimutz, -7 ild a/ - Ph afr /-14-dAy.1 ()kir '27.t.1 / TIC. State of North Carolina Department of Environment, Health and Natural Resources Division of Environmental Management 512 North Salisbury Street ' Raleigh, North Carolina 27604 James B. Hunt, Jr., Governor Jonathan B. Howes, Secretary. March 23, 1993 Mr. Willie Bethea Employee Relations Supervisor Wellman, Inc. Post Office Box 20 Fayetteville, NC 28302 Subject: NPDES Permit No. NC0003719 Monsanto Company Wellman Facility Tour Cumberland County Dear Mr. Bethea: This letter is to confirm our facility tour on Tuesday, March 30, 1993. Our group will be meeting with Mr. Patel at Monsanto at 10:00 AM, Mr. Iwerks at ICI at 3:00 PM and would like to meet with you and your staff at 1:00 PM. We certainly appreciate you and your staff taking the time to familiarize us with your operation and look forward to meeting you. Please do not hesitate to call if you have further questions concerning the meeting. I can be reached at (919) 733-5083. cc: Dave Goodrich, Technical Support Branch Grady Dobson, Fayetteville Regional Office Si es . Lowe Environmental Engineer Permits & Engineering Unit Regional Offices Asheville Fayetteville Mooresville Raleigh Washington Wilmington Winston-Salem 704/251-6208 919/486-1541 704/663-1699 919/571-4700 919/946-6481 919/395-3900 919/896-7007 Pollution Prevention Pays P.O. Box 29535, Raleigh, North Carolina 27626-0535 Telephone 919-733-7015 An Equal Opportunity Affirmative Action Employer - 6 6 6 6 6 6 6 • 0 1.1i to II oi• law .14 %. State of North Carolina Department of Environment, Health and Natural Resources Division of Environmental Management 512 North Salisbury Street • Raleigh, North Carolina 27604 James B. Hunt, Jr., Governor March 22, 1993 Mr. Manhar Patel Environmental Safety Manager Monsanto Company Post Office Box 2307 Fayetteville, NC 28302 Jonathan B. Howes, Secretary. Subject: NPDES Permit No. NC0003719 Monsanto Company Facility Tour Cumberland County Dear Mr. Patel: This letter is to confirm our facility tour on Tuesday, March 30, 1993. Our group will plan to arrive shortly before 10:00 AM that morning. We intend to meet with Mr. Bethea at Wellman, Inc. at 1:00 PM and Mr. Iwerks at ICI at 3:00 PM. We certainly appreciate you and your staff taking the time to familiarize us with your operation and look forward to meeting you. Please do not hesitate to call if you have further questions concerning the meeting. I can be reached at (919) 733-5083. c= y, Charles M. Lowe Environmental Engineer Permits & Engineering Unit cc: Dave Goodrich, Technical Support Branch Grady Dobson, Fayetteville Regional Office Regional Offices Asheville Fayetteville Mooresville Raleigh Washington Wilmington Winston-Salem 704/251-6208 919/486:1541 704/663-1699 919/571-4700 919/946-6481 919/395-3900 919/896-7007 Pollution Prevention Pays P.O. Box 29535, Raleigh, North Carolina 27626-0535 Telephone 919-733-7015 An Equal Opportunity Affirmative Action Employer DIVISION OF ENVIRONMENTAL MANAGEMENT WATER QUALITY SECTION April 10, 1995 MEMORANDUM TO: Carla Sanderson THROUGH: Dave Goodrich FROM: Jeanette Powell Y., SUBJECT: NC0003719 Monsanto Company Waste Load Allocation Request The enclosed information outlines the methods and procedures used to determine NPDES permit limits for Monsanto Company under their proposed flow expansion. Limits indicated are summer limits and winter limits will be double the summer value. In reviewing the following information, keep in mind that the Monsanto wastewater treatment plant has several waste stream components, including wastewater from two other facilities: ICI and Wellman. The data considered cover a study period from April 1993 to May 1994, which was identified as a "representative period" by the company. Note that the month of March 1994 encompassed a plant upset. The NPDES group would like to request a meeting to discuss this wasteload allocation request prior to the scheduled April 19, 1995 site visit. 1. BOD5 Limits The BOD5 limits were determined using a combination of calculated BAT limits for the Monsanto wastestream and the OCPSF effluent guidelines (40 CFR 414) for the Wellman and ICI wastestreams. This approach began with a preliminary review of the submitted wastestream data which revealed no correlation between BOD5, production, or flow. Therefore, calculation of BAT limits was based on the removal efficiency of the wastewater treatment plant, OCPSF guidelines, and an assumed linear relationship between mass and production. The BOD5 loading from domestic waste, estimated at 2 lb/day, is considered to be negligible for purposes of calculating monthly average and daily maximum limits. A. Monthly Average The Monsanto portion of the wastestream consists of two discrete components: The main process stream (Monsanto Tech) and centrifuge spent wash (CSW). There is no direct BOD5 data provided in the engineering proposal for either component, but COD and flow are reported for each. The CSW discharges through a SBR, for which specific CODBOD5 relationships were provided by the facility. Therefore, the influent BOD5 loading frorp the CSW was determined using the average monthly COD data provided in the Yearly Influent Summary and the relationship Influent BOD5 = Outlet COD * 0.1225, which was provided by the facility. The influent BOD5 loading for the Monsanto Tech wastestream was determined using the average monthly mass balance data provided in the NPDES permit application. The flow diagram (Existing Fayetteville Waste Treatment System) provided in the application indicates that BOD5 samples collected at the chem lift station (indicated as A. Chem Lift) consist of combined Monsanto Tech and Wellman flow components. Since BOD5 data was provided for the Wellman flow component, the Monsanto Tech BOD5 was calculated by subtraction of the monthly average Wellman Chemical BOD5 from the Chem Lift BOD5. Using the data provided in the Engineering Proposal for NPDES Permit Application, the computed BOD5 influent for Monsanto, and BOD5 data provided for ICI and Wellman, a spreadsheet was created which computed the actual monthly removal efficiency of the wastewater treatment plant. Excluding the month of March 1994, when a plant upset occurred, the actual removal efficiency for each month in the study period was in excess of 99% (March 1994 had a 89.9% removal efficiency). An assumed linear relationship between mass and production was applied to determine the total predicted Monsanto influent BOD5 by summing the Monsanto Tech and CSW influent BOD5, multiplying by the proposed maximum production (6182000 pounds per month) and dividing by the actual monthly production. The maximum monthly BOD5 influent is computed to be 14733 lb/day. Holding the wastewater treatment plant BOD5 removal efficiency at 99%, the maximum Monsanto BOD5 monthly average is then computed to be 147.31b/day. The monthly average BOD5 is then determined by summing the computed monthly average BOD5 from Monsanto, Wellman and ICI. Wellman and ICI are subject to the OCPSF guidelines (40 CFR 414, Subparts C and D, respectively), which were used to calculate the monthly average BOD5 component for each facility. Wellman and ICI monthly average BOD5 is 0.751b/day and 52.04 lb/day, respectively. Therefore, the cumulative monthly average BOD5. is 200 lb/day. As detailed in the March 20, 1995 memo from Dave Goodrich to Steve Tedder regarding proposed limits for Monsanto WWTP expansion, other options investigated for determining monthly average BOD5 included, but are not limited to, the following: Assuming a BOD5 removal efficiency of 99%, an increase in Monsanto's production by 50%, and an increase in ICI's flow by 30%, the predicted BOD5 mass loading to be discharged was computed. This loading ranges from 99.161b/day to 207.74 lb/day. Based on this computation, BAT was determined to be 207.74 lb/day which is similar to the 2001b/day BOD5 limit based on application of the guidelines for the OCPSF flow and the calculated BAT for Monsanto's contribution to the discharge. B . Daily Maximum Data from DMR's for the months corresponding to the study period of April 1993 through May 1994 were used to determine the actual ratio of the daily maximum to the monthly average BOD5. The highest ratio is 2.3, as is shown on the attached effluent ratio table. This ratio is employed as a multiplier for the monthly average of 200 lb/day to determine the BOD5 daily maximum limit of 460 lb/day. Other options investigated for determining daily maximum BOD5 included the following: Page 2 of 4 (i) The Monsanto BOD5 influent was determined as in the monthly average calculations, with the exception of using the high monthly BOD5 for Well Chem and Chem Lift instead of the monthly average used previously. The CSW component was still based on monthly average values since the Yearly Influent Summary does not provide high monthly COD for Monsanto CSW. The daily maximum effluent BOD5 for Wellman and ICI is calculated using the applicable effluent guidelines. Holding the 99% removal efficiency applied in the monthly average calculations, the total effluent BOD5 at 99% removal ranges from 252.01 lb/day to 903.77 lb/day. Therefore, the daily maximum BOD5 would be rounded down to 900 lb/day. This method of calculation was not used as the effluent information applied was based on monthly averages. This underestimated removal efficiencies. Assuming that the effluent guidelines in 40 CFR 455.22 (pesticide manufacturing) are directly applicable to Monsanto, who is exempted from these guidelines, the guideline ratio of 4.625 (monthly average/daily maximum) was applied to the Monsanto component of the monthly average BOD5 (147.21 lb/day). The ratio of 2.6 (monthly average/daily maximum) in the OCPSF effluent guidelines was applied to the monthly average BOD5 from ICI and Wellman'? (52.79 lb/day). The application of the monthly average/daily maximum ratios in the effluent guidelines results in a total BOD5 daily maximum of 822 lb/day which would be rounded down to 800 lb/day. This approach was abandoned since it would be inconsistent to consider the guideline allotment for Monsanto's contribution to the discharge. 2. COD Limits The monthly average COD limit is based upon a 90% removal efficiency. This assumed removal efficiency is significantly lower than the 99% used in the BOD5 calculations because the removal efficiencies for COD are more variable than those for BOD5. The actual COD removal efficiencies calculated range from 93.88% to 97.27%. At 90% removal efficiency, the maximum potential effluent COD is computed to be 4981 lb/day. This number shall be rounded up to a COD monthly average of 5000 lb/day. Data from DMR's for the months of April 1993 through May 1994 were used to determine the actual ratio of the daily maximum to the monthly average COD. The highest ratio is 1.6, as is shown on the attached effluent ratio table. This ratio is employed as a multiplier for the monthly average of 5000 lb/day to determine the daily maximum limit for COD of 80001b/day. 3. NH3-N Limits Monsanto is proposing a summer NH3-N limit of 351b/day in conjunction with their flow increase to 1.3 MGD. The facility is currently permitted at a monthly average of 231b/day with a flow of 0.859 MGD. The proposed NH3-N limit corresponds to an equivalent mass to flow ratio as that which is currently permitted. DMR data for the past 2 years indicates that the maximum reported NH3-N value is 12.83 lb/day. Given these considerations, the NPDES Group agrees that a monthly average limit of 35 lb/day NI1-N is reasonable, and should be permitted with a daily maximum of 701b/day NI1-N. Page 3 of 4 4. OCPSF Limits Under the expansion proposal, ICI will be manufacturing a new product line and increasing flow. Therefore, the NPDES group suggests that the list of OCPSF parameters in 40 CFR 414, Subpart I may need to be reinstated at a frequency which should be based upon findings during the currently scheduled April 19, 1995 site visit. Daily maximum and monthly average limits are computed for these OCPSF parameters in the attached spreadsheet. 5. TSS Limits Monsanto is proposing to reduce their TSS summer monthly average limit from the currently permitted 6601b/day to 4571b/day. Given that the facility will be reducing TSS discharges while increasing flow, the proposed monthly average limit of 4571b/day TSS would seem acceptable. A multiplier of 2.0 was used in the current NPDES permit to determine the TSS daily maximum. Accordingly, the daily maximum for this permit cycle shall employ the same factor, making the daily maximum TSS 914 lb/day. Page 4 of 4 MONSANTO BAT SPREADSHEET BOD MONTHLY AVERAGE BOD5 - MONTHLY AVERAGE Combined Predicted M Monsanto Monsanto TechMonsanto Tech Monsanto CSW Monsanto CSW Monsanto Monsanto Wellman Wellman ICI ICI P Production Avg. Flow Influent Avg. Flow Influent Influent Influent* Avg. Flow Influent Production Avg. Flow Date (1000 Ibs) (MGD) (lb/day) (MGD) (lb/day) (lb/day) (lb/day) (MGD) (lb/day) (Ibs) (MGD) Apr-93 1536 0.208 2067 0.001132 157 2224.00 8951.02 0.002 18 16464.00 0.14 May-93 1255 0.182 2389 0.000396 52 2441.00 12024.11 0.002 14 16584.00 0.13 Jun-93 1763 0.25 3185 0.000916 162 3347.00 11736.33 0.002 12 20219.00 0.15 Jul-93 1769 0.249 4032 0.000882 155 4187.00 14632.01 0.002 18 16086.00 0.14 Aug-93 1743 0.262 3974 0.001147 180 4154.00 14733.23 0.002 28 16545.00 0.13 Sep-93 1488 0.246 2875 0.000751 114 2989.00 124118.01 0.003 54 20032.00 0.14 Oct-93 1110 0.205 2134 0.000664 76 2210.00 12308.31 0.003 7 17016.00 0.15 Nov-93 1996 0.284 2465 0.001154 194 2659.00 8235.44 0.003 3 16413.00 0.17 Dec-93 1966 0.256 1622 0.001447 244 1866.00 5867.55 0.002 3 20860.00 0.17 Jan-94 1515 0.192 2619- 0.001224 189 2808.00 11458.12 0.005 0 14603.00 0.16 Feb-94 1938 0.22 2032 0.001215 200 2232.00 7119.83 0.004 23 14856.00 0.19 Mar-94 1899 0.192 1480 0.001142 260 1740.00 5664.39 0.002 0 19976.00 0.20 Apr-94 2001 0.182 1822 0.001473 260 2082.00 6432.25 0.003 0 16299.00 0.11 May-94 1963 0.173 2527 0.001676 176 2703.00 8512.45 0.003 0 16225.00 0.12 FOOTNOTES: Influent is predicted b[Y dividing combined Monsanto influent by production, and multiplying by 6180 (maximum proposed production). ** Predicted ICI influent is based on a predicted loading factor of 1.3. *** Predicted Influent is the sum of predicted Monsanto influent, Wellman influent, and predicted ICI influent. **** Predicted flow effluent is the sum of Monsanto's average flow increased by a factor of 1.5, Wellmans average flow, and ICI's average flow increased. by a factor of 1.3. The sum is then multiplied by the ratio of the effluent flow to the total influent flow. 1 1 4/10/95 Page 1 of 2 MONSANTO BAT SPREADSHEET BOD MONTHLY AVERAGE Predicted Predicted Total Predicted Actual ICI K l Total Total Flow Flow Flow Total Removal Assuming Assuming Assuming Assuming 98.5% R.E. Assuming 98% R.E. Influent Influent** Influent Influent*** Influent Effluent Effluent**** Effluent Efficiency Actual % R.E. 99.2% R.E. 99 % R.E. (lb/day) (Ib/day) (Ib/day) (Ib/day) (MGD) (MGD) (MGD) (lb/day) (%) (lb/day) (lb/day) (lb/day) (Ib/day) (lb/day) 6743.00 8765.90 8985 177351 0.35 0.49 0.70 33.35 99.63 65.83 141.88 177.35 266.02 354.70 4872.00 6333.60 7327 18372 0.31 0.38 0.54 20.55 99.72 51.53 146.97 183.72 275.58 367.43 4781.00 6215.30 8140 17964 0.40 0.42 0.60 16.70 99.79 36.85 143.71 179.64 269.45 359.27 4711.00 6124.30 8916 20774 0.39 0.41 0.58 18.50 99.79 43.11 166.19 207.74 311.61 415.49 3914.00 5088.20 8096 19849 0.39 0.36 0.51 13.30 99.84 32.61 158.80 198.49 297.74 396.99 3782.00 4916.60 6825 17389 0.39 0.53 0.75 26.80 99.61 68.28 139.11 173.89 260.83 347.77 3426.00 4453.80 5643 16769 0.36 0.41 0.58 17.90 99.68 53.19 134.15 167.69 251.54 335.38 3599.00 4678.70 6261 12917 0.46 0.45 0.65 16.00 99.74 33.01 103.34 129.17 193.76 258.34 3767.00 4897.10 5636 10768 0.43 0.46 0.66 19.60 99.65 37.45 86.14 107.68 161.51 215.35 3257.00 4234.10 6065 15692 0.36 0.41 0.57 42.05 99.31 108.80 125.54 156.92 235.38 313.84 3324.00 4321.20 5579 11464 0.41 0.49 0.69 54.55 99.02 112.09 91.71 114.64 171.96 229.28 3274.00 4256.20 5014 9921 0.39 0.47 0.65 506.35 89.90 1001.85 79.36 99.21 148.81 198.41 2680.00 3484.00 4762 9916 0.30 0.43 0.61 26.02 99.45 54.18 79.33 99.16 148.74 198.32 3415.00 4439.50 6118 12952 0.30 0.48 0.68 35.84 99.41 75.87 103.62 129.52 194.28 259.04 r •E 4/10/95 Page 2 of 2 Monsanto Company NC0003719 EFFLUENT RATIOS (lb/day) Date BOD BOD BOD COD COD COD Mo. Avg. Daily Max. Ratio Mo. Avg. Daily Max. Ratio Apr-93 33.35 35.7 1.1 1138.50 1327.0 1.2 May-93 20.55 21.4 1.0 463.50 559.0 1.2 Jun-93 16.70 20.7 1.2 326.00 348.0 1.1 JuI-93 18.50 22.1 1.2 602.50 728.0 1.2 Aug-93 13.30 15.0 1.1 940.50 1129.0 1.2 Sep-93 26.80 33.9 1.3 548.00 724.0 1.3 0ct-93 17.90 20.7 1.2 523.00 754.0 1.4 Nov-93 16.00 23.5 1.5 658.00 807.0 1.2 Dec-93 19.60 20.1 1.0 491.50 568.0 1.2 Jan-94 42.05 46.3 1.1 695.00 751.0 1.1 Feb-94 54.55 62.0 1.1 799.00 918.0 1.1 Mar-94 506.35 984.9 1.9 771.00 985.0 1.3 Apr-94 26.02 56.0 2.2 877.90 1366.0 1.6 May-94 35.84 83.8 2.3 986.90 1362.0 1.4 MONSANTO BAT SPREADSHEET COD MONTHLY AVERAGE COD - MONTHLY AVERAGE Combined Predicted M Monsanto Monsanto TechMonsanto TechMonsanto CSW Monsanto CSW Monsanto Monsanto Wellman Wellman ICI IG P Production Avg. Flow Influent Avg. Flow Influent Influent Influent* Avg. Flow Influent Production Avg. Flow Date (1000 lbs) (MGD) (lb/day) (MGD) (lb/day) (lb/day) (lb/day) (MGD) (lb/day) (Ibs) (MGD) Apr-93 1536 0.208 7084 0.001132 1283 8367.00 33675.00 0.002 100 16464.00 0.14 May-93 1255 0.182 7749 0.000396 426 8175.00 40269.20 0.002 112 16584.00 0.13 Jun-93 Jul-93 1763 0.25 8889 0.000916 1325 10214.00 3581,5.63 0.002 131 20219.00 0.15 1769 0.249 8930 0.000882 1262 10192.00 356-1 7.27 0.002 120 16086.00 0.14 Aug-93 1743 0.262 8807 0.001147 1471 10278.00 36453.58 0.002 117 16545.00 0.13 Sep-93 1488 0.246 5874 0.000751 930 6804.00 28267.69 0.003 152 20032.00 0.14 Oct-93 1110 0.205 5529 0.000664 619 6148.00 34240.48 0.003 136 17016.00 0.15 Nov-93 1996 0.284 8206 0.001154 1583 9789.00 30318.44 0.003 117 16413.00 0.17 Dec-93 1966 0.256 9349 0.001447 1989 11338.00 35651.84 0.002 110 20860.00 0.17 Jan-94 1515 0.192 6913 0.001224 1540 8453.00 34492.70 0.005 268 14603.00 0.16 Feb-94 1938 0.22 10953 0.001215 1631 12584.00 40141.53 0.004 198 14856.00 0.19 Mar-94 1899 0.192 8409 0.001142 1538 9947.00 32381.44 0.002 149 19976.00 0.20 Apr-94 2001 0.182 8674 0.001473 2126 10800.00 33366.12 0.003 111 16299.00 0.11 May-94 1963 0.173 9176 0.001676 2358 11534.00 36323.58 0.003 156 16225.00 0.12 NOTES: * Influent is predicted by dividing combined Monsanto influent by production, and multiplying by 6180 (maximum proposed production). ** Predicted ICI influent is based on a predicted loading factor of 1.3. I *** Predicted flow effluent is the sum of Monsanto's average flow increased by a factor of 1.5, Wel!mans average flow, and ICI's average flow increased. b a factor of 1.3. The sum is then multiplied by the ratio of the effluent flow to the total influent flow. 4/10/95 Page 1 of 2 MONSANTO BAT SPREADSHEET COD MONTHLY AVERAGE P Predicted Predicted Total Predicted Actual la ICI Total Total Flow Flow Flow*** Total Removal Assuming Assuming Assuming 95% R.E. Assuming 98% R.E. Assuming 99 % R.E. Influent Influent** Influent Influent Influent Effluent Effluent Effluent Efficiency Actual % R.E. 90 % R.E. (lb/day) (lb/day) (lb/day) (lb/day) (MGD) (MGD) (MGD) (Ib/day) (%) (lb/day) (lb/day) (lb/day) (Ib/day) (lb/day) 10121.00 13157.30 18588 46932 0.35 0.49 0.701138.50 93.88 2874.57 4693.23 2346.61 938.65 469.32 7253.00 9428.90 15540 49810 0.31 0.38 0.54 463.50 97.02 1485.65 4981.01 2490.51 996.20 498.10 7315.00 9509.50 17660 45456 0.40 0.42 0.60 326.00 98.15 839.11 4545.61 2272.81 909.12 454.56 7411.00 9634.30 17723 45372 0.39 0.41 0.58 602.50 96.60 1542.42 4537.16 2268.58 907.43 453.72 6101.00 7931.30 16496 44502 0.39 0.36 0.51 940.50 94.30 2537.22 4450.19 2225.09 890.04 445.02 6266.00 8145.80 13222 36565 0.39 0.53 0.75 548.00 95.86 1515.50 3656.55 1828.27 731.31 365.65 6623.00 8609.90 12907 42986 0.36 0.41 0.58 523.00 95.95 1741.84 4298.64 2149.32 859.73 429.86 6757.00 8784.10 16663 39220 0.46 0.45 0.65 658.00 96.05 1548.73 3921.95 1960.98 784.39 392.20 6560.00 8528.00 ' 18008 44290 0.43 0.46 0.66 491.50 97.27 1208.82 4428.98 2214.49 885.80 442.90 5200.00 6760.00 13921 41521 0.36 0.41 0.57 695.00 95.01 2072.90 4152.07 2076.04 830.41 415.21 6069.00 7889.70 18851 48229 0.41 0.49 0.69 799.00 95.76 2044.20 4822.92 2411.46 964.58 482.29 6679.00 8682.70 16775 41213 0.39 0.47 0.65 771.00 95.40 1894.21 4121.31 2060.66 824.26 412.13 5110.00 6643.00 16021 40120 0.30 0.43 0.61 877.90 94.52 2198.46 4012.01 2006.01 802.40 401.20 5899.00 7668.70 17589 44148 0.30 0.48 0.68 986.90 94.39 2477.11 4414.83 2207.41 882.97 441.48 4/10/95 Page 2 of 2 FACILITY Monsanto OCPSF Flow 0.265 MGD Row is based on processes only 7010s 791 cfs Qavg 4340 cfs PF 1.3 MGD Human Hlth Human Hlth Allowable Allowable Limit Limit Fedl Standard Standard Allowable Allowable Aquatic Life Human Hlth Limit Daily Monthly Daily Monthly Daily Monthly State Aquatic Organisms conc. Aquatic conc Organisms Based Max Avg. max avg max avg Ufe Life Organisms on: Parameter ug/I ug/l #/d #/d stdrd µg/ µg/l 11g/1 PO #Iday #/day #/day Acenaphthene 59 22 0.130 0.049 FC no stdrd 2700.00 no stdrd 1062600.74 no stdrd 11511.508 OCPSF 0.130 #/day 0.049 Acrylonitrile (c) 242 96 0.535 0.212 FC no stdrd 0.66 no stdrd 1422.20 no stdrd 15.407 OCPSF 0.535 #/day 0.212 Benzene (c) 136 37 0.301 0.082 SS no stdrd 71.40 no stdrd 153856.02 no stdrd 1666.774 OCPSF 0.301 #/day 0.082 Carbon Tetrachloride (c) 38 18 0.084 0.040 SS no stdrd 4.42 no stdrd 9524.42 no stdrd 103.181 OCPSF 0.084 #/day 0.040 Chlorobenzene 28 15 0.062 0.033 FC no stdrd 21000.00 no stdrd 8264672.46 no stdrd 89533.952 OCPSF 0.062 #/day 0.033 1,2,4-Trichlorobenzene 140 68 0.309 0.150 FC no stdrd no stdrd no stdrd no stdrd no stdrd no stdrd OCPSF 0.309 #/day 0.150 Hexachlorobenzene (c) 28 15 0.062 0.033 FC no stdrd 7.70E-04 no stdrd 1.659 no stdrd 1.80E-02 CHRONIC 1.659 µg/I 1,2-Dichloroethane (c) 211 68 0.466 0.150 FC no stdrd 99.00 no stdrd 213329.77 no stdrd 2311.073 OCPSF 0.466 #/day 0.150 1,1.1-Trichloroethane 54 21 0.119 0.046 FC no stdrd no stdrd no stdrd no stdrd no stdrd no stdrd OCPSF 0.1 19 #/day 0.046 Hexachloroethane (c) 54 21 0.119 0.046 FC no stdrd 8.90 no stdrd 19178.13 no stdrd 207.763 OCPSF 0.1 19 #/day 0.046 1,1-Dichloroethane (c) 59 22 0.130 0.049 FC no stdrd no stdrd no stdrd no stdrd no stdrd no stdrd OCPSF 0.130 #/day 0.049 1,1,2-trichloroethane (c) 54 21 0.119 0.046 FC no stdrd 42.00 no stdrd 90503.54 no stdrd 980.455 OCPSF 0.119 #/day 0.046 Chloroethane 268 104 0.592 0.230 FC no stdrd no stdrd no stdrd no stdrd no stdrd no stdrd OCPSF 0.592 #/day 0.230 Chloroform (c) 46 21 0.102 0.046 FC no stdrd 470.00 no stdrd 1012777.69 no stdrd 10971.758 OCPSF 0.102 #/day 0.046 2-Chlorophenol 98 31 0.217 0.069 FC no stdrd 400.00 no stdrd 157422.33 no stdrd 1705.409 OCPSF 0.217 #/day 0.069 1,2-Dichlorobenzene 163 77 0.360 0.170 FC no stdrd 17000.00 no stdrd 6690449.13 no stdrd 72479.866 OCPSF 0.360 #/day 0.170 1,3-Dichiorobenzene 44 31 0.097 0.069 FC no stdrd 2600.00 no stdrd 1023245.16 no stdrd 11085.156 OCPSF 0.097 #/day 0.069 1,4-Dichlorobenzene 28 15 0.062 0.033 FC no stdrd 2600.00 no stdrd 1023245.16 no stdrd 11085.156 OCPSF 0.062 #/day 0.033 1,1-Dichloroethylene (c) 25 16 0.055 0.035 FC no stdrd 3.20 no stdrd 6895.51 no stdrd 74.701 OCPSF 0.055 #/day 0.035 1,2-trans-Dichloroethylene 54 21 0.119 0.046 FC no stdrd no stdrd no stdrd no stdrd no stdrd no stdrd OCPSF 0.119 #Iday 0.046 2,4-Dichlorophenol 112 39 0.248 0.086 FC no stdrd 790.00 no stdrd 310909.11 no stdrd 3368.182 OCPSF 0.248 #/day 0.086 1,2-Dichloropropane 230 153 0.508 0.338 FC no stdrd 39.00 no stdrd 15348.68 no stdrd 166.277 OCPSF 0.508 #/day 0.338 1,3-Dichioropropylene (c) 44 29 0.097 0.064 FC no stdrd 1700.00 no stdrd 3663238.46 no stdrd 39685.083 OCPSF 0.097 #/day 0.064 2,4-Dimethylphenol 36 18 0.080 0.040 FC no stdrd 2300.00 no stdrd 905178.41 no stdrd 9806.099 OCPSF 0.080 #/day 0.040 2,4-Dinitrotoluene (c) 285 113 0.630 0.250 FC no stdrd 9.10 no stdrd 19609.10 no stdrd 212.432 OCPSF 0.630 #/day 0.250 2,6-Dinitrotoluene (c) 641 255 1.417 0.564 FC no stdrd no stdrd no stdrd no stdrd no stdrd no stdrd OCPSF 1.417 #/day 0.564 Ethylbenzene 108 32 0.239 0.0711Q/NOE( 325.000 29000.00 127905.65 11413119.11 1385.644 123642.124 OCPSF 0.239 #/day 0.071 Flouranthene 68 25 0.150 0.055 FC no stdrd 370.00 no stdrd 145615.66 no stdrd 1577.503 OCPSF 0.150 #/day 0.055 Methylene Chloride (c) 89 40 0.197 0.088 FC no stdrd 1600.00 no stdrd 3447753.85 no stdrd 37350.667 OCPSF 0.197 #/day 0.088 Methyl Chloride 190 86 0.420 0.190 FC no stdrd no stdrd no stdrd no stdrd no stdrd no stdrd OCPSF 0.420 #/day 0.190 Hexachlorobutadiene (c) 49 20 0.108 0.044 FC no stdrd 49.70 no stdrd 107095.85 no stdrd 1160.205 OCPSF 0.108 #/day 0.044 Naphthalene 59 22 0.130 0.049 FC no stdrd no stdrd no stdrd no stdrd no stdrd no stdrd OCPSF 0.130 #/day 0.049 Nitrobenzene 68 27 0.150 0.060 FC no stdrd 1900.00 no stdrd 747756.08 no stdrd 8100.691 OCPSF 0.150 #/day 0.060 2-Nitrophenol 69 41 0.152 0.091 FC no stdrd no stdrd no stdrd no stdrd no stdrd no stdrd OCPSF 0.152 #Iday 0.091 4-Nitrophenol .. 124 72 0.274 0.159 FC no stdrd no stdrd no stdrd no stdrd no stdrd no stdrd OCPSF 0.274 #/day 0.159 2,4-Dinitrophenol 123 71 0.272 0.157 FC no stdrd 14000.00 no stdrd 5509781.64 no stdrd 59689.301 OCPSF 0.272 #/day 0.157 4,6-Dinitro-o-cresol 277 78 0.612 0.172 FC no stdrd 765.00 no stdrd 301070.21 no stdrd 3261.594 OCPSF 0.612 #/day 0.172 Phenol 26 15 0.057 0.033 FC no stdrd 4600000.00 no stdrd ############ no stdrd 19612198.925 OCPSF 0.057 #/day 0.033 4/10/95 1 • FACILITY Monsanto OCPSF Flow 7Q10s Qavg PF Parameter Bis(2-ethyihexyl) phthalate (c) Dibutyl phthalate Diethyl phthalate Dimethyl phthalate Benzo(a)anthracene (c, PAH) Benzo(a)pyrene (c, PAH) 3,4-Benzofluoranthene (c, PAH) Benzo(k)fluoranthene (c,PAH) Chrysene (c, PAH) Acenaphthylene Anthracene Fluorene Phenanthrene Pyrene Tetrachloroethylene (c) Toluene Trichlororethylene (c) Vinyl Chloride (c) PAH (total -µg/I) (c) " Total Chromium " Total Copper Total Cyanide " Total Lead " Total Nickel " Total Zinc' 0.265 MGD Flow is based on processes only 791 cfs 4340 cfs 1.3 MGD Human Hlth Human Hlth Allowable Allowable Limit Limit Fedl Standard Standard Allowable Allowable Aquatic Life Human Hlth Limit Daily Monthly Daily Monthly Daily Monthly State Aquatic Organisms conc. Aquatic conc Organisms Based Max Avg. max avg max avg Life Life Organisms on: ug/I ug/I #/d #/d stdrd µg/1 µg/i PO µg/l 4/day #/day #/day 279 103 0.617 0.228 FC no stdrd 5.90 no stdrd 12713.59 no stdrd 137.731 OCPSF 0.617 #/day 0.228 57 27 0.126 0.060 FC no stdrd 12000.00 no stdrd 4722669.98 no stdrd 51162.258 OCPSF 0.126 #/day 0.060 203 81 0.449 0.179 FC no stdrd 120000.00 no stdrd 47226699.75 no stdrd 511622.581 OCPSF 0.449 #/day 0.179 47 19 0.104 0.042 FC no stdrd 2900000.00 no stdrd ############ no stdrd 12364212.366 OCPSF 0.104 #/day 0.042 59 22 0.130 0.049 FC no stdrd 0.05 no stdrd 105.59 no stdrd 1.144 OCPSF 0.130 #/day 0.049 61 23 0.135 0.051 FC no stdrd 0.05 no stdrd 105.59 no stdrd 1.144 OCPSF 0.135 #/day 0.051 61 23 0.135 0.051 FC no stdrd 0.05 no stdrd 105.59 no stdrd 1.144 OCPSF 0.135 #/day 0.051 59 22 0.130 0.049 FC no stdrd 0.05 no stdrd 105.59 no stdrd 1.144 OCPSF 0.130 #/day 0.049 59 22 0.130 0.049 FC no stdrd 0.05 no stdrd 105.59 no stdrd 1.144 OCPSF 0.130 #/day 0.049 59 22 0.130 0.049 FC no stdrd no stdrd no stdrd no stdrd no stdrd no stdrd OCPSF 0.130 #/day 0.049 59 22 0.130 0.049 FC no stdrd 110000.00 no stdrd 43291141.44 no stdrd 468987.366 OCPSF 0.130 #/day 0.049 59 22 0.130 0.049 FC no stdrd 14000.00, no stdrd 5509781.64 no stdrd 59689.301 OCPSF 0.130 #/day 0.049 59 22 0.130 0.049 FC no stdrd no stdrd no stdrd no stdrd no stdrd no stdrd OCPSF 0.130 #/day 0.049 67 25 0.148 0.055 FC no stdrd 11000.00 no stdrd 4329114.14 no stdrd 46898.737 OCPSF 0.148 #/day 0.055 56 22 0.124 0.049 FC no stdrd 8.85 no stdrd 19070.39 no stdrd 206.596 OCPSF 0.124 #/day 0.049 80 26 0.177 0.057 SS/AQ 11.000 200000.00 4329.11 78711166.25 46.899 852704.301 OCPSF 0.177 #/day 0.057 54 21 0.119 0.046 SS no stdrd 92.40 no stdrd 199107.78 no stdrd 2157.001 OCPSF 0.1 19 #/day 0.046 268 104 0.592 0.230 SS no stdrd 525.00 no stdrd 1131294.23 no stdrd 12255.688 OCPSF 0.592 #/day 0.230 aromatic hydrocarbons SS no stdrd 0.0311 no stdrd 67.02 no stdrd 0.726 CHRONIC 67.016 µg/I 2770 1110 0.000 0.000 SS 50.000 no stdrd 19677.79 no stdrd 213.176 no stdrd OCPSF 0.000 #/day 0.000 3380 1450 0.000 0.000 SS -AL 7.000 no stdrd 2754.89 no stdrd 29.845 no stdrd OCPSF 0.000 #/day 0.000 1200 420 0.000 0.000 SS 5.000 no stdrd 1967.78 no stdrd 21.318 no stdrd OCPSF 0.000 4/day 0.000 690 320 0.000 0.000 SS 25.000 no stdrd 9838.90 no stdrd 106.588 no stdrd OCPSF 0.000 #/day 0.000 3980 1690 0.000 0.000 SS 88.000 no stdrd 34632.91 no stdrd 375.190 no stdrd OCPSF 0.000 #/day 0.000 2610 1050 0.000 0.000 SS -AL 50.000 50.00 19677.79 19677.79 213.176 213.176 OCPSF 0.000 #/day 0.000 'Total Zinc for Rayon Fiber Manufacture that uses the viscose process and Acrylic Fiber Manufacture that uses zinc chloride/solvent process is 6,796 ug/L and 3,325 ug/L for maximum for any one day and maximum for monthly average, respectively. " Metal should only be limited if Total metal bearing wasteflow: process contains metal bearing wasteflow. Cyanide should only be limited if Total cyanide bearing wasteflow: process contains cyanide bearing wasteflow. 4/10/95 2 DIVISION OF ENVIRONMENTAL MANAGEMENT • WATER QUALITY SECTION NPDES'GROUP March 20,1995 MEMORANDUM To: Steve Tedder Water Quality Section Chief Through: Don Sa Technical Support Branch Assistant Chief Coleen Sullins Permits and Engineering Unit Supervisor From: Dave Goodrich NPDES Group upervisor Subject: Proposed Limits for Monsanto WWTP Expansion NPDES Permit #NC0003719 Cumberland County After reviewing the preliminary information provided by TRC Enivronmental Corporation (Monsanto's consultant) and discussing permitting issues with you and Water Quality Section staff, I would offer the following comments regarding the development of limits for this facility. There are three general methods of developing limits for permits: 1) Base limits on model results. 2) Base limits on BPJ. 3) Base limits on BAT. The existing permit limit of 350 lbs/day for BOD5 (summertime limit) was derived through a combination of #1 and #3, although it was primarily the BAT limits which were suggested by Monsanto. EXISTING WATER QUALITY CONCERNS Ambient monitoring data are collected by the Division in the mainstem of the Cape Fear River on a monthly basis. These data indicate that dissolved oxygen levels are depressed in the area of Monsanto's discharge to levels below 6 mg/1 under summertime conditions. Instream BOD5 concentrations are also much higher in the Cape Fear River mainstem when compared to nearby rivers like the Black and South Rivers which do not have significant point source impacts. It should be noted that the ambient data reflect existing loading from point and non -point sources as opposed to permitted loading to this system. Facility instream data are also collected which show levels of DO below the standard on the mainstem of the river (see attachment). It is possible that these data don't corroborate the information collected by the Division as a result of differences in the time of day in which samples are collected and/or the effect of algal activity upstream of the lock and dams. QUAL2E MODEL RESULTS Although model results are not finalized, Monsanto discharges to the beginning of a DO sag which is predicted to depress levels of oxygen below the standard {see attachment). Monsanto is one of many discharges which contributes to this sag. The significance of this finding is that existing permitted loading is Lut predicted to protect the dissolved oxygen levels in the Cape Fear River basin. BPJ CONSIDERATIONS Over the past few years, the Division has been assigning limits no less stringent than 12 mg/1 (summertime BOD5) and 2 mg/1 (summertime NH3) to all expanding domestic facilities upstream of Lock and Dam #1 on the Cape Fear River. Although these limits were derived from preliminary modeling evaluations, the 12 and 2 limits are considered "BPJ" since they have been applied to virtually every expanding discharger without regard to total loading to the system. It was the concensus of Water Quality Section staff that these limits are appropriately applied to municipal and domestic wastewater discharges only. Another consideration was to .examine what the Division • was requiring other similar industrial discharges to meet in this area. DuPont is an-OCPSF discharger in the proximity of the Monsanto discharge with a flow limit of 2 MGD and a BOD5 summertime limit of 175 lbs/day .(equivalent allowable concentration of 10.5 mg/1 at design flow). After reviewing information about the specific operation of this plant and type of wastestream being treated, it was decided by staff not to recommend equivalent loading be given to Monsanto based purely on this type of "BPJ". DETERMINATION OF BAT The simplest way to predict mass limits based on BAT would be to calculate average concentrations of BOD5 which are currently being discharged and extrapolate this concentration to the requested permitted flow limit. Based on the data provided by Monsanto, the average concentration of BOD5 in the effluent is 5.8 mg/1 (summer) and 10.3 {winter - excluding March 1994). This would equate to mass effluent limits of 63 lbs/day (summer) and 112 lbs/day (winter). However, is this an appropriate method to use when determining a BAT limit? In this case, it is probably not. Since production and wastewater flow are not increasing proportionately, Monsanto will most likely experience an increase concentration of influent BOD5. The idea of averaging effluent concentrations also does not provide for operational variations at the facility. Therefore, in order to calculate limits based on BAT, two factors were determined: • Removal efficiency of treatment system • Relationship between production and resultant predicted influent BOD5 loading The assumption of a removal efficiency of the treatment system is an important element in determining what type of treatment is reasonably achieved at a given WWTP. Although a difference of one or two percentage points would appear to be inconsequential, this is not the case. For example, in considering a BPJ limit of 120 lbs/day, removal efficiencies of 98% and 99% were assumed in order to calculate the mass of influent BOD5 which could be treated by the WWTP. The results were: Effluent Limit % Removal Assumed . Max. Influent Mass which could be accepted by the WWTP 120 lbs/day 120 lbs/day 98% 99% 6000 lbs/day 12000 lbs/day This determination, then, is extremely important, and was a focus of the analysis to recommend BAT limits. Based on information supplied by the company, the removal efficiencies for Monsanto's WWTP are listed in the following table: Date Observed Removal Efficiency Apr 1993 99.6% May 1993 99.7% Jun 1993 99.8% Jul 1993 99.8% Aug 1993 99.8% Sep 1993 99.6% Oct 1993 99.7% Nov 1993 99.7% Dec 1993 99.6% Jan 1994 99.3% Feb 1994 99.0% Mar 1994 89.9% Apr 1994 99.4% May 1994 99.4% This period of time was presented to the Division by Monsanto as representing a typical production period and was also assumed to represent the range of treatment capability. Also, note that the March 1994 removal efficiency was a result of a major plant upset which was corrected by the company and not represented in the data collected during the following month. It was not considered a representative removal efficiency in this analysis. Monsanto has committed to increasing treatment of BOD5 at their Fayetteville facility and should be able to do so with the proposed changes to the wastewater treatment system (see attachments). Summertime removal efficiencies range from 99.4 - 99.8%. However, again realizing the potential for operational variation, a removal efficiency of 99% was assumed in this analysis. This matches the lowest removal efficiency documented in the representative months above and is also quoted as the removal efficiency in all four of the treatment methods performed during the company's treatability study. Since ICI and Wellman are both OCPSF facilities, allowable BOD5 limits are determined using the Federal Guidelines (40 CF13. 414). Based on predicted wasteflow and the highest monthly average flow observed during the representative time period, 52.8 lbs/day should be allowed for these wastestreams. Measured influent values for Monsanto were increased by a ratio of lbs/day of BOD5 to lbs/day of product produced multiplied by the maximum predicted production rate in a single month. The resulting influent values ranged from 5664 lbs/day to 14733 lbs/day. Assuming the highest predicted monthly mass (147331bs/day) and a 99% removal efficiency, the BAT limit for Monsanto's contribution to the treatment system would be 147.3 lbs/day. Therefore, when added to 'the allowance from the -OCPSF facilities (52.8 lbs/day), the Division should require Monsanto to meet a limit of 200 lbs/day. These values were checked by ignoring the OCPSF requirements and increasing the influent loading from ICI by 30%. Effluent values from the resulting worst -case month <i.e., BAT limit) was 208 lbs/day which is comparable to the 200 lbs/day limit recommended. Fig. xx. Self -monitoring data (April - October, 1993 & 1994) Cape Fear Liver: Buckhorn Dan to Lock & Dam #3 2- 0 0 — —standard g on L i 72 mites a Et2) z p cSt ,_1 —11 el Si; ' Lillingtofl WWTP Erwin Mills Fayetteville - Cross Creek WWTP Fayetteville - Rockfish Creek WWTP Monsanto Permitted loads under summer condtio Os co 'O (0 • ([18w) QQ cr) N O O . E m 2 E a O 0 Buckhorn Dam to Lock Dam 3 MONSANTO: EXISTING TREATMENT WORKS The existing Monsanto treatment system consists of a spill basin (1 MG - seldom used), an equalization basin (4 MG), oil/water separator, pH adjustment, two aeration basins (0.4 MG, 1 MG), two clarifiers (90 ft - in use, 50 ft - not in use), sandfilters-(not in use), chlorine contact chamber (not in use), an aerobic sludge digestor, a sludge storage basin and sludge drying beds. Additionally, Monsanto has side -stream treatment systems for some of their more highly concentrated waste stream (centrifuge spent wash wastewater) that are not in use, including two sequencing batch reactors and an incinerator. Currently, waste streams from different production areas and sanitary contribution are brought into the treatment system at different points. For example, the centrifuge spent wash is added to the treatment system after the equalization basin and the sanitary contribution is added at the second aeration basin MONSANTO RECONFIGURATION: Monsanto is proposing to re -pipe the existing influent waste streams to the head of the wastewater treatment plant and modify the existing in -ground components to obtain better levels of treatment. The reconfiguration of the system still does not propose to use all of the treatment components that are on - site, specifically, the sequencing batch reactors, the 50 ft clarifier, the sandfilters, the chlorine contact basin and the incinerator are not proposed to be used. Additionally, the function of the existing remaining units will be modified: Oil/water separator (same function, propose to modify slightly) Spill Basin - converted to equalization basin (1 MG - permitted flow requested is 1.3 MGD, therefore, size as an equalization basin is more than sufficient) Equalization basin - converted to primary aeration basin (4 MG capacity) Aeration basin - proposing to convert one of the existing two aeration basins into a sludge digestor, the initial proposal is to convert the larger.(1 MG) to a sludge digestor and use the smaller aeration basin (0.4 MG) in series with the new primary aeration basin (4 MG). Proposal also includes piping to bypass the secondary aeration basin and potentially not use it in the treatment scheme. Clarifiers - continue to use the 90 ft diameter clarifier, not proposing to use the smaller clarifier. This reconfiguration will consist of relocating the pH adjustment to the lift station at the head of the treatment plant, adding four 7.5 HP mixers to the new equalization basin, relocating existing aerators to the new equalization basin and adding six additional aerators to the primary aeration basin. TREATMENT DESIGN CONSIDERATIONS A comparison of the existing design parameters to the reconfigured system supports the determination that the system will provide equal or slightly better levels of treatment. The current system is providing a detention time of 74 hours in the aeration system, producing average effluent concentrations of 8 mg/1 BOD5 and 1 mg/1 NH3. Under the expansion and reconfiguration the aeration detention time will be 80 hours. The 90 ft. clarifier is also adequately sized to handle the loading rate that is projected to occur. Therefore, it appears that the system will provide similar levels of BOD5 /NH3 removal as those currently being achieved. Proposed permit limit“BODS = 200 #/day, or -18 mg/1) should provide an adequate window for compliance. rtr An 1414k4 t Ail AI S i}fir i Monsanto Wellman ICI A. Chem Lift bypass I . f Dry beds I Ma C. Spill Basin < Effluent I. Sludge Stor. 0o6 d Shor✓ CO5hn6 L,c1h SOH- G�Gvif)Cr) S�uln�{ J a-lutfor5) 51nd l-itk rs Date. 03/09/1995 TI nee 10113 a, n, B. pH Pit 4l+dh' D. EQ Basin G. Clarifier eta' Ii. Digester Decant E. AB 1 (Sanitary t•Oikt F. AB #2 _f EXISTING FAYETTE'VILLE WASTE TREATMENT SYSTEM Monsanto Agriculture Company ./ ' , Fayetteville, NC Page 1 of 1 ICIRE.f ' �`�" .k` a It Mg. MOM * MINN EMIR r3� ISanitar, Monsanto Wellman ICI 4 CSW J. Oil/Water Sep. A. Chem Lift <Dry beds C. E$ Basin bypass <Ethuent milliiir B. pH Pilt7 i emergency bypass 1MN= =MN- Primary Aeration 4-761 D. I. Sludge Stor. G. Clarifier 'VI E. Secondary Aeration Secondary Digester Decant F. Primary Digester . * Bold lines indicate changes in system routing Date.' 03/09/1995 TWO O 9149 a. n, Drawl no FI I a ' M I SCPRbJW50010A 4 PROPOSED FAYETTEVILLE WASTE TREATMENT SYSTEM Monsanto Agriculture Company Fayetteville, NC Page 1 of 1 TRC TRC Environmental Corporation March 17, 1995 Mr. David Goodrich, Supervisor NCDEHNR Division of Environmental Management P.O. Box 29535 Raleigh, North Carolina 27626-0535 6340 Quadrangle Drive, Suite 200 Chapel Hill, NC 27514 2:1. (919) 419-7500 Fax (919) 419-7501 RE: Monsanto Company -Fayetteville, NC Plant Addendum No. 1, NPDES Permit Application (NC0003719) TRC No. 18-153 Dear Mr. Goodrich On behalf of Monsanto Company, please find enclosed three copies of Addendum No.1 to Monsanto Company's NPDES permit application. This addendum includes copies of the original permit application transmittal letter and permit application cover page. In addition, corrections to the engineering proposal influent data table, including a revised data table, are included. These revisions should be incorporated into the permit application. The influent data table revisions were initially submitted to you via telecopier on March 12, 1995. Please notify us at your earliest convenience if additional information is necessary or if you have any questions. Sincerely, 14:dv C Environmental Corporation Jan Smith, P.E. 51..j42 Attachments cc: Manhar Patel Peter Smith Edward Juravic • Offices in California, Colorado, Connecticut, Illinois, Louisiana, Massachusetts, Minnesota, New Jersey, New York, North Carolina, Ohio, Oregon, Texas and Utah A TRC Company Printed on Recycled Paper An Equol Opportunity Employer Monsanto THE AGRICULTURAL GROUP P.O. BOX 2307 FAYETTEVILLE, NORTH CAROLINA 28302 PHONE (910) 323-3300 March 15, 1995 Ref: Monsanto Company, Fayetteville, N.C. Plant NPDES Permit Application (NC0003719) Mr. David Goodrich, Supervisor NC-DEHNR Division of Environmental Management P. O. Box 29535 Raleigh, NC 27626-0535 Dear Mr. Goodrich: In accordance with 15A NCAC 21H.0100, please find enclosed three copies of Monsanto Company's NPDES permit application and the processing fee of $400. As discussed with you during several meetings, the major differences associated with the expansion plans involve additional process equipment as well as modification to the waste treatment system to accommodate this expansion. Monsanto neither anticipates nor requests any modifications to the existing permit associated with the storm water requirements, outfall #003, the biomonitoring and the OCPSF requirements. The information contained in this application is a request to allow Monsanto Company to discharge, via outfall #002, the parameters at the levels reflective of Monsanto's own expansion needs while also accommodating the needs of the previously announced ICI Americas expansion project. The information contained in this application, as well as the Engineering Proposal document (Ref: TRC No. 18-153), are both regarded by Monsanto Company to be company confidential information. It is, therefore, expected that the information will be treated as such. Mr. David Goodrich 3/15/95 Page 2 of 2 Should additional information or clarification be necessary, or additional questions arise, please notify us right away since, as you are well aware, Monsanto's plans to implement this project continue to be on aggressive timing. This timing requires breaking ground on June 1, 1995, for the year end start-up. We continue to appreciate your cooperation and thank you for the assistance you have always provided. Sincerely, 0 H. Van Bell Plant Manager tw Enclosures p lc] 111111111 NORTH CAROLINA DEPT. OF NATURAL RESOURCES AND COMMUNTTY DEVELOPMENT ENVIRONMENTAL MANAGEMENT COMMISSION NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM APPLICATION FOR PERMIT TO DISCHARGE WASTEWATER STANDARD FORM C - MANUFACTURING AND COMMERCIAL SECTION I. APPUCATION AND FACILITY DESCRIPTION Unless od1WWISA specified on this form all hems are to be coenplesd. 1 an hem Is not eppliosble indicate TIA'. ADDITIONAL INSTRUCTIONS FOR SELECTED ITEMS APPEAR IN SEPARATE INSTRUCTION BOOKLET AS INDICATED. REFER TO BOOKLET BEFORE FIWNG OUT THESE ITEMS. Piens, PAW or Type Monsanto Company 1. Legal Nene of Appdbent (see instructions) 2 Mailing Ackkess of Appicant (see Instructims) Number 8 Street City Stem Zip Code a Applicants Authorized Agent (see Instructions) Name and Tide Number 8 Street City Stsie Zip Code Telephme 4 Previous Application ff a previous application for a permit under to National Pollutant Discharge Elimination System has been rnade, to date d application. 101 102a 102b 102c 102d 103a 103b 100c 100d 103e 1031 104 P.O. Box 2307, Cedar Creek Road Fayetteville North Carolina 28302 la323-3300 Area Number Code 93 02 04 YR MO DAY 1 certify Chad I am !intim with the information contained in this application and that ID the best d my knovAedge and belief stxti Information is true, comple1e, and acarate. H. Van Bell 102s Plant Mana er Printed Name of Person Signing Tide 1021 Signature of Applicant or Authorized Agent YR MO DAY Date Application Signed North Centro General Statue 143-215.6 (bX2) provides that Any person who knowingly males any false statement representation, or certification in any applicator', record, report, pier!, or other document ales or required b be maintained under Article 21 or regulations of the Erwtronmental Management Commission implementing that Article, or who falsifies, tampers with, or knowingly renders inaccurate any recordng or monitorirg device or method required to be operated or maintained under Article 21 or regulations of the Environmental Management Commission implementing that Article, shall be guilty d a misdemeanor punishable by a fine not to exceed $10,000, or by imprisonment not to exceed six months, or by both. (18 U.S.C. Section 1001 provides a punishment by a One or not more than $10,000 or imprisonment not more than 5 years, or both, br a similar offense.) Note 'changes in the "Yearly Influent Summary" . . 1. Change in tonne of table to "Yearly Influent Swnmary - Histdric Plant Daia".to*. - . . • .: • distinguish it from bioreactor data... • • •2. Wellman' Chemical: • September 1993 • 1; .: Flow - high is changed from .002 to .023 ..•.. BOD - • htgh is changed from 54 to 65 • COD = •high is changed from 404 to .4036 ..: . bruary 1994 . •• ....... . • Flow •-high is changed from-.004 to .036 • :'•••BOD '- highiis changed from 35 to 42 :: •: COD - high is changed from.:407 to 4I 8. 3. ICI • :. : : . • . • . . . • May 1993: _ ... • . • .. . -- .. COD -= Fill in blank high number with 18062 = Year . . • . • COD high is changed from 28371 to 15951 4.CSW • : •.December 1993 . •: • • • Flow - Fill in blanks with 326 (low), 2307 (high) and 1447 (aye) • .Wellncian Sanitary . August 1993 . • • Flow • •COD • September 199 • Flow COD • high is changed from .032 to .32 - high is changed from 43 to 430 3 . . . - high is changed from .036 to .32 -: high is changed from 29 to 259 a Well Chem 1993 Apr - Varlahles law MA ave ► owiatta 0�.001 0.004 0.002 n0D(RAO 9 33 18 con n) 20 104 100 Mon Tack Haw twee 0.174 0.262 0.208 cootlMiu)) 1835 11593 7084 ICI Mon CPA' Flow Ova SOD (IMO COD OW) Row(gl0) COO (MO 0.062 0.269 0.140 631 18888 6743 859 28371 10121 95 2517 1132 1283 May Jana July 0A01 0.004 0.002 0.001 0.004 0.002 0.001 0.007 0.002 7 28 14 6 23 12 8 57 18 15 494 112 18 638 131 0 280 120 0.169 0.593 0.182 0.137 0.256 0.250 0.195 0.279 0249 4993 21025 7749 23(6 13745 $R119 2350 11914 8930 0.063 0.191 0.125 0.078 0.251 0.147 0.031 0.217 0.142 1449 11365 4872 1635 11517 4781 543 17715 4711 2450 18062 7253 2740 17634 7315 856 16839 - 7411 178 564 396 40. 1992 916 299 1252 - 882• 426 1325 1262 Mon Saa Well San COD (ravel Raw(myd) COD Obid1 0.035 72 0.036 0.043 0.04 11 51 35 0.033 0.044 0.038 28 87 47 0.037 0.039 0.021 77 82 44 0.032 0.043 0.036 0.012 0.077 0.054 7 38 23 2 24 22 1993 Oct ' Nor . ' . Dec • v■riableat lew hi ave low - ' 1� ave law hlah' ' ave ' low hf Well Chem Haw (mld) 0.001 0.023 0.003 0.000 0.008 0.003 0.001 0.010 . 0.003 0.001 0.003 0.002'...1 Eon abs)• 24 - • 65 '77 ' 0 ' . 22 7 1 10, 3 2 . 5 3. Car) 0&d) ' 1 ' • • 4036 152 • 0' • 1268 ' ' 136 7 1515 117. 3 490 • 110 Mon Ted) Bow Crrabdf 0.099 0.313 0.246 0.088 : 0.615 0.205 0208 0.316 ' 0.284 0.212 0.288 0.256 COD MAIM 107..• 14604' • 5874 . 231 • 25659 5529 5103 • 12058` 8206 4831... 13205 9349 • ICI flaw (uyd) 0.0855 . 0.221 , 0.136 0.109, ' . • 0.198 0.151 0.108 . • 0.241 0.167 0.038 . •0.227 0.170 umnad1 1314 . 9939 •'. 3782 • 1728 .. 6651 3426 1776 7253 • 3599 522 8845. 3767 • COD pn/d) 2401 • 16983 6266 2701 •11647 6623 3686 • 12106 6757 935 -. 18089 •: 6560 Man CSW flowtem 0 1403 • 751• . 0 1368 664 581 • 1548. 15153 326 2307 1447 Con (O M1 9r30 619 1989 Ltowtrardr 0.033 0.033 0.043 0.044 Mon San 91. gl • cola mod) 68 Well San Haw0rsd) 0.031 . 0.32 . 0.042 0.029 : 0035 0.042 0.011 • 0.035 . 0.032 0.03 • 0.036 . 0.032 COD (third) 10 259 • 24 '• • 8 • ' ' 38 - ' - 25 2 •' •• 13 • . •8 • 11 • 22 ' :16' Aug law kith ave 0.001 0.004 0.002 12 50 28 • 6 696 117 0.000 0.321 I 0.262 0 15711 880E 0.081 0.173 0.125 1331 10465 3914 • 1913 10639 6101 211 • 1766• 1147 • • 147I 0.014 30 0.015 0.32 0.061 . 7 430 48 1994 Jan - - Feb `• ' '' Vaiiabla : , lupJi ave taw . ' hlgh.--$v Well Chen\ flnw MO 0.001 . 0.009 0 005 • 0.001 0.036. 0.004 DOD WO 0 • 0 0 : - ' 10 . . 42 . • 23. con midi ' 8 ' 1538 268 12 ` • 4068' • 193 • 0.052. 0.246 0.192 6 12334' '• 6913 Man Ted) Flow DNA COD (ib 1&y) ICI, Moo CSW new nova a01) (DM COD (NM Row () cOnes 0.086 : 0.245 n.160 765 .' ' 9504 ' : 3257 1119 ' 14841 • 5200 0' 2437 1224, 1540 Mao San Plow Ore Con nbrd) 0.044 92 Well San I flan() cx)n nwa) 0.025. D.032 0.031 11) 13 12 0.176 0.273 0.220 6265 17413 10953 0.117 : 0.268 . 0.188 806' '' 7057 3324 2011 14826 6069 691 1734. 1215 1631 0.041 • 86 0.03 0.041 0.034 •g 19 12 Mom' Air . ' . _ lyl■r:, . Year • low • , ' hiftF+ • '• • awe •: • low • • tab . ave • law Mgh• . • • av■ lawi blab ate 0.001 0014 0.002 0.001 0.005 0.003 0.001, 0.004 0.003 0.000 0.010. . 0.003 0 0 : 0 0 0 • 0 0;• ' 0 . 0 • • 0 :'• • 57 • 13' • 14 850 • '' 149 12: ' 568 •111 ' 5' ' 521• 156 ' ' 0 • 1538'• . 141 • 0.153 0231 . 0.192 0.131 0.199 0.182 0.148 0205 0.173 0 . 0.284 0.222 3738 11228 8409 2643- 10411 8674 ' 4757 "10693 9176 0 ' ' 25659 •8182 0.086 . 0.406 • 0.196 0.017 0.153 0.112 0.028 . 0.171 , 0.118 0.017 0.406 .0.148 177 •.•' 11311•. 3274' 305 5511 2680 .'487 ' 6632 3413• 1771', 18888 '• 3968 • 603 21207 6679 644 9128 ' 5110 937 12941 5899 603 • 15951 • 6640 522 •• 1476 1142 . 419. 1923 1473 485 2017 1676 .0. 2317 ' 1087 087 • ' 1538 2126 : • 2358 0.04 0.038 • . 0.036 0.036 83 79 74 74 0.033 0.037' 0.035 6' . 19 12 0.032 0 048 0.037 10 ' 23 : 14 Yearly lnt1uan' Summary - Historic Plant Data 0.036 • 0.087 0.039• 8 ' 34- 12 • 0.011. 0.087 • • 0.039 2 87 ' 22 96/£t /£0 6SZT b69 tna • •,•--; • :..;1ITS & ENGIN. UNIT 97 R i s pm 1: I MONSANTO COMPANY Fayetteville Plant Fayetteville, NC NPDES PERMIT APPLICATION March 15, 1995 fur t Legal Mimed AppWerd inspons) >E WINAO's: ttAp days, fkoe tna) owl Number & attet City Sra� 2�p Code a Applicant's AuShorIzed Agora (sea Instruction') Nate and Tito Number ii Street City z.Coda Tedephoete ` r a prate apptita f kr a permit under {hs Noticed Polktb ,7t Discharge lamination late daft tistem t bon. boon ade. Siva NORTH CAROLINA DEPr, OF NATURAL RESOURCES AND COMMUNITY DEVELOPMENT ENVIRONMENTAL MANAGEMENT COMMISSION NATIONAL POLLUTANT DISCHARGE EUNt(NATION SYSTEM APPLICATION FOR PERMIT TO DISCHARGE WASTEWATER STANDARD FORM C MANUFACTURING AND COMMERCIAL SECTION 1. APPLICATION AND FACILITY DESCRIPi1ON Dim adwiiie* WAN/ oe+ dhts font at Irma ere l0 to CIRWtwQ. / an OM la not googol* bdicoto Iietin NDIICATT . R'i BOBQCKLET' B ITEMS NG � man. SEPARATE Il�l9tRtlC?10N BOOKLET A3 Ramo Afif or Type • Monsanto Company 101 101 P.O=Box 2307, Cedar Creek Road Fayetteville North Carolina 28302 321-3300 _ At+ea Number Cods 93 02 04 Y � MO DAY — I tart (ta t am lemlbs with be tnbti atbn oartteireid in We app eal:on and,tat b the bast oi<etty krQMedpe and ballet s dt Norman is Pus, eomelvb, and omega. H . Van Bell •�•` tinted Name al ,canon Matting Sonoma* d Antic= or Autot i100 QMti t02i t Plant Manatler SOM 1995' 3 MD Dm Application MowDAY Notch Contra Gomel Statue 143.21556 2) protects lhat Any person Weo makes any Use adamant or oanireoition m any ARrecord. repm plan. or other &corner s or mquted tb be maintained tmder • i or mtiationa of the annicamental htartagement Coetntniesien ImpIomentinp that Ankie. or who to 1io ', tampon wth. tlr lenders irhaee>utale any tsoadng or monitoring dov es emoted ed required b be opam d or maintained ender Amide 21 or atone otdie Environmental C>xttatission Implementing that Amide. iha1 be ¢ratty of mescbrnaarlor punishable by• be not b exceed$16,000. et by net 10 exceed six months, or by bath. 8 U.S.0 Section 1 ;miles a purl shrew, by fine or not mote than $►t0P 0 esonn:era not mote them 5 years, ago fors ARI Iml Pirl t•� furl 1119 Forl IHE RR 5 Facility (see instructions) Give the nine, ownershiipp, and physical location of the plantar other operating fealty where discharges) presently occur(s) or will occur. Name Ownership (Pubic, Private or both Public and Private) Check block Na Federal fadlity wentory CCoontro N mu berGSA M Location: Number & Street City County state a Nature of Business State the nature of the business conducted at the plant or operating fsta1ity. 7. Facility Intake Water (see instructions) Indcate water intake volume per day by sources. Estimate average volume per day in thousand gaiFons per day. Municipal or private water system Surface water Groundwater Other Total item 7 • If there is intake water from bther', specify the source. E Facility Water Use Estimate average volume per day in thousand gallons per day for the following types of water usage at the facility. (See instructions) Noncontact cooling water Borer feed water Process water (including contact cooing water) Sanitary water Other Total Item 8 •• is Peciffre are discharges to bther. If there is "Sanitary' water use, give the number of people served. 106a 106b 106c 105d 105e 1051 1059 106h 106a 106b 107a 107b 107c 107d 107e 1071 108a 10Eb 108c 108d 108e 108E 1039 108h Monsanto Company Fayetteville Plant PUB © PRV ❑ BPP El FED N/A P.O. Box 2307 cedar creeK Road hayettevilie Gum berland North Carolina 28302 Manufacture of weed control agents and treatment of poTvester wastes. AGENCY USE N/A thousand gallons perday 2266 gals per day N / A thousand gallons per day N / A thousand gallons per day 2266 thousand gallons per day 924 thousand gallons perday 190 thousand gallons perday 1022 thousand gallons per day 100 thousand gallons par day 730 thousand gallons perms 2266 thousand gallons per See Section 1, Item 12 b / U people served 1�4 PEI Pal PEI PEI PEI 1111111 1 9 All Faal• Des and other Losses. Number and Dischomarge (See tnstnxcons)Volume Specify the number of ci points and the volume of water dscharged or lost the facility accordng to the categones below. Estimate average volume per day in thousand gallons day Number of Discharge Points Total Volume Discharged, Million Gallons Per Day Surface Water 1o9a1 I 109e2 =2 / t Sanitary wastewater transport sys 103b1 N/A 109b2 Storm water transport system 10901 ..12 109c2 Combined sanitary and storm water WW1 1 1091:2 transport system Surface Impoundment with no 109e1 ALA_ A 109e2 effluent Undetground percolation 109f1 , N/ A 1092 Weil injection 1o991 N/A 1MV2 Waste acceptance fnm .109h1 N/A 109h2 Evaporation 109i1 6 10912 Consumption UM 2 1012 Other 109k1 1 10912 Total Itemity ers and volwne 10911 11 if there are discharges to 'other, 109m1 specify 10. Permits, Licenses and Applications List all existing, pending or denied permits, licenses and applications related to dirsdharges from this facilty (see instructions) 10912 N/A .250 .002 N/A N/A N/A N/A .943 .020 .030 2.516 erating. Issuing Agency For Use of Permit or License ID Number Dale Filed YR/MO/DA Date Issued YR/MO/DA Datle Denied YR/MO/DA Eq*Ulicm Daim YR/MO/DA :/may (}a yL, aI 3 (j ■a +■ ....•juj NC. Dept .ram.{ R+'xP;{'.£f•$. A:r<:} NPDES NCb003719 93/3/4 94/4/1 - 96/5/31 of Natu- :fi&. r ``' :•b AiR 4319R7 93/9/24 93/10/2i - 98/10/ YY iii?, `,.:,:`>. '•h : Land WQ000195994/7/2S 94/ 11/ 1( 99/10/3 ti.•1 .ttA1• \V .,x . ::Application 11. MOPS and ��s See attachments: Section 1, Attach al maps and drawings to the bank of this apptication. (see instructions) Items 11A, 11B, and 11C. 12. AddEtional tnbrmation • : item ,t:` 112 Number 108G 109 Information -4 Waste Incinerator Scrubber 30k GPD DifferenrP hptwppn Fari1ity intakp and disrharge reflects storm water transport system, which discharges to #001. Pug NORTH CAROLINA—CUMBERLAND CO.. 7.5 MINUTE SERIES (TOPOGRAPHIC) NEJ4 SAINT PAILS 15' QUADRANGLE norl ran 11+ Rom ch'• "/ 47' 30" AEI forl 75 '.% eM .»0•f• •• I� • _ ,/ sM---• '.f- • r -r•• • '02 r20111; 3 _ .-cCoo FEE" r .• • 1; 11 • CrMonsanto Company °i Discharge Points 001, 002, 003 NPDES No.: NC0003719 LAT: 34° 58' 08" LONG: 78° 48' se' • • •14 i 1 . • V r • �• • • + .i 0. .1J, ' . 1 ../. 132 78° 45' •-*-35 SECTION 1. ITEM 11 a F'ACITLY LOCATION Monsanto Agriculture Company Fayetteville, NC Page 1 of 1 Cerri• 3075 3e74 450( FEE: 3873 3872 3871 /70 • • • 1� I 1 1 3 woo war. .N 0 atom Galati — C) same r • 1M. met vput!t1rts 144 • a o1:1 lard tunas H...tII M!{I — - — rya cm tag) s1'111 Wit 01101111 V Nita Mlwal n 0 CO co -1 0 Z to p 1.1 CA n fa Z v 0 cm 0 0 z nn o w Z t in lf:l�1l tw--��lt1 P. 1 F — alli r_____,) Flu" (gia------- Li] lH1Ql1 tl.11 kale .waft ism tam Gf{G alto l IN tt0,401 . 'lima* goat 1.tt • J iplates EMI MIL ill an diii tea 'Mali Vial h/ ./1a t1 iota Vim kw ./agt Damao vain tom Na{MN INrt! VaVilits halal Nttltt 11111tit low 10.41 OM. 1. UV SO MI 1*N M.1011I1011 au.[ 11 a M/1at MN* M'-N• tttl Gy .$M'aa1N !. itarsVelit /!tV 11_11 tiwi eiT! es* icun • ' I g11l1 1' G�IMI11, M1W ifi K4 Monsanto : :'fit........ .7E45E:L€s i..•..na(ffVll1 SHE OEVU.OPMENT LaBLEERNI i WIN PI 3 t?!Ed • .1 1 1 1 1 1 1 1 1 4 l 1 1 1 1 1 l ATMOSPHERE .003 1 Li BACKWASH POND .190 DOMESTIC WATER TREATMENT .019 .002 r-r L ICIA PROCESS Fll PROCESS .755 .251 .010 .070 SANITARY .100 DEMIN. WATER BLOWDOWN .010 SOFTENER .168 .852 EFFLUENT TREATMENT ATMOSPHERE .012 .020 ATMOSPHERE .024 TECH. PROCESS FORM. PROCESS .027 .924 BOILER .428 .260 BLOWDOWN PROCESS .002 COOLING TOWER .022 64.174 64.174 PROCESS COOLING RIVER WATER INTAKE FIRE POND Date* 03/15/1995 Times 10101 a. n. Drawing FlIe' HISCPRDJW50009A BLOWDOWN .038 ATMOSPHERE .002 .027 .007 PRODUCT .020 r NOTE#2 .019 ( ATMOSPHERE I .886 INCINERATION (ATMOSPHERE .016 DISCHARGE # 003 1- * .030 NOTE#1 SBR #2 SBR #1 NO7E#1: TO BE OPERATED AS NEEDED NOTE#2: TO BE OPERATED AS NEEDED 44- * = SAMPLE POINT DISCHARGE # 002 �' * 1.300 FINAL OIITFALL TO RIVER SECTION I, ITEM 11 c PROCESS WATER FLOW DISTRIBUTION Monsanto Agriculture Company Fayetteville, NC Page 1 of 1 fml Poi lug fun PIM p IC ; EWA Kt'! 111111E11 STANDARD FORM C. MANUFACTURINGAND COMffi SECTION II. BASIC DISCHARGE DESCRIPTION Complete this section for each discharge Indicated in Section 1, hems 9, that is to surface waters. This includes discharges to municipal sewerage systems In which the waste water does not go through a treatment works prior to being discharged to surface waters. Discharges to wells must be described where there are also discharges to surface waters from this fadlim, SEPARATE DESCRIPTIONS OF EACH DISCHARGE ARE REQUIRED EVEN IF SEVERAL DISCHARGES ORIGINATE IN THE SAME FACILITY. All values for an existing discharge should be representative of the twelve previous months of operation. If this Is a proposed discharge, values should reflect best engineering estimates. ADDITIONAL INSTRUCTIONS FOR SELECTED ITEMS APPEAR IN SEPARATE INSTRUCTION BOOKLET AS INDICATED. REFER TO BOOKLET BEFORE FILLING OUT THESE ITEMS. 1)12LS:offal No. Arf)4! Name (see instructions) b. Discharge Name Give the name of dscharge. if any (see instructions) c. Previous Discharge Serial No ff a previous permit application was made for this &- charge (Item 4, Section 1) provide previous discharge serial number. • Disduune Operating Dates a Disciarge Began Date If the discharge clescrbed bebw is in operation, give the date (within best estmate) the dscharge began b. Discharge to Begin Date ff the discharge has never occurred but is planned for some future date, give the date the discharge wil begin. c. Discharge b End Date If the discharge is scheduled to be discontinued within the next 5 years, give the date (within best estimate) the cbcharge will end. a Engineering Report Available Check if an engineering report is available to reviewing agency upon request (see Instructions) 4 DscIwge Location Name the political boundaries within which the point of dischasge is located: Stale County (If applicable) City or Town a Discharge Point Desaiption (see instructions) Discharge into (check one) Stream (includes ditches, arroyos, and other Water0311MeS Lake Ocean Municipal Sanitary Wastewater Transport System Municipal Combined Sanitary and Storm Transport System 201a 201b 201b 2323 2:i2b 202c 203 204a 204b 204c 205a 002 Waste Treatment Effluent 002 69 6 El N/A YR MO N/A YR MO North Carolina Cumberl and Favettevi 1 le S T R LKE O OCE 0 MTS ▪ MCS 204e I 204f Agency A! Po! rfin Pon Pni fan fmn rag Fon fun Pon Pon Pln inn fml a•� 111111111 DISCHARGE SERIAL NUMBER 002 Municipal Storm Water Transport System ; Well (injection) Other If 'other' is checked, specify type 6 Discharge Point- LatlLong. Give the precise location of the point of cischargeb the nearest second. Wide Longducle 7. Discharge Receiving Water Name Name the waterway at the pant of dscharge. (see instructions) 0 the dsc rirough an cued! that extends beyond the ne or is below the mean km water line, complete item 8, 113-7.171M IEMMI KENN,I AiimR 8 Offshore Discharge a Discharge Distance from Shore 208a b. Discharge Depth Below Water 208b 9 Discharge Type and Occurrence a Type of Discharge Check whether the discharge is continuous or intermittent. (See instructions) b. Discharge Occurrence Days per Week Enter the average number of days per week (during periods of discharge) this dscharge oowrs. cDischarge Occurrence- Months 209c If this c6scharge normally oper- ates (either intermittently or continuously) on less than a around basis (excluding shun cbwns br routine maintenance) check the months during the when the discharge is operating (see instructionsj camplo Items 10 and 11 if Intermittent is w edb'n Item 9.a Otherwise, proceed b hem 12 10. kmterrnitient Discharge Ouantity State the average volume per ds- 210 charge occurrence in thousands of gallons 11. Intermittent Discharge Duration and Frequency a Intermittent Discharge Duration Per Day State the average 211a number &d hours per day thechargeoperaing b. Intermittent Discharge Frequency State the average 211b number of discharge per when 12 Maximum Flow Period Give the time period in which the maximum 212 low of this discharge occurs 206b 206a 206b 207a 207b 207c ❑ STS ❑ WEL [] OTH 33=DEG. 58 M1N. =sEc 7-DEG. Cape Fear River bet bet See Section II, Item 26 ® (con) Continuous 0 (int) intermittent 7days per week ❑ JAN APR ❑ JUL ❑ OCT ❑ FEB 0 MAY ❑ AUG ❑ NOV ❑ MAR ❑ JUN ❑SEP ❑ DEC N A thousand gallons per day N/Achy N/Aascharge commences per day From 6 to 8 month month PEI • ter plal.r_LcI4i7ifill-zi1 1111/1111 rzr DISCHARGE SERIAL NUMBER fml ran r�r rmr 1101 13. Activity Description Give a narrative description of activity produdng this dschaige (see instructions) 002 213a See Section II, Item 26 14. Activity Causing Disdharge For each SIC Code which A gibes the activity causing this disdharge, supply the type and maximum amount of either the raw material consumed (Item 14a) or the product produced (Item 14b) in the units speafied m Table I of the instruction Booldet.. For SIC Codes not listed in Table I. use raw material or production units normally used for measuring production instructions) a Raw Materials 214a 21 Maximum SIC Code Name Amount/Day (1) (2) (3) (See Table I (4) Unit Shared Discharges (Serial Number) ) (5) b. Prods SI Name Maximum AmounVDa SeeTable I Shared Discharges (Serial Number) 4b (1) (2) (3) (4) (b) 2824 Polyester Resin 1320 L-1 N/A 2824 Polyester Resin 760 L-1 N/A 2879 Glyphosate 192 R-1 N/A 2879 IPA Salt of 130 R-1 N/A Glyphosate See Section II, Item 26, for expanded table, raw materials and products. mrp Mrr `/• e+Lij 111111111 13 Waste Abatement a Waste Abatement Preview Describe the waste abatement practices used on this dis- charge with a brief narrative (see instructions) b. Waste Abatement Codes Using the codes fisted in Table u of the Instruction Booldet; describe the waste abatement processes for this discharge in the order in whidi they occur 1 possible. DISCHARGE SERIAL NUMBER 002 215a 216b Nwratior See Section 11 , item Z 1 (4 (10 (16 (19 (22 (25 (28) PRMIXED (29) CCLDIS (11 (14 (1 (20 2 (s (g (12 (15 (18 21 F:1 1111111/1 rain DISCHARGE SERIAL NUMBER rEI lowl Rol Pal 16. 002 Wastewater Characteristics (see Section I I , Item 26) Check the box beside each constituent which is present in the effluent (dsaharge water). This determination is to be based on actual analysis cr best es6mate.(see instructions) Parameter 216 Present Parameter 216 Present Color 03090 X -gaff ` X '0610 `a X 01045 X 00605tic nitrogen X o1�061 N X MagnesiumX 0008922 Nitrite• 00615 se Oi X Primus s X 71900 Mercury Sulfate • 00945Sulfide X OMO%tadenum 00745 ' Nickel 01067 X Sulfite 00740 selenium 01147 Bromide 71870 Silver 01077 Chlonde 00940 X Potassium X anode X Soum OE 29 X Fluonde 00951 Thallium 01059 Aluminum 01105 X Titanium 01152 AntTin 01097� 01102 0 Arsenic02 01092 n X Beryllium 01012 A iades' 74051 . 0 mum Chlorinated organic compounds' X on X 74053 Pesticides' X • 01027 wm = Oil and grease 00550 X 009160m X Phenols 32730 X X Chromium 01034 X Chloride 50060 X 7Fecal conform bacteria X Radioactivity aE•7 • Specify substances, compounds and/or elements in Item 26. Pesticides (insecticides, flings ides, and rodennicides) must be reported in terms of the acceptable common names specified in Acceptable Common Names and Chemical names for the Irgredent Statement on Pesticide Labels, 2nd Edtion, Environmental Protection � Enforoenrient�of�tha� tcederaffnsecticide�FungJune +ade. l972, as andFioden�oade q+ L��� 162.7(b) of the Regulations brthe PEI aua rIM 002 ROIL AGENCY USE 1 ' L1•1lt11Lt 17. Oriatttion of Intake and Dinkins rairi Poi teach of the parameters fisted below, enter In the appropriate ttoz the value et code letter answer called for teae Ntatructlont) . . M addition, enter the perimeter name and code and all required values for any of the following parameters if theyium.twere . cnot oft and hecked in m 16;. • 01tmonta. cyenlde, aluminum, arsenic. beryllium, cadmium, chromium, copper, Mad. mercury. �« et+d Chlorine (nittdust). furl furl rulrl Pal for furl furl Diodteticsl Oznen Demu d (DOD Sday) •l bs/day -96346. °Other discharges sharing intake flow (serial numbcrs)W(ee instructions) * See Section II, Item 26. u4 Effluent felt 11111 Z�SH (3) (4) (s) (6) (7) tR) 1.3 0.741 N/A Cont. NJA N/A 3/7 156 G N/A N/A N/A N/A N/A 3/7 156 C 3/7 156 C 3/7 156 C N/A N/A N/A 4/A N/A N/A N/A N/A N/A N/ON/A Owl r�r (See Sect Dissolved 0 Rol foul furl r�r Poi IIi lls-S4$7[1,f4IZij 1111:11111 17. ( DISCHARGE SERIAL NUMBER 002 Parameter arid Code 217 tntluent ttauent Untreated Intake Water (Daily average) (1) In -Plant Treated Intake Water (Daily average) _(2) 'Daily - Average _(3) Minimum Value Observed or Expected During Discharge Activity (4) Maximum Value Observed or Expected During Discharge vity (5) !aquaria), of Analysis T6) Number d Anayses (7) sampe Type (6) ion II, Item 26) , cvgen(Min. )ma/L N/A N/A I N/A 5.0 N/A 3/7 154 G kGl yphosate N/A N/A M M M Monthly 12 C ',Fecal Col i fnrm N/A / N/A M M � Mnnt 1 by 12 G ',Total N2, P N/A N/A M M M Quarter I y 4 C . ACute..Toxi•eity N/A N/A N/A P/F. 090 J /A uartPrIy 4 C OCPSF Analysis N/A N/A N/A N/A 1 N/A Annual l j 1 C 18. Plant Controls Check if the following plantcontrolsare available for this dschargAlternate power source for major pumping facility Alarm or emergency procedure for power or equipment failure Complete Item 19 if dscharge is fn cooing and/or steam water generation and water treatment adcftives are used 19. Water Treatment Additives If the dscharge is treated with any conditioner, inhibitor, or algicide, answer the following: a Name of Material(s) b► Name and address of manufacturer 218 219a 219b c, amity (pounds ackled per 219c million gallons of water treated) * M = Monitor Only 0 APS QX ALM • CorrosjQn inhibitors are added to cooing tower water. Polymer i i l be ad • ed to cl a ifyers to aid . . i 1 , . - eatmedt emic. s wi •e use. as needed. ( see Secti of (See Section II, Item 26) II, Item 26) (See .Section II, Item 26) A. inn Fowl n°r ran ran DISCHARGE SERIAL NUMBER 002 d Chemical composition of these219d Polymer - not available. additives (see bsb,�ns) I I water treatment alai ti ves - see Section I I , Item 26. Complete Items 20-25 if there is a thermal discharge (e.g., associated with a steam and/or power gg++ plant, steel mil, petroleum refinery, or any o$ wri manufactu process) and the btal discharge flow is 10 million per day or more. (see instructions) 20. Thermal Discharge Source. Check the appropriate item(s) indicating the sour+oe of the discharge (see instructions) Boiler Biowdown Boiler Chemical Cleaning Ash Pond Overflow Boiler Water Treatment - Evaporator Bbwdown Oil and Coal Fred Plants -Effluent from Air Pollution Control Devices Condense Cooing Water Cooling Tower Slowdown Manufacturing Process Other 21. Disdharge/Receiving Water Temperature Difference Give the maximum temperature difference between the discharge and receiving waters for summer and winter operating conditions (see instructions) Summer Vlllnbar rim 22 DischargePTiHuerature , Rate of ChangeGive the maximum possible rate of dse arge unde of P oiconcfltions (see instructions) 23. Percentile Watert(Frreequuency of Oocunrenoe) In the table below, enter the temperature which is exceeded 10)6 of the year, 5% of the year.1 % of the year and not at ail (maximum y temperature). (see rim Frequency of occurrence a Intalu3 subjter Temperature � to natural changes b. Discharge Water Temperature 24. Water Intake Velocity (see instructions) 25. Retention Time Give the length of time, in minutes, from start of water temperature rise to discharge of cooing water. (see instructions) 220 221a 221b 222 223a 223b 22'4 225 N/A BLBD (� BCCL • APOF [� EPBD • OCFP COND CTBD [] MFPR OTHR N A °F / A °F N/A °flour N/A 10% 5% 1% Maximum °F °F °F °F °F °F °F °F N/Afeet/sea. N/A minutes An 111111111 STANDARD FORM C • MANUFACTURING AND COMMERCIAL SECTION III. WASTE ABATEMENT REQUIREMENTS & IMPLEMENTATION (CONSTRUCTION) SCHEDULE This section requires inbrma con on any uncompleted implementation schedule which may have been imposed for construction of waste treatment facades. Such requirements and implementation schedules may have been estabished by local, State, or Federal agencies or by court action. In addition to completing the bllowi items, a co of an official implementation schedule should be attached to this application. IF YOU ARE SUBJECT TO SEVERAL DIFFERENT IMPLEMENTATION SCHEDULES, EITHER BECAUSE OF DIFFERENT LEVELS OF AUTHORITY IMPOSING DIFFERENT SCHEDULES (ITEM 1a) AND/OR STAGED CONSTRUCTION OF SEPARATE OPERATIONAL UNITS (ITEM 1c), SUBMIT A SEPARATE SECTION Ill FOR EACH ONE. FOR AGENCY USt {S �A r•'r:::':4YYr r' r�yn'-.. .}v .�{; {vk+v. •�� / 1. Improvements a Discharge Serial Numbers Affected List the discharge serial numbers, assigned in Section II, that ere covered by this implementation schedule b. Authority imposing Require- 301a ment Check the appropriate item indicating the authority br the implementation schedule If the identical implementation schedule has been ordered by more than one authority, check the appropriate Items. (see instructions) Locally developed plan 301b Areawide Plan Basin Plan State approved implementation schedule Federal approved water fluty standards implementaton plan Federal enbrcement procedure or aeon State cam order Federal avert order a Facility Requirement Specify the 3-character code of those fisted below that best describes in general terms the require- ment of the implementation 301c schedule and the applicable six - character abatement codes(s) from Table II of the instnxdon booklet If more than one 301d schedule appries to the facility, because ofa staged con scedue, state the stage of con- struction beiPa��aPprte � action code. Submit a separate Section III for each stage of construction panned. 002 N/ A ❑LOC DARE Owls ❑� ❑wos ENF []CRT El FED 3-character (general) 1CL 6-charades specific (see Table II) See Section II, Item 215b New Facility NEW Modification (no increase in capacity or treatment) MOD Increase in Capacity INC Increase in Treatment Level INT Both increase in Treatment Level and Capacity ICT Process Change PRO Elimination of Discharge EU Owl PER r■n 105 Pwl r■n Rol j a•_111. e! L. &I ij 2 ImOementation e and 3. Actual Completion Dates Pmvvide a � by schedule and any actual dates completion br implementation steps ism below. Indicate dates as accurately as possible. (see instructions) Implementation Steps 2 a Preliminary plan complete h Fnal plan submission cRnal plan complete d Rnancing complete & contract avarded a Site acquired t Begin construction ti End construction h Begin dscharge i. Operational level attained Schedule (yr/Mo/Day) 302b 302c 332d 302e 3021 302h 302i 95 /03 /31 .4411Q- 2 14115_ 95 /J5 /01 V111_1__ 95 )06 /01 �5 i10 /31 95 26/02/29 3. Actual Completion (Yr/MoJDay) 303a 303b 303c 303d 303e 3331 3Ceg 302 303i 2 ImOementation e and 3. Actual Completion Dates Pmvvide a � by schedule and any actual dates completion br implementation steps ism below. Indicate dates as accurately as possible. (see instructions) Implementation Steps 2 a Preliminary plan complete h Fnal plan submission cRnal plan complete d Rnancing complete & contract avarded a Site acquired t Begin construction ti End construction h Begin dscharge i. Operational level attained Schedule (yr/Mo/Day) 302b 302c 332d 302e 3021 302h 302i 95 /03 /31 .4411Q- 2 14115_ 95 /J5 /01 V111_1__ 95 )06 /01 �5 i10 /31 95 26/02/29 3. Actual Completion (Yr/MoJDay) 303a 303b 303c 303d 303e 3331 3Ceg 302 303i rw1 ferl Pol N. C. DEPARTMENT OF NATURAL RESOURCES & COMMUNITY DEVELOPMENT ENVIRONMENTAL MANAGEMENT COMMISSION NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM APPLICATION FOR PERMIT TO DISCHARGE ADDITIONAL REQUIRED INFORMATION APPUCATION NUMBER DISCHARGE SERIAL NUMBER 002 REFER TO DIRECTIONS ON REVERSE SIDE BEFORE ATTEMPTING TO COMPLETE THIS FORM Parameter (Code) 1 j Untreated fr Wait r average) Treed Intake Water (Daily average) Aaverape Value um Vialuemum Frequency Number Matins sample (1) (2) (3) (4) (5) —(6) (7) (8) See Section II T tPm 217 REMARKS: Anticipated characteristics of the facility intake and discharge after expansion are described fully in Section II,:Item 217: -See also Section II, Item 26. I certify that I am famliiar with the information contained in this report and that to the best of my knowledge and belief such inbrmation is true, complete and soaurate. • Date Form Completed Name of At toned Agent Signature prockiction, if possible. N samples we taken at periods of less than maximum production, state in 'Remarks' fie percent of Or'recOrons - For each parameter fisted, complete maximum production that was obtained during the sampling the information requested in each column in the units specified period according b the insVuc ons given below. Column 1- Enter the daily average value of the Make water at the pokmt it enters the facility. N intake water if from more than one source, and enters the facility at separate entry pants the value given In column 1 should be weighted proportional weightedb the quantity of flow contributed from each source. N water is treated before use, completion of this column is not required (see instructions for column 2). Values of intake we not required for mining acdvities. Column 2- N all or part of intake water Is treated before use, provide values br btai intake here instead on in Column 1, Also describe briefly in item 26'additional inbimaticn' the trim of treatment performed on intake warner (e. ., rapid sand on, ooagutabon, flocculation, ion ex , etc.)) and the percent of intake water confuting b this gift has been treated. 9 • Supply city average value for the days when discharge is actually operating or is expected b be operating (a new discharge). Davy average values are to be by weighing the daffy value in proportion to the daily low. If a discharge areg ularfy the value supplied in the column marked 'D�aii Average should represent an occurs.• A nhe average for ot days sou ds'redd for a Ha�qq�y c conductance and bacteriological parameters (e.g., otibacteriatonn ). Columns 4 and 5- Supply minimum and maximum value observed (or expected for new dsdharge) over any one y whens Columnsdischarge Speafy�the average frequency of analysis for each ter as number analyses per number c days (e.g., T is equivalent b three analyses performed every 7 days). If continuous. enter'CONT.' When analyses we conducted on more tan one individual sample collected the same day, the analysis should reflect one analysis whose value is the average the indhvidusl grab sample measurements. Average frequency should be based on an month.Column Column 7- Spethe number of analyses p � at the average frequency specified incolumn 6, up b Column 8- sample type as follows: G For grab sample (md ' sample collected in dC For composite sump�8 a is b be replaced by the less than 15 minutes averaae number Of hours over which ie composite sample was collected. Composite samples are combinations of irndvidual samples obtained at intervals over a time period, either the volume of each individual sample is dire* proportional b dsc harge flow rates or the sampling interval I (for constant volume samples) is inversely proportional to the flow rates over the time period used b prockuce the composite. NA N'CONT' was entered in odumn 6. methods- Appendix A contains all parameters levels, test desaiptions, and references. The parameter can be determined either by use of the standard analytical methods as described in table A or by methods pnaviously approved by the EPA Regional Administrator or Director of a federaily approved State ram (or their authorized representative) who has over the State in which the dscharge occurs. If the t used is not one shown in table A, the last procedure should be referenced in 'Remarks' or on a separate sheet.. N values are determined to be less tan the detectable limits (as determined by referenced standard anaytical techniques and/or instrument manufacturers literature),.spedfy 'LT(Value of detectable limit)• in the appropriate space. For rocampte, N the detectable kmd is .005 molland quantities of less tan this are determined, fy'LT .005.' Do not enter descriptors such as'NIL, 'TRACE; 'NEG' etc. for this purpose. If it is your reasoned judgment tat one or more of the required parameters is not present in the initial untreated or treated Process water and/or the discharge, enter an 'A' (meaning absent') in the appropriate space. fn order for values reported to be representative, ft is recommended that they be based on from at feast five to seven analyses of composite sampleslif applicable). Each of the composite samples should be obtained byoomposinng frequent samples in proportion b Now over an operating day. Samples should be taken during period of maximum • MIME DISCHARGE SERIAL NUMBER 002 23. Adchanal information nacmaaon Monsanto Supplemental Attach. 208 Offshore Discharge (See Monsanto Supplemental Attachment No. 208, No. 8, Items 208a and 208b) Monsanto Supplemental Attach. 213 Monsanto Supplemental Attach. 214 Activity Description (See Monsanto Supplemental Attachment No. 213, No. 13 Item 213a) Activity Causing Discharge (See Monsanto Supplemental Attachment No. 214, No. 14, Items 214a and 214b) Monsanto Supplemental Attach. 215 Waste Abatement (See Monsanto Supplemental Attachment No. 215, No. 15, Item 215a) mq Monsanto Supplemental Attach. 216 Monsanto Supplemental attach. 217 Wastewater Characteristics (See Monsanto Supplemental Attachment No. 216. No. 16. Item 216) Description of Intake and Discharge (See Monsanto Supplemental Attachment No. 217. No. 17. Item 217a) Monsanto Supplemental Attach.:219 Water Treatment Additives and Quantities and MSDS min Reference owl I II TTT Additional Information Engineering Proposal.(production data; influent data; schematics of proposed treatment works) 1994 Fourth Quarter OCPSF Reports Annual Pollutant Analysis. 1993 PEI Monsanto Supplemental Attachment 208 No. 8 - Offshore Discharge Items 208a & b MEI Discharge 002 Section II Item 208 a) The outfall line is submerged and extends approximately 80 feet offshore. F.' b) The discharge depth of the outfall pipe is approximately 20 feet below the surface. Pal PEI foul Monsanto Supplemental Attachment 213 No. 13 - Activity Description Item 213a Discharge 002 Section II Item 213a Contributions to Discharge 002 result from herbicide manufacturing activities as well as wastes received from the adjoining facilities (ie., ICIA and Wellman, Inc.) that produce polyester resins and fibers. Laboratory and sanitary wastes are routed to the biological treatment system and discharged via 002. Polyester resin is manufactured from ethylene glycol and dimethyl terephthalate by a polymerization process. The base polyester resin is spun into continuous filament. This system also handles wastewater which does not come in contact with process contaminants. These non -contact streams have been identified in the attached flow diagrams and are listed as: 1) Backwash Pond Blowdown (Water Treatment Settling Pond) 2) Demineralized Water Treatment Blowdown 3) Boiler Blowdown 4) Cooling Tower Blowdown The herbicide intermediate, N-phosphonomethyl imino-diacetic acid, is converted to N- phosphonomethyl glycine, concentrated in an evaporator, separated and washed in a centrifuge. The cake is stored either wet or dry. The wet material is separately reacted with isopropyl - amine and then formulated in a water solution with a surfactant and packaged. The dry material is shipped to customers. The plant -wide stormwater collection system, which separately collects stormwater runoff from buildings and streets, discharges stormwater via outfall #001. Outfall #001 will be sampled and analyzed according to the permit conditions. Supporting facilities and activities include water treatment, waste treatment systems, warehousing, raw material storage, maintenance facilities, and administrative offices. FM MR Monsanto Supplemental Attachment 214 No. 14 - Activity Causing Discharge Discharge 002 Section II Item 214a & b ran See attached table for detailed information regarding current and projected raw material use and production rates. i Monsanto Company Confidential Information PEI 1 MEI min log Production: ICl/Wellman -Maximum/Day (k/lb) Current Expansion '96 - '99** Projected (k/lb) OCPSF Product: • Polyester Resin (ICIA) (2824) • Polyester Resin (Wellman) 660 380 * 1320 760 Raw Material: • • Ethylene Glycol ■ DMT ■ Methanol • (Purified)Terethalic Acid 230 250 50 - 660 500 250 600 * Wellman portion estimated • * * Per H. Benson Pesticides: Monsanto Current lbs/day(k) (max) Expansion*** '96 - '99 Projected lbs/day (k) (max) Products: • Glyphosate ti • IPA Salt of Glyphosate 64.2 145.1 * * * * 191.8 130 ***• Raw Material: • Glyphosate Intermediate (2879) 91.2 270.4 *** Per Jeff Cross * * * * As is liquid product formulated from People: (Post Expansion) - Full Time estimates (including contract full time workers). Monsanto 150 ICI 275 Wellman 2445. 670 Total Complex Monsanto Supplemental Attachment 215 No. 15 - Waste Abatement Item 215a Discharge 002 Section II Item 215a In process waste abatement practices include separate process drainage systems, segregation of water, use of surface condensers, emergency waste storage facilities, special seals on pumps, minimization of air blow transfers, centrifuge wash recycle, recycle of water, use of multieffect evaporators, and monitoring of effluent. To allow year-round biological treatment of glyphosate using GDA (Glyphosate Degrading Activity), a smaller scale -- SBR (Sequential Batch Reactor) treatment tank and associated equipment is installed for pretreatment of glyphosate prior to entering the aeration basins. However, the operation of SBR is limited to an as needed basis and is not normally used. The glyphosate waste incineration unit is in place, if needed, as a backup means of destroying glyphosate bearing waste. The incineration unit has not been in operation for a number of years. Effluent from the polyester and herbicide manufacturing areas is discharged to an influent pump station (identified as Chem Lift in the Engineering Proposal schematics) with pH adjustment. Wastewater is pumped to an oil/water separator and then flows to an aerated equalization basin with pH adjustment capabilities. The equalized wastes then flow to the activated sludge biological treatment system. The activated sludge system consists of primary and secondary aeration followed by and clarification. Excess sludge is aerobically digested and then dewatered on sand drying beds prior to land application, or liquid sludge is land applied. Sanitary wastes are also treated by the activated sludge process. Effluent may be disinfected by chlorination prior to discharge. Schematics of the existing and proposed waste treatment systems are attached. I l 1 1 1 ] J 7 I 1 3 1 ] 3 1 I J 1 1 lcsw Monsanto Wellman ICI I Sanitary bypass C. rel. Spill Basin A. Chem Lift ry beds <Effluent Sludge Stor. lud B. pH Pit D. EQ Basin G. Clarifier A. Digester Decant E. AB #1 F. AB #2 Dates 03/13/1995 'Tine/ 4110 p. n. Drawl n9 FI le. Fi \MISCPRtJ\N50011 A EXISTING FAYETTEVILLE WASTE TREATMENT SYSTEM Monsanto Agriculture Company Fayetteville, NC Page 1 of 1 Sanitary Monsanto Wellman ICI J. Oil/Water Sep. A. Chem Lift/ H Adjustment <Dry beds [.. bypass C. EQ Basin <Efflnent Ilmillir H. pH Pit A id emergency bypass r D. Primary Aeration G. Clarifier I. Sludge Stor. E. Secondary Aeration 1 No - H. Secondary Digester 401 Decant F. Primary Digester * Bold lines indicate changes in system routing PROPOSED FAYETTEVILLE WASTE TREATMENT SYSTEM Monsanto Agriculture Company Fayetteville, NC Page 1 of 1 Date' 03/13/1995 Times 4103 p.m. Drawing Fileo Fi\N1SCPRUJ\N50010A Monsanto Supplemental Attachment 216 No. 16 - Wastewater characteristics mit Item 216 Discharge 002 Section II Item 216 The following list of chemicals further identifies compounds which may be present in the discharge: a) Ammonia may be added as a nutrient to the biological treatment plant and may be present at low levels in the sanitary wastewater. It will be neutralized before discharge. b) Calcium hydroxide may be used to neutralize and precipitate materials from a waste stream. It will be neutralized before reaching the effluent. c) Chlorine may be used to disinfect wastewater before discharge, to meet the fecal coliform standard. ,,.,, d) Formaldehyde is in the wastewater influent to the biotreatment system for removal; however, virtually all of it is biodegradable. e) Formic acid is in the wastewater sent to the biotreatment system for removal. f) Salts of phosphoric (and phosphorous) acid will be present in measurable quantities, after neutralization, in the wastewater effluent because of the nature of the manufacturing sources. g) Sodium hydroxide is used as a neutralizing chemical and its salts, for example a sodium phosphate, will be in the wastewater effluent. h) Sulfuric acid, as a neutralized salt such as sodium sulfate, will be in the wastewater effluent. i) During chlorination trace quantities of cyanogen chloride have been detected in the plant outfall. Samples of the waste treatment effluent, outfall 002, were collected at Monsanto's Fayetteville Plant, Fayetteville, North Carolina, during 1993 and 1994 by plant personnel. The samples were submitted to outside testing agencies (*) for analyses. Analytical results of the 002 outfall water samples are attached. Refer to Item 26, Additional Information, Reference II and III - Fourth Quarter 1994 OCPSF Reports and 1993 Annual Pollutant Analysis, respectively. * Burlington Research, Inc. Monsanto Supplemental Attachment 217 No. 17 - Description of Intake and Discharge Item 217a Discharge 002 Section II Item 217 Influent water from the Cape Fear River is treated for solids removal by coagulation, sedimentation, and filtration. Water is demineralized for process needs using ion exchange. Zeolite softeners are used for boiler feedwater. Drinking water is chlorinated. Flow 1111 The maximum total daily intake from the Cape Fear River directly contributing to discharge 002 is estimated at 2.266 million gallons per day. The raw intake water from the Cape Fear River is monitored periodically. Water characterization data are attached (ChemTreat, Inc. Analytical Reports). Samples of the influent streams to the waste treatment facility have been collected under the influent evaluation program referred to as the OCPSF program. Concurrent to the OCPSF program, the total outfall from #002 has also been analyzed for an extended period. Analytical results of the influent and effluent samples are included in References II and III, Fourth Quarter ''"'' 1994 OCPSF Reports and 1993 Annual Pollutant Analysis, respectively. Fon twi fml Pon tioN Rml rml fml r46r run PEI Monsanto Supplemental Attachment 219 No. 19 - Water Treatment Additives Items 219a & c Discharge 002 Section II Item 219 Utility and water treatment additives are summarized on the following table (attached) . MSDS appear on the following pages. NOTE: No biocides are used on site for treatment. Corrosion inhibitor is used for cooling tower water treatment. Item 219b Name and Address of Supplier: Calgon Corporation Box 1346 Pittsburgh, PA 15230 ChemTreat, Inc. 500 Lickinghole Road Ashland, VA 23005-3294 Mel UTILITY/WT LIST YEAR 1994 MATERIAL USE MATERIAL REC'D MAX. ON MATERIAL HAND USED SARA 313 COMPOUND PRESENT Minibulk H2SO4 Flake Caustic Caustic (50% Conc.) Freon 12 Freon 11 Liquid Alum Chlorine Sodium Chloride 28,800 13,200 2,002,980 8,000 600 541,360 15,750 97,600 9,600 2,000 80,000 28,000 600 80,000 1,200 28,000 21,600 12,000 1,953,680 8,000 600 505,360 15,150 70,500 7,200 1,200 49,300 28,000 0 36,000 600 27,100 ChemTreat/CI-1436 ChemTreat/BL-1102 ChemTreat/CT-907 ChemTreat/BL-1544 ChemTreat/B-120 Sulph ChemTreat/F-90 ChemTreat/CT-58 ChemTreat/D-2409 ChemTreat/P-801E Poly CI* Polymer Wetting Agent* Steam Additive for Corrosion For Boiler Condensate Additive Fuel Oil Additive CI* Defoamer for WTP** Polyelectrolyte for WTP** 12,460 24,790 12,578 19,986 14,504 13,090 5,896 11,256 4,000 1,500 4,221 1,500 1,200 1,500 0 0 0 0 8,368 15,496 9,933 11,550 2,100 3,751 450 0 0 4,092 9,294 2,645 8,436 1,900 470 750 0 0 Water Treatment/Utility Chemicals Being Phased Out of Use Calgon 2392 Polymer Calgon 2005C Poly EZ Polymer Combustrol 400 Calgon/EC-210 Defoam Calgon Resinaid 150 Polymer for WTP** O 7,000 O 0 O 0 O 0 O 750 O 750 250 0 0 0 750 750 6,750 0 0 0 0 0 *For Tower/CI = Corrosion Inhibitor for cooling tower water/chilled water. **For Water Treatment Operations HAZARDOUS CHEMICAL LIST REF: SARA TITLE III SECTION 311(D)(1) CHEMICAL NAME SEQUENCE Chemical/Common Name No. Days on Site (Utilities) Avg. Daily on Site Max. Daily ChemTreat CL-1436 365 6,500 14,504 Chlorine 365 900 1,200 Freon 12 365 28,640 28,640 Fuel Oil No. 6 365 4,130,000 4,956,000 Liquid Alum 365 40,000 80,000 Nitrogen 365 170,000 234,000 Sodium Chloride 365 12,000 28,000 Sodium Hydroxide 365 50,000 85,000 Sulfuric Acid 365 6,000 9,600 DIVISION OF ENVIRONMENTAL MANAGEMENT WATER QUALITY SECTION NPDES GROUP March 12,1995 MEMORANDUM To: Ruth Swanek Instream Assessment Unit Supervisor Through: Coleen Sullins C Permits and Engineering Unit Supervisor From: Dave Goodrich' NPDES Group Supervisor Subject: Limits for Monsanto WWTP Expansion NPDES Permit #NC0003719 Cumberland County After reviewing the preliminary information provided by TRC Enivronmental Corporation (Monsanto's consultant) and discussing permitting issues with you, your staff, and the Fayetteville Regional Office, I would like to offer the following comments regarding the development of limits for this facility. There are three general methods of developing limits for BODS and NH3 in this permit: 1) Base limits on QUAL2E model results. 2) Base limits on BPJ (i.e., 12 and 2 or base on consistency with existing permits). 3) Base limits on BAT. The existing permit limit of 350 mg/1 for BODS was derived through a combination of #1 and #3, although it was primarily the BAT limits which were requested by Monsanto. I suspect that it will be worthwhile to look at all three methods for this proposed expansion prior to the March 14,1995 meeting. The NPDES Group will attempt to develop limits based on BAT which will be presented at the March 14th meeting. As for the model results and the BPJ discussion, I would like to discuss answers to the following questions in preparation for the meeting: Page -2- Memo to Ruth Swanek Limits for Monsanto WWTP Expansion March 12, 1995 What do existing D.O. data from DMR's and ambient monitoring document? What does the QUAL2E model demonstrate? What will the model support in terms of limits? Can we use the model to argue BAT/BPJ approach? Vogt's Level B model determined that limits of 20 mg/1 (BOD5) and 4 mg/1 (NH3) would protect. What mass did these concentrations represent at the time? What is the basis for DuPont's BOD5 limit? As I mentioned to Steve Bevington, I invited Michael Wicker to this meeting since this discussion will have a direct bearing on the facilities in his region. I realize that the intent of this meeting isn't only to discuss the decisions which need to be made at Monsanto, but I hope this memo can serve as a tentative "agenda" for this portion of the meeting. Let me know if you have questions or comments. cc: Steve Bevington Michael Wicker Jeanette Powell Betsy Johnson Jason Doll PIMP IMPEI ., MONSANTO COMPANY Fayetteville, NC ENGINEERING PROPOSAL FOR NPDES PERMIT APPLICATION TRC No. 18-153-000 Document No. CH-95-32 March 1995 by TRC Environmental Corporation 6340 Quadrangle Drive, Suite 200 Chapel Hill, NC 27514 (919) 419-7500 TRC TRC Environmenta! Corporation ADDITIONAL INFORMATION REFERENCE I ENGINEERING PROPOSAL n 1 NPDES-EngineeringProposal Monsanto Company March 15, 1995 Confidential Information MONSANTO COMPANY FAYETTEVILLE, NORTH CAROLINA ENGINEERING PROPOSAL firm 1011 1.0 Proposed Waste Discharge Origin, Type and Flow ,r, 1.1 Summary of Activities Producing Waste Monsanto Company's Fayetteville, North Carolina Plant, located on Highway 53 East - 210 South on Cedar Creek Road, produces the crop control chemical Roundup. The Fayetteville Plant, a part of Monsanto's Crop Chemicals Division, has been in operation since 1981. Monsanto Company also owns and operates its own water utilities, including a water treatment plant and wastewater treatment facilities. In addition, Monsanto supplies water to and treats wastewater from adjoining facilities owned by ICI Americas Inc. (ICIA) and Wellman Inc. (Wellman). 0"'' Contributions to existing NPDES Discharge 002 result from Monsanto's herbicide manufacturing activities as well as wastes received from these adjoining facilities that produce polyester resins and fibers. Process and sanitary wastes from the three facilities (i.e., Monsanto, ICIA and '`' Wellman Inc.) are transported to the biological treatment system and discharged via 002. ICIA, in conjunction with Wellman, Inc., produces polyester fiber. Polyester resin is ''' manufactured from ethylene glycol and dimethyl terephthalate by a polymerization process. The base polyester resin is spun into continuous filament. Pul At the Monsanto facility the herbicide intermediate, N-phosphonomethyl imino-diacetic acid, is converted to N-phosphonomethyl glycine, concentrated in an evaporator, separated and washed in a centrifuge. The cake is stored either wet or dry. The wet material is separately reacted with ram isopropyl -amine and then formulated in a water solution with a surfactant and packaged. The dry material is shipped to customers. These facilities also generate wastewater which does not come in contact with process contaminants. These non -contact streams include backwash pond blowdown (water treatment settling pond), demineralized water treatment blowdown, boiler blowdown and cooling tower blowdown. In addition, there are sanitary waste stream components from these facilities. PEI The projected wastewater treatment facility design flow is 1.3 million gallons per day (MGD). The design flow represents an increase in the existing average monthly discharge limitation (0.859 MGD) of 0.441 MGD. 1.9 rimy 18-153 1 TRC Environmental Corporation run 1.2 Proposed Expansion NPDES-EngineeringProposal Monsanto Company March 15, 1995 Confidential Information Monsanto Company is proposing to put in place expansion plans in order to meet business needs triggered by substantial demand worldwide. The Fayetteville Plant was selected for Monsanto's business expansion based on the existing supporting utilities, successful operations of the utilities and capacity to integrate this expansion, while fulfilling the worldwide market demand. r..r The scope of the proposed expansion will increase the overall production capacity of the Monsanto Fayetteville Plant by approximately 200 percent from the current base, resulting in a production increase of three times the present production rate. The ICIA proposed expansion will run increase their overall production capacity by approximately 100 percent from the current base, resulting in a production increase of 2.0 times the present production rate. Actual production rates for the last three years and five year projected production rates are included in Appendix pul A. Monsanto proposes to install the project at the Fayetteville facility so that the technology and chemistry involved is identical to the present conventional glyphosate manufacturing technology at this location. This expansion will therefore represent an "add -on" process, parallel to the current process. All unit operations involved are identical to the present and as such will not run introduce other unknowns from the chemical and technological points of view, other than operational changes. The process expansion will require upgrades or increase in operational efficiency at the raw material handling, processing, finished goods, packaging, and shipping areas, rsrl as well as the wastewater treatment facilities in support of the overall expanded operations at the plant. rim The simultaneous Monsanto and ICIA expansions will require Monsanto to upgrade its waste treatment facilities in order to meet the associated increase in waste flow and loads. 2.0 Summary of Wastewater Treatment and Disposal Options run 2.1 Alternative Waste Treatment and Disposal Options Considered F-1 The following treatment and disposal scenarios were evaluated by the Monsanto's Environmental Operations group: 14P1 Option 1 - Pollution Prevention (including source reduction and recycling) Option 2a - Upgrade existing activated sludge plant - Upgrade existing structures, increase aerator efficiency and treatment efficiency Option 2b - Pretreatment or no treatment and discharge to the Fayetteville POTW Option 3 - Reuse Option 4 - On -site spray irrigation rim 18-153 2 TRC Environmental Corporation Fowl mit A letter from Environmental Operations that summarizes the treatment options investigated is 1411 included in Appendix B. rem 3.0 Description of Proposed Treatment Works The facility expansion will result in increases in the hydraulic load to the waste treatment facility as well as increases in the level of BOD, COD and TSS loading. However, based on the pilot treatability study, the BOD, COD and TSS loadings will not increase proportionately to flow. To accommodate the projected flow and loading, the existing wastewater treatment facility will 1411 be upgraded to increase the efficiency of the activated sludge treatment process. NPDES-EngineeringProposal Monsanto Company March 15, 1995 Confidential Information 3.1 Narrative Description of Proposed Upgrade A narrative description of the proposed upgrade to the existing treatment works is summarized below. In addition, schematics of the existing treatment system and proposed treatment system, and preliminary design schematics, including treatment unit volumes, of the proposed system are included in Appendix C. • route Monsanto sanitary wastewater and centrifuge spent wash, and ICIA wastewater discharge, to the chemical lift station at the head of the plant • add pH adjustment capability to the chemical lift station • add new oil skimmer unit 1141 • convert the former spill basin to the new aerated equalization basin, pipe oil skimmer wastewater discharge to the new aerated equalization basin, add four (4) 7.5 HP mixers to the new equalization basin ,w, convert the former equalization basin to primary aeration basin, pipe flow from new equalization basin to new primary aeration basin, the underground portion of the new piping will be double contained, add pH control to the primary aeration 1•11 basin, add six (6) 150 HP floating aerators to the primary aeration basin relocate existing aerators (from the former equalization basin which will be converted to the primary aeration basin) to the new secondary aeration basin and primary aerated sludge digester • add new piping to connect the primary aeration basin to the secondary aeration basin (formerly aeration basin No. 1) and the existing clarifier 'as' add new piping to connect the new primary aerated digester (formerly aeration basin No. 2) to the secondary aerated digester (formerly the digester) clarifier rim 18-153 3 TRC Environmental Corporation Pal NPDES-EngineeringProposal Monsanto Company r..l March 15, 1995 Confidential Information The proposed treatment facility schematics, located in Appendix C, depict the upgrade and ,,.g arrangement of major components. The system upgrade design is based on the results of several years of operations and operating ,., data at the existing treatment plant and based on the results of a recently completed pilot treatability study which accounted for the incremental increases in flow and loading from Monsanto and ICIA. A summary of the treatability studies is included in Appendix D. In R-, addition, current BOD, COD, ammonia nitrogen and glyphosate loading are included in Appendix E. 1101 fool Rol PIM 18.153 4 TRC Environmental Corpoi P�1 1L1-111 V V•0 111V 1V'L1 11r1V 1 !11L.1 11.U1LLG 1 111 11V. �71U''1JJ`t .1V 1 i V`1 Monsanto THE AGRICULTURAL GROUP P.Q. BOX 2307 FAYETTEVILLE, NORTH CAROLINA 28302 PHONE (910) 323-3300 March 9, 1995 Ref: NPDES & Mr Permit Applications • 1995 Supervisor, NPDES Permits Division of Environmental Management NC DEHNR P. O. Box 29535 Raleigh, NC 27626-0535 Dear Sir: SUBJECT: Production Information Per requirements stated in conjunction with the above permits and as a part of the "Engineering Proposal" information request from your department, Monsanto Company is submitting the following: production information for the past three years (actual and the future production estimated (forecast) under expansion premises for: 1) Monsanto Co. Fayetteville Plant 2) ICI Americas Inc. - Fayetteville Site This information is marked as "confidential" since it is proprietary and we are confident that it will be treated as such. tw Attachments Yours truly, 0i4.•~Z.Etek.--• H. Van Bell Plant Manager nun v v., iiiu 1u'CC 11I1V rl1ICI iCulLLC )/9/95 TE PCT 1O1 SA8T0 COMM, FAYETTEVILLE, IC ACTUAL & FORECASTED GLYPH TECH PRODUCTION rru NU. uiu4J34C1u *;...COBPABY C01FID£6TIAL'""s r. uD 1811TH JAA FEB I!*8 Pin in SLIT 3111 JUL *UB SEF OC! 101 DEC ,i, TOTAL IsM r*19 OATH JA8 Psa 3A8 API 8*Y Ji11 JUL AUG SEP OCT 101 DEC ACTUAL PRODUCTION LBS (M0'S) 1992 1993 1996 FORECAST JCL RUN LBS PER 1994 DAYS DAY 999 1811 1515 31 199438 824 1557 1938 28 199438 1838 1825 1899 31 199438 198 1536 2001 38 199438 962 1255 1963 31 199430 1842 1763 2275 38 199438 1795 1769 2816 31 92882 1977 1743 2226 31 92882 1758 1488 1774 30 92882 1589 1118 1954 17 92882 1934 1996 2243 38 92882 1681 1966 2103 31 92882 16693 19819 ssanas z22162 1998 FORECAST 23987 351 MOMS asssa 10. LBS PER LBS PER 8111 LBS Pik 801TH YEAR DAYS DAY 4888'S) (8888'S) 31 28 31 38 31 38 31 31 38 17 38 31 mg TOTAL 351 sass= Pot 199438 199438 199438 199438 199438 199438 199438 188129 185425 105425 105425 185425 6182 5584 6182 5983 6182 5983 6182 5584 3163 1792 3163 3268 78888 70888 78888 71888 70180 78800 78880 63225 37084 37804 37884 37804 59249 :aza2as LBS PER 181TH SM8'S) 6182 5584 6182 5983 6182 5983 2855 2855 2762 1565 2762 2855 1999 FORECAST 1997 FORECAST LIS PER LBS PER LBS PER YEAR LBS PER I01TH YEAR (0801) DAY (888'S) (888'S) 78888 199438 6182 78088 78880 199438 5584 78880 78888 199438 6182 78880 70080 199430 5983 70880 78888 199438 6182 78880 78888 199438 5983 78888 32321 188080 5588 63188 32321 98528 3854 34583 32321 98528 2956 34583 32321 98528 1675 34583 32321 98528 2956 34583 32321 98528 3854 34583 51751 55372 LBS PER DAY 199438 199438 199438 199430 199438 199430 199438 199430 199438 199438 124767 115967 LBS PER LBS PER KITH YEAR (8881) (8081) 2888 FORECAST LBS PER LBS PER LBS PER 80871 YEAR DAY i880' S) (M8' S) 6182 70000 199438 6182 78888 5584 78888 199438 5584 70008 6182 78888 199430 6182 78888 5983 78888 199438 5983 78880 6182 78800 199438 6182 7800 5983 71888 199430 5983 78808 6182 78888 199438 6182 78888 6182 70308 199430 6182 78808 5983 70888 199438 5383 71880 3390 78888 199438 3390 78800 3743 43793 199430 5983 70880 3595 48784 198983 5918 67807 65173 69736 ammum. assssse t++f'OOHPABY COHFIDENTIAL.tt;, MAR- 9-95 THU 16:22 MAC FAYETTEUILLE FAX NO. 9104334210 P.06 PPR-09-095 36 FROM TO 94334240 P. 0i Films ICI AMERICAS INC. FAYSI7EMLESITE FAX NO. 910-433-8389 IIHQNE NO. 910-433-8?AO FAX 'FAX MB FOLLOWING PAGE(S) - ...pother _Yatel ram Barry. 2• Benson • DATE: mq ec &1 9. _.This vasmt tORqhe. m+ , Q1e facil fr a to caU Bob at 433-a237 ar z of U at 43 - 242. pm pm pm pm pm pm pm LOCATION FAXN .. An'ENTION: Airun Monsanto C a 433.4240 od eti•.c.. - per ho -1 ester and our future - ca n: U CO CO CT) r : : WORMII Fayetteville Summary of Estimated Polymer Production MT Arise s Janus Februa March A.r7I Ma Juno Ju Au ' ust Se ternber October November December Subtotal Lbs!Wee Lbs1D PTA Assets January February March April Miley June July August September October November December Subtotal LbslVlree LbsiDary Totals Year Aclual Year Estimated Total Year rt bs!Da fitp 220,000 i 240.000 241.000 4.635 03/09/95 E �, IAA 241, 00C 4,635 —662 481,000 481,000 481,000 9,250 1 321 PNI NPDES-EngineeringProposal Monsanto Company Confidential Information March 15, 1995 APPENDIX B TREATMENT OPTIONS 18-153 TRC Environmental Corporation OPTIC:RV Ts DI$CRA :GE OF FAYETTEVILLE WASTEWATER PO _LtITANTS "m ].. The primary option: reviewed for discharge of wastewater pollutants from the Fayetteville operations was pollution prevention. This included source reduction as well as recycling. This option was m, used to significantly reduce the pollutants sent to the waste treatment operations. This included process modifications that reduced impurity make in the reactor. it also included various purification operation improvements that also reduced the mm pollutants discharged. Recycle was also incorporated into this. This recycled not only wastewater, but also recycled impurities back through the process. This also reduced the production of mm pollutants. 2. This was followed by the option to reduce the wastewater effluent pollutants by extensive biological treatment. An option considered tom, was the discharge of wastewater to the local POTW. This option was rejected in favor of on -site biological waste treatment with the systems that were designed specifically to treat these pollutants at a much higher efficiency than would be afforded by the POTW. mm The Mionsanto Fayetteville wastewater treatment facility was recognized by the EPA as the Best Practical Technology (BPT) and Best Conventional Technology (BCT) in comments submitted in support of the Pesticide Effluent Guidelines. The treatment facility of P' this plant will average 99%. Specific SPA comments are as follows at FR56, 50651: rim "EPA agrees vi::h these comments. The wastewater treatment technologies =stalled at the facilities manufacturing these it PAIs are equivalent to the SPT technology, i.e., the technologies include both in -plant treatment to control PAIR and end -of -pipe: biological treatment to control BOD and TSS. rum Because these manufacturers are meeting the BPT-level limitations oil. BOD, TSS and pH, it appears that these technologies are being well -operated." M' 3. Other options thc- t were considered were the subsequent reuse of water after waste treatment, either internally or for external use. It was determined that this water was not suitable for reuse within mm the plant becaus,v of the co -mingling of pollutants that would interfere with the reaction process, and could result in the increased product ion of pol' lutants . It also could affect the safety of the process due to possible side reactions. mm 4. Use of the water for irrigation was also considered, however, due to the local soil conditions, the amount of wastewater available and build-up of salinity, this option was also rejected. MR 5. The attached chart. shows the significant reductions in wastewater pollutants afforded by the pollution prevention options noted P, above. All process effluent will also be processed by a state-of- the-art wastewater treatment unit that uses the Best Practical Technology and Best Conventional Technology to further reduce the discharge of wastewater pollutants. MR ratrvLant.X% rixCA . 3005 MAR- 9-95 THU 17:08 MAC• FAYETTEUILLE FAX NO. 9104334210 P. 03 BASIS: TABLE 4 DISCHARGE ALLOWANCES (PERMIT LIMIT) MINIMUM (SUMMER LIMITS) (a) PROD'N FACTOR BOD (LBS) Ci (LBSI CASE 1 ('93-'94) 1 350 34 CASE 4* ('96= 99) 2 2.24 346 5 CHANGE (%) 224 -1.1 TABLE 4 lb) CASE 1 )D DAY) 70 36 TSS (LBS/DAY) 660 457 NH3-N (LBS/DAY) RATIOS: LBS PER M - LBS PRODUCTION PROD'N FACTOR 1 CASE 4* 6OD 17 2.24 4,9 CHANGE (%) 241 -71 COD 23 35 TSS 169 79 NH3-N 32 1,1 6.5 0.4 *CASE 4; Prorated Production Factor = 2,24 (Flow Weighted: ICIA/Monsanto) -53 -80 -64 NPDES-EngineeringProposal Monsanto Company Confidential Information March 15, 1995 + APPENDIX C DESIGN SCHEMATICS 18453 TRC Environmental Corporation l l l l 1 l l l : ] 1 l 1 l l 7 l l 1 Monsanto Wellman ICI bypass C. relSpill Basin A. Chem Lift ry beds I I I <Effluent I. Sludge Stor. 11111 H. pH Pit D. EQ Basin 11, G. Clarifier vis H. Digester Decan E. AB #1 F. AB #2 Date. 03/13/1995 Tine. 4410 p. n. Drawing Files Fi\MISCPRtJW50011A EXISTING FAYETTEVILLE WASTE TREATMENT SYSTEM Monsanto Agriculture Company Fayetteville, NC Page 1 of 1 1 1 I 1 1 1 1 1 1 1 1 1 I 1 1 I ] 1 1 ISanitary Monsanto Wellman ICI Ply J. Oil/Water Sep. A. Chem Lift/ pH Adjustment <Dry beds C. EQ Basin bypass <Effluent ummill H. pH Pit r emergency bypass D. Primary Aeration I. Sludge Stor. \G. Clarifier/a H. Secondary Digester 1101 E. Secondary Aeration 1 Decant F. Primary Digester * Bold lines indicate changes in system routing Dates 03/13/1995 TI nee 44 03 pais Drawln9 Fl les Fs \NISCPRDJW50010A PROPOSED FAYETTEVILLE WASTE TREATMENT SYSTEM Monsanto Agriculture Company Fayetteville, NC Page 1 of 1 SAN vrAP Y 5E,„/Ek tosAvra TEM PRIEM POISMITO MUTES vauwi CHEMICAL r-B44-4123 CRAW TO R-3 SEWER LJ 1▪ r-53-1M \rt14.'. ft‘' 1 Z -AR E CD3 rx tr 4- - r ▪ Zai jirx r ,--„, rilT)1 tad nurr ma= '-'11,_ Lc.;1- TA i.r PAMELBOARO —17-P' r-i--'4 r - - — ; 1...,-. I 1 1 WU USE 7P IL t REMOTAAE TRASH SCREERS MO a / 77 Ye 23:1 Zt =1EII— ,01 SPLITTER BOX CCHRISTIE Vif1.141 230(7)11 45-211 (4511-2_1)2 733C---)2111 415-211 CHEMICA.-fEWER aPP PP LIFT STATER / / / S'!--115 Otinglajo/ Do 0 000 GAL 2313-213 SPUTTER BIC I IRO C5Trc DAY "TA PR QM:SITE SAIeLER • !!.5/. A.G./ „/ e 653 /1—/ 7 / xres./ / / 1 , 4 1 3 1 2 1 1 21' X ir 23.C:D311 MEWL =ROL FROM UTILITY NIG. PMELRONIO 5- ) FILL E L5J1ij r J i) Pr;,.."ar--) For ,,/,1 k 1 e +-0 PH C1,11)RL P11> Vcj /Isl. V4 1 1) '411 S A P VIEW NO OEPPIINT nwIT amo fikIMAISORTO aggit0 COPAIIY CESVPICIONIML =VT OF imomon OmPoo• Min= MO o Oa KNO,ILItitIL =Pm DICIIPEERNO DEPARTMENT St LOWS. IMSOLIN wee enrols es Twe corowami. 0.0 El TO — — 111MV m ft./MOM= p... worm/ mart OM MITSMOT OV nemorrO. IT MART On MCM1019 MOM. maT Ili IIIIIIImmon m IMMO 011 °OW ornowr ormn N- M= MOM iMilimo°,11 MOT OE IOLOOMOD to ComForon Mom OPT. AT — 111E MOM INCOLEST.ILIT ft — OMPLIOM ar OM NOM CM aM. 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J. :T own moo wRwrro nvaatTIPA. corm( MONSWO I IRTIFITT CarA1r lsuRta1>Y1.T1...... ■ TT. ---,.. umc moo or Hrilfi .mos•w..wan . TO s IOTO lLT Or O".eTO D Aal..Ili OT VOrONTO."MOT• acaMIWISO loft& OOP O[ O7iniMooli. l Olei Or row OnIp1T .0 TwrTTp 1e /d-YMO.O...T S MOOED TO 1Ow20/10 W.CLT COIOMPro Alf MINT • ONOWAT0�1t TC. 1111.1% at MTa ' Wm �TO MP OAT 1. . T7 MO. A MOM l/LO.T1s TO Tm 004l00.IN1 wwwul IMMO= Imo► 0.m.rs A T.. osoina"T.n POOP .TOO Ora - .a Ow/ TO am TKO Toe MOM OVENN0.11 TT. TIM A. C 1IMO/1O11 IOO.O11. TRJ1fT FAYETTEVILLE F i YTL + woo•452 01T[ 1 —a 1MTTa !ip/E j 1 r sal= k ` r1....�� ,.�r 1 f.�a • _ 1147 743 ID, 00.000I 0 13e5 NPDES-EngineeringProposal Monsanto Company March 15, 1995 Confidential Information APPENDIX D TREATABILITY STUDY 18-I53 TRC Environmental Corporation U3/U9/8b 16: Uti x"314 6U4 11011 MAC-U4H WASTEWATER TREATMENT FEASIBILITY STUDY FOR PROPOSED FAYETTEVILLE PLANT EXPANSION INTRODUCTION In support of the Fayetteville Plant bioexpansion project, laboratory studies were conducted to determine the feasibility of treating the increased waste using 4 different treatment configurations. .The reactors were all Eckenfelder design with the series reactors hooked up to external clarifiers operating with sludge recycle and the parallel reactors using baffles as clarifiers (Fig. 1). Feed for the reactors (shipped from Fayetteville and mixed in St. Louis) consisted of pH pit [existing waste not including Monsanto/Wellman sanitary or glyphosate centrifuge spent wash (CSW)), additional Tech Overheads and ICI waste, plus CSW. The reactors were first acclimated to the existing waste and flow. The waste (and flow) was then increased step -wise fashion until it reached the estimated expansion level (2.5 times increase in Tech Overheads flow and up to 50% increase in CSW). Also incorporated into the `projected waste stream" treated by the bioreactors was the increase in ICI waste due to their expansion project (30% increase in current flow of existing waste matrix). EXPERIMENTAL SERIES CONFIGURATION: 1. The Fay 1-2 series was a traditional series operation with the first stage scaled to the 3.5 M gal basin and the second stage scaled to the larger of the existing aeration basins (1.2 M gal). Influent entered the system in the first stage and sludge was recycled from the clarifier to the first stage. Sludge production was quite low and the only wasting from these reactors was for sampling purposes (from the reactors) and TSS in the effluent. The reactors were operated at 21° C (70° F). 2. The CSW series was set up somewhat differently with the first stage the smaller of the two stages. All of the centrifuge spent wash (CSW) was added to 20% of the total "expansion" flow and fed into Stage 1. The effluent then flowed into Stage 2 (which was receiving the remaining 80% of the "expansion flow") for additional treatment. The first stage reactor was originally designed to treat only the CSW, but the flow was so low that combined with loss to evaporation produced a situation where there was no overflow into Stage 2. When this happened, the salt began to build-up and microbial activity (as measured by TOC and COD) was retarded. The sludge recycle from the clarifier emptied into Stage 2 and 100 mi/day from Stage 2 was recycled back into Stage 1 to maintain the solids level at 4,000 mg/L. There was also some wasting from Stage 2 in order to maintain the solids level in that reactor at 6,000 mg/L. The reactors were operated at 21° C (70° F). COMPANY CO FIDE PoII 03/09/95 16 : 07 e314 694 1259 MAC-04H I j 003 Teri PARALLEL CONFIGURATION: 8. The parallel reactor Fay 3 was scaled to represent the 3.5 M gal aeration basin. It was operated at 28 ° C (84° F). There was no sludge edge recycle stream since a baffle inside the reactor provided the quiescent zone for clarification instead of a separate clarifier. Fay 3 was operated with a solids level of 4500 mg/L. Wasting from the reactor was necessary to maintain the solids at the design level. 4. Fay 4 was operated in identical fashion to Fay 3 except that mixed liquor solids were maintained at 6,000 mg/L. The reactors were acclimated for 3 HRTs at each level. Data was then collected during a 5 day kinetic study on the reactors, the effluent from the reactors and the feed to the reactors. Samples were all filtered (including effluent for BOD testing) before analysis. 0.1 RESULTS Key results of the bioreactor testing are shown in Table 1. BOD treatment efficiences averaged 99% in all treatment configurations which were evaluated. COD or TOC treatment efficencies were somewhat more variable but ranged from 91-98%. Sludge settling was good in all reactors and no significant florl toxicity was associated with bioreactor effluents. It must be stressed that bioreactor feasibility studies are used as tools in the design of activated sludge biological treatment systems. We are designing our treatment system to average 98% BOD removal and 90% COD removal on an annualized basis at the proposed expanded production rates for Monsanto and ICI operations. This is based upon: 1. The historical excellent BOD and COD treatment efficiencies achieved in the field must be maintained at hydraulic retention times in the aeration basin reduced from 11 to 5.6 days. 2. Laboratory treatment studies evaluated conditions of annualized production, not uistaneous peak waste loadings which the biosystem must be able adequately treat. (Studies to determine peak waste treatment capacities and associated safety factors are ongoing.) Fool 3. In our laboratory investigations, we measured only the BOD content of the treated effluent associated with the soluble fraction. Since we filtered the effluent samples, we did not measure any BOD which may be associated with particulates. (Weare also currently investigating in our laboratory the amount of BOD which may be associated with efluent TSS.) COMPANY CONFWWE 1IAL 03/09/95 16:OS ' 314 694 1259 MAC-04H 004 Bele Emnmt to Waste Mixer Air Stone COMPANY CONFIDENTIAL Figure 1. 1 PARAMETER FAY 1-2 SERIES 21°C FAY 3 PARALLEL 28°C FAY 4 PARALLEL 28°C SERFS 21°C MLVSS (mg/L) 3677 4580 6080 3988 Eff MLVSS (m 186 54 146 10 Sludge Production...19 solids/9 BOD) 0.063 0.204 .............. .0.192 0.114 BOD Removal (%) 99 99 99 99 COD Removal (%) 91 91 94 9 7 TOC Real (%) 95 95 96 98 HRT (days) 6.22 4.48 — 4.78 5.13 BOD F/M 0.19 0.18 0.15 0.17 COD FIM 0.34 0.27 . 0.25 0.22 NH3 (mglL) 0.45 Toxicity (fathead minnow mortality)* 5% 0 0 0 *Control mortality was 2.5% for each of the effluent samples tested. COMPANY CONFIDENTIAL Table 1 SUMMARY OF FAYETTEVILLE BIOREACTOR STUDY AT THE "58 Mib" LEVEL 1 1 I 1 1 1 Variables low 093. Aar M41, are low May 1 are low Jane hip area... low July high are low Aug hitb ave Wen Chap FwIw) 0.001 0.004 0.002 0.001 0.004 0.002 0.001 0.004 0.002 0.001 0.007 0.002 0.001 0.004 0.002 BOO Mk!) 9 35 18 7 28 14 6 23 12 8 57 18 12 50 28 co001114 020 104 100 15 494 112 18 638 131 0 280 120 6 696 117 Mon Tech Fbwo rad) 0.174 0.262 0.208 0169 0.593 0.182 0.157 0.256 0.250 0.196 0.279 0.249 0.000 0.321 1 0.262 C OO/deo) 1835 11593 7084 4893 21025 7749 2316 13745 8889 2350 11914 8930 0 15711 8807 ICI How (n ) 0.062 0.269 0.140 0.063 0.192 0.125 0.078 0.251 0.147 0.031 0.217 0.142 0.081 0.173 0.125 son() 631 18888 6743 1449 11365 4872 1635 11517 4781 543 17715 4711 1331 10465 3914 COD OW) 859 28371 10121 2450 7253 2740 17634 7315 R56 16839 7411 1913 10639 6101 Maw CSW How QM) 95 2517 1132 178 564 396 40 19922 916 299 1252 882 211 1766 1147 MONO 1283 426 1325 1262 1471 Moa San limo*) 0.035 0.037 0.039 0.021 0.014 COD(d) 72 77 82 44 30 Wd1 San lbw(n+(d 0.036 0.043 0.04 0.033 0.044 0.038 0.032 0.043 0.036 0.012 0.077 0.054 0.015 0.032 0.061 Coot 11 51 35 29 87 47 7 38 23 2 24 22 7 43 48 Vadsbks %Ow • Sept hid, ara le* Oct e low Nov hid+ are Dec .•' ave 0.002 3 110 0.256 9349 Well Cbew1 Row(314/ BOD taerd) cod pow 0.001 - 7A 1 . 0.002 54 404 0.003 77 152 0.000 0 0 0.008 22 1268 �6 :a 0.003 7 136 0.001 1 7 0.010 10 1515 0.003 3 117 a ter' 0.001 0.003 2 S 3 490 Mon Ted, rbw(wsa) COD PAW 0099 . 107 0.313 14604 0.246 5874 0.088 231 0.615 25659 0205 5529 0.208 5103 0.316 12058 0.284 8206 0.212 4831 0.288 13205 ICI Ha•(ieoa) 0.085 0.221 0.136 0.109 0.198 0.151 0.108 0.241 0.167 0.038 0.227 0.170 eOD() 1314 9939 3782 1728 6651 3426 1776 7253 3599 322 8845 3767 ammo) 2404 16983 6266 2701 11647 6623 3686 12106 6757 935 18089 6560 Moa CSW m (z 0 1403 751 0 1368 664 581 1548 1154 CODOb) 930 619 1583 1989 Moa San Fbwtn) 0.033 0.033 0.043 0.044 mow) 68 68 91 91 Wen Sao Row () 0.031 0.036 0.042 0.029 0.035 0.042 0.011 0.036 0.032 0.03 0.036 0.032 CO0(1440 10 29 24 . 8 38 25 2 13 8 11 22 16 1994 Jaw Feb Varblbir- rr Mw bilh eve L C s.a+�•.."s•�r�'.�'.!!Ib Wdl ChemFlow 016d) 0.001 0.009 0.005 0.001 0.004 0.004 DOD OW) COD Wt 0 O 0 0 10 35 23 8 1538 268 12 407 198 COMPANY CONFIDENTIdi. Mar Apr May low are low bigl,. Iva low 0.001 0.004 0.002 0.001 `0.005 0.003 0.001 0.004 0.003 O 0 0 0 0 0 0 0 0 14 850 149 12 568 111 5 521 156 Mon Tecb fewome) coo (billy) ICI Paw Oral) HOD (16rp COD (brat 0.052 0.246 0.192 0.176 0.273 0.220 6 12334 6913 6265 17413 10953 0.086 0.245 0.160 0.117 0.268 0.188 766 9504 3257 806 7057 3324 1119 14841 5200 2011 14826 6069 Moa CSW Moa San Wd1 San Row Old) tyro OM!) Year low high arc 0010 0.010 0.003 O 57 15 O 1538 141 0.153 0.231 0.192 0.131 0.199 1 0.182 0.148 0.205 0.173 3738 11228 8409 2643 10411 8674 4757 I0693 9176 0.086 0.406 0.196 0.017 0.153 0.112 0.028 0.171 , 0.118 177 11311 3274 305 3511 2680 487 6632 3415 603 21207 6679 644 9128 5110 937 12941 5899 O 2437 1224 691 1734 1215 1540 1631 0.044 0.041 92 86 O 0.284 0222 O 25659 8182 0.017 0.406 0.148 177 181188 3968 603 28371 6640 522 1476 1142 419 1923 1473 485 2017 1676 15311 2126 2358 0.025 0.032 0.031 10 13 12 0.03 0.041 0.034 8 19 12 O 2517 1087 1434 0.04 0.038 0.036 83 79 74 0.033 0.037 0.035 0.032 0.048 0.037 0.036 0.087 0.039 6 19 12 10 23 14 R 34 12 0.036 74 0.011 0.087 0.039 2 87 22 Yearly Mlluenl Summary NPDES-EngineeringProposal Monsanto Company March 15, 1995 Confidential Information APPENDIX E INFLUENT LOADING PARAMETERS 18-153 TRC Environmental Corporation INFLUENT IN ell Chem Mon Tech Chem lift ICI PH Wt ..ft 616,4 hien CSW Man Dem 1993 Apr May 31oe low high .9e J1117 {6w hRh are Mass Bala Ce Ant 1a9r bilk awe Variable Iw hiFh 069 low high 7646(110W 0273 0 311 0629 0166 0.111 01.1 0 261 0 536 0.161 0140 0301 0.669 0.096 0331 0440 71.. 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SPLITTER EAST. SPILL BASIN EXIST. INSTR%*(Nt SHED EXIST. FLOW SPUTTER BOX rALvt Box F1ANC AREAUEL St0R. EXIST. CHEMICAL I E ICAL SEwER Slat ION EXIST. SPILL BASIN PIT SxllMER L 1 TYPICAL CRE SNOwN S2100 S.2200 • EMT. BASIN ExIST. ROAD EXIST. CAUSTIC EXIST. PM CONTROL ExfST. AERATION •I EBAS111 STORAGE 0 S.2400 5.26011 5.2T00 E1O' DWAAR.IIFIER XCESS SLUDGEIST. PUHP STATION ExfST. CLARIFIER ISY'•0.01A.1 EXIST. BACKWASH PIRO PIT Tk EXIST. M.C.C. III CxIST.CLCLORINATIO1 mew �xCOMM1i1U talS.. .R .4"1 DOGE PUMP STA E01 1 ERATION AIST. CLARIFIER 01STR18U11ON BOr A ET. FILTER EXIST. AEROSIC DIGESTER ExIST PSLu*GE PRE \ PI PUMP Epp . INSTRuHF.N1 EXXIIST.T. PARSNALL L1MNARY 1 1 I r z r 4•r-r.14 A 1 a 1 1 1 i 0 E 4 0 A monadtotswo ° S ~� wilier mown..10./11.di.�al. ...� IATETTEVILLE N.C. CIVIL PLOT PLAN WASTE TREATMENT AREA 11 M.. •pw 1147 a.. F 743 0 00.003 Yq C 1 3 A, J NPDES-EngineeringProposal Monsanto Company March 15, 1995 Confidential Information Fowl mul el APPENDIX G 1.1 FINANCIAL QUALIFICATION STATEMENT mut run 1o1 Fillq PRI WI WM Mai 18-153 TRC Environmental Corporation MAR- 9-95 THU 16:21 MAC FAYETTEUILLE FAX NO. 9104334210 P.03 Monsanto THE AGRICULTURAL GROUP P.O. BOX 2307 FAYETTEVILLE, NORTH CAROLINA 28302 PHONE (910) 323-3300 March 9, 1995 Ref: NPDES and Air Permits Supervisor NPDES Permits Div. of Environmental Management 1-1 NC DEHNR P. O. Box 29535 Raleigh, NC 27626-0535 Dear Sir; SUBJECT: Financial Resourcing This is to confirm that Monsanto Corp. is solvent and has sufficient financial assets to provide the monies for the $25M expansion of the Roundup' process and associated waste treatment facilities. The entire project will be funded through company funds. Yours truly, Van Bell Plant Manager tw