NC0005126_Permit (Issuance)_20090824

NPDES DOCUMENT :;CANNING COVER SHEET
NPDES Permit:
NC0005126
Harmony Rendering Plant
Document Type:
Permit Issuance
Wasteload Allocation
Authorization to Construct (AtC)
Permit Modification
Complete File - Historical
Engineering Alternatives (EAA)
Correspondence
Owner Name Change
Instream Assessment (67b)
Speculative Limits
Environmental Assessment (EA)
Document Date:
August 24, 2009
This document is printed on reuse paper - ignore any
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FM.�Iv°/Mii iAt�11
ern
NCDENR
North Carolina Department of Environment and Natural Resources
Division of Water Quality
Beverly Eaves Perdue Coleen H. Sullins Dee Freeman
Govemor Director Secretary
August 24, 2009
Daniel Crowe, Plant Manager
Tyson Foods, Inc.
P.O. Box 185
Harmony, North Carolina 28634
Subject: Issuance of NPDES Permit NC0005126
Harmony Rendering Plant
Iredell County
Dear Mr. Crowe:
Division personnel have reviewed and approved your application for renewal of the subject permit.
Accordingly, we are forwarding the attached NPDES discharge 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 October 15, 2007 (or as subsequently amended).
This final permit includes the following major changes from the draft permit sent to you on July 1, 2009:
• Limits for the facility have been re -calculated in accordance with the 40 CFR part 432, Subpart J.
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, conforming to Chapter 150B of the North
Carolina General Statutes, and filed with the Office of Administrative Hearings (6714 Mail Service Center, Raleigh,
North Carolina 27699-6714). Unless such demand is made, this decision shall be final and binding.
1617 Mail Service Center, Raleigh, North Carolina 27699-1617
Location: 512 N. Salisbury St. Raleigh, North Carolina 27604
Phone: [phone] FAX: [phone] Customer Service: 1-877-623-6748
Internet www.ncwaterquality.org
,4n Equal Opportunity \ Affirmative Action Employer
No��thCarolina
atura!!y

Please note that this permit is not transferable except after notice to the Division. The Division may
require modification or revocation and reissuance of the permit. This permit does not affect the legal requirements
to obtain other permits which may be required by the Division of Water Quality or permits required by the
Division of Land Resources, the 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 Sergei Chernikov at
telephone number [phone].
Sincerely,
Coleen H. Sullins
cc: MRO-Surface Water Protection
NPDES File
Central Files
1617 Mail Service Center, Raleigh, North Carolina 27699-1617
Location: 512 N. Salisbury St. Raleigh, North Carolina 27604
Phone: [phone] FAX: [phone] Customer Service:1-877.623-6748
Internet: www.ncwaterquality.org
An Equal Opportunity Affirmative Action Employer
NorthCarolinan
7atura!!q

Permit NC0005126
STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
DIVISION OF WATER QUALITY
PERMIT
TO DISCHARGE WASTEWATER UNDER THE
NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM
In compliance with the provision of North Carolina General Statute 143-215.1, other lawful standards
and regulations promulgated and adopted by the North Carolina Environmental Management
Commission, and the Federal Water Pollution Control Act, as amended,
Tyson Foods, Inc.
is hereby authorized to discharge wastewater from a facility located at the
Harmony Rendering Plant
501 Sheffield Road
Harmony
Iredell County
to receiving waters designated as Hunting Creek in the Yadkin Pee Dee River Basin in accordance with
effluent limitations, monitoring requirements, and other conditions set forth in Parts I, II, III, and IV
hereof.
The permit shall become effective October 1, 2009.
This permit and the authorization to discharge shall expire at midnight on March 31, 2014.
Signed this day August 24, 2009.
l
oleen H. Sullins, Director
Division of Water Quality
By Authority of the Environmental Management Commission

Permit NC0005126
SUPPLEMENT TO PERMIT COVER SHEET
All previous NPDES Permits issued to this facility, whether for operation or discharge are hereby, revoked. As of
this permit issuance, any previously issued permit bearing this number is no longer effective. Therefore, the
exclusive authority to operate and discharge from this facility arises under the permit conditions, requirements,
terms, and provisions included herein.
Tyson Foods, Inc. is hereby authorized to:
1. Continue to operate a 0.5 MGD wastewater treatment facility (outfall 001) that includes
the following components:
> Flow equalization basin/anoxic reactor #1 with subsurface air jet diffuser system
> Flow equalization basin/reactor effluent pump station
> Nitrification reactor #2 with subsurface air jet diffuser system
> Clarifier influent flocculation tank
> Final clarifier
> Aerated lagoon with mechanical aerators
> Effluent disinfection
> Chemical pH adjustment
> Flow measurement equipment
This facility is located at Tyson's Harmony Division, off Sheffield Road near Harmony in
Iredell County.
2. Discharge from said treatment works at the location specified on the attached map into
Hunting Creek which is classified WS-III waters in the Yadkin -Pee Dee River Basin.

Latitude: 35'57'16"
Longitude: 80°43'12"
Quad: Callahan, N.C.
Stream Class: WS-III
Subbasin: 03-07-06
Receiving Stream: Hunting Creek
NC0005126
Harmony Rendering Rant
IredeLL County
Facility
Location
SCALE 1:24000

Permit NC0005126
A. (1) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS
During the period beginning on the effective date of this permit and lasting until permit expiration, the
Permittee is authorized to discharge treated wastewater from Outfall 001. Such discharges shall be
limited and monitored by the Permittee as specified below:
:MONITORING REQUIREMENTS
PARAMETER '
EFFLUENT LIMITATIONS
Monthly Average
Daily Maximum
Measurement
Frequency
Sample Type
-Sample .. 1
Location
Flow
0.5 MGD
Continuous
Recording
Effluent
BOD, 5-day, 20°C
281.4 pounds/day
562.8 pounds/day
Weekly
Composite
Effluent
Total Suspended Solids
347.6 pounds/day 63
695.2 pounds/day'F"v
Weekly
Composite
Effluent
Oil and Grease
165.5 pounds/day
331.0 pounds/day
Weekly
Grab
Effluent
NH3-N
115.9 pounds/day
231.7 pounds/day
Weekly
Composite
Effluent
Total Residual Chlorine'
28 µg/L
Weekly
Grab
Effluent
Fecal Coliform
(geometric mean)
200/100mL
400/100mL_
•
Weekly
Grab
Effluent
Temperature
Weekly
Grab
Effluent
pH
> 6.0 and < 9.0 standard units
Weekly
Grab
Effluent
Total Nitrogen
(NO2+NO3+TKN)
134.0 mg/L
194.0 mg/L
Weekly
Composite
Effluent
Total Phosphorus
Weekly
Composite
Effluent
Chronic Toxicity2
Quarterly
Composite
Effluent
MBAS
Weekly
Composite
Effluent
Dissolved Oxygen
Weekly
Grab
Effluent
Notes:
1. The facility shall report all effluent TRC values reported by a NC certified laboratory including'field
certified. However, effluent values below 50 µg/L will be treated as zero for compliance purposes.
2. Chronic Toxicity (Ceriodaphnia) limit at 1.8% with testing in January, April, July, and October (see A. (2)).
There shall be no discharge of floating solids or visible foam in other than trace amounts.

Permit NC0005126
A. (2) CHRONIC TOXICITY PERMIT LIMIT (Quarterly)
The effluent discharge shall at no time exhibit observable inhibition of reproduction or significant mortality to Ceriodaphnia
dubia at an effluent concentration of 1.8 %.
The permit holder shall perform at a minimum, quarterly monitoring using test procedures outlined in the "North Carolina
Ceriodaphnia Chronic Effluent Bioassay Procedure," Revised February 1998, or subsequent versions or "North. Carolina
Phase II Chronic Whole Effluent Toxicity Test Procedure" (Revised -February 1998) or subsequent versions. The tests will be
performed during the months of January, April, July and October. Effluent sampling for this testing shall be performed at
the NPDES permitted final effluent discharge below all treatment processes.
If the test procedure performed as the first test of any single quarter results in a failure or ChV below the permit limit, then
multiple -concentration testing shall be performed at a minimum, in each of the two following months as described in "North
Carolina Phase II Chronic Whole Effluent Toxicity Test Procedure" (Revised -February 1998) or subsequent versions.
The chronic value for multiple concentration tests will be determined using the geometric mean of the highest concentration
having no detectable impairment of reproduction or survival and the lowest concentration that does have a detectable
impairment of reproduction or survival. The definition of "detectable impairment," collection methods, exposure regimes, and
further statistical Methods are specified in the "North Carolina Phase II Chronic Whole Effluent Toxicity Test Procedure"
(Revised -February 1998) or subsequent versions.
All toxicity testing results required as part of this permit condition will be entered on the Effluent Discharge Monitoring
Form (MR-1) for the months in which tests were performed, using the parameter code TGP3B for the pass/fail results and
THP3B for the Chronic Value. Additionally, DWQ Form AT-3 (original) is to be sent to the following address:
Attention: NC DENR / DWQ / Environmental Sciences Section
1621 Mail Service Center
Raleigh, North Carolina 27699-1621
Completed Aquatic Toxicity Test Forms shall be filed with the Environmental Sciences Branch no later than 30 days after the
end of the reporting period for which the report is made.
Test data shall be complete, accurate, include all supporting chemical/physical measurements and all concentration/response
data, and be certified by laboratory supervisor and ORC or approved designate signature. Total residual chlorine of the
effluent toxicity sample must be measured and reported if chlorine is employed for disinfection of the waste stream.
Should there be no discharge of flow from the facility during a month in which toxicity monitoring is required, the permittee
will complete the information located at the top of the aquatic toxicity (AT) test form indicating the facility name, permit
number, pipe number, county, and the month/year of the report with the notation of "No Flow" in the comment area of the
form. The report shall be submitted to the Environmental Sciences Branch at the address cited above.
Should the permittee fail to monitor during a month in which toxicity monitoring is required, monitoring will be required
during the following month. Should any test data from this monitoring requirement or tests performed by the North Carolina
Division of Water Quality indicate potential impacts to the receiving stream, this permit may be re -opened and modified to
include alternate monitoring requirements or limits.
If the Permittee monitors any pollutant more frequently then required by this permit, the results of such monitoring shall be
included in the calculation & reporting of the data submitted on the DMR & all AT Forms submitted.
NOTE: Failure to achieve test conditions as specified in the cited document, such as minimum control organism survival,.
minimum control organism reproduction, and appropriate environmental controls, shall constitute an invalid test and will
require immediate follow-up testing to be completed no later than the last day of the month following the month of the initial
monitoring.

lyson
July 30, 2009
Tyson Foods, Inc.
Sergei Chernikov, Ph.D.
North Carolina Department of Environmental and Natural Resources
Division of Water Quality
1617 Mail Service Center
Raleigh, North Carolina 27699-1617
RE: Draft NPDES Permit NC0005126 - Harmony Rendering Plant
Dear Mr. Chernikov:
I write on behalf of Tyson Foods, Inc. (Tyson) concerning draft NPDES permit NC0005167 for the
Harmony Rendering Plant. The reference permit was sent to Tyson on July 1, 2009. After
reviewing the document, Tyson is submitting the comments listed below.
The Draft permit states the facility is subject to new technology based limits for Ammonia, BOD,
TSS, Total Nitrogen, and Oil & Grease according to 40 CFR Part 432, Subpart K. This regulatory
citation and corresponding effluent limitations are established for Poultry First Process. However,
the Tyson facility in Harmony is a Rendering Plant. The regulatory citation in the draft permit
should be changed to 40 CFR Part 432, Subpart J. In addition, the effluent limitations in the
permit should be revised to reflect the following:
Table 1
Regulated Parameter
Daily Maximum
Monthly Average
BOD5
591.9 Ibs
295.9 lbs
Fecal Coliform
400 geo mean per 100 ml
200 geo mean per 100 ml
Oil & Grease
348.1 lbs
174.1 lbs
TSS
731.1 lbs
365.6 lbs
Ammonia (as N)
243.7 lbs
121.9lbs
Total Nitrogen
194 mg/I
134 mg/I
The effluent limitations listed in the Table 1 were established using the performance standards
established in Subpart J and a maximum production rate of 1,740,738 pounds per day of raw
material at the Harmony plant. The maximum production rate was established using the
maximum monthly production rates at the Harmony plant which occurred during May 2005.
RECEIVED
JUL 31 2009
DENR - WATER OUAIJ1Y
POINT SOURCE BRANCH
Tyson Foods, Inc. Environmental, Health and Safety Services 2210 West Oaklawn Drive Springdale, AR 72762-6999
800-643-3410 479-290-4713 Fax: [phone] www.tysonfoodsinc.com

Tyson appreciates the opportunity to provide these comments and looks forward to reviewing the
revised permit. If you have any questions or need additional information, please contact Doug
Baxter at [phone] or me at [phone].
Sincerely,
Steve Patrick, P.E.
Director — EHS Services
Tyson Foods, Inc.
cc: Dan Crowe, Tyson
Doug Baxter, Tyson
Danny Wyatt, Tyson

Tyson Foods, harmony rendering Plant, NC - NC0005126
Average daily production for the facility is: Ib/day
Limits for the facility are calculated in accordance with Subpart J effluent
guidelines (40 CFR part 432)
Ammonia calculations
Ammonia daily max = 0.14 Ib/1000 Ib * 1655207 Ib/day = 231.7 Ib/day
Ammonia monthly average = 0.07 lb/1000 Ib * 1655207 Ib/day = 115.9 Ib/day
BOD5 calculations
BOD5 daily max = 0.34 Ib/1000 Ib * 1655207 Ib/day = 562.8 Ib/day
BOD5 monthly average = 0.17 Ib/1000 Ib * 1655207 Ib/day = 281.4 Ib/day
Oil and Grease calculations
Oil and Grease daily max = 0.20 Ib/1000 Ib * 1655207 Ib/day = 331.0x Ib/day
Oil and Grease monthly average = 0.10 Ib/1000 Ib * 1655207 Ib/day = 165.5 Ib/day
TSS calculations
TSS daily max = 0.42 Ib/1000 Ib * 1655207 Ib/day = 695.2 Ib/day
TSS monthly average = 0.21 Ib/1000 Ib * 1655207 Ib/day = 347.6 Ib/day
Total Nitrogen (CFR requirements):
Daily max = 194 mg/L
Monthly Avergae = 134 mg/L

MEMORANDUM
To:
From:
Subject:
July 1, 2009
Britt Setzer, Regional Engineer
NC DENR / DEH / Public Water Supply Section
Mooresville Regional Office
Sergei Chernikov, Environmental Engineer II, NPDES-W
Division of Water Quality (fax-919-807-6495)
Review of the discharge locations for the following:
Harmony Rendering Plant
NC0005126
Iredell County
Please indicate below by August 3, 2009 your agency's position or viewpoint on the facility
listed above. We cannot issue the permit without your concurrence. Please return this form
at your earliest convenience.
RESP SE:
cc: file
This agency has reviewed the draft permit and determined that the proposed
discharge will not be sufficiently close to any existing or known proposed
public water supply intake so as to create an adverse effect on water quality.
We concur with the issuance of this permit provided the facility is operated
and maintained properly, the stated effluent limits are met prior to discharge,
and the discharge does not contravene the designated water quality standards.
Concurs with issuance of the above permit, provided the following conditions
are met:
Opposes the issuance of the above permit, based on reasons stated below, or
attached:

North Carolina } ss
Mecklenburg County)
The Charlotte Observer Publishing Co.
Charlotte, NC
Affidavit of Publication
THE CHARLOTTE OBSERVER
DINA SPRINKLE
NCDENR/DWQ/POINT SOURCE BRANCH
1617 MAIL SERVICE CENTER
RALEIGH NC 27699
REFERENCE: 30063432
6361919 wastewater permit
Before the undersigned, a Notary Public of said
County and State, duly authorized to administer
oaths affirmations, etc., personally appeared,
being duly sworn or affirmed according to law,
doth depose and say that he/she is a
representative of The Charlotte Observer
Publishing Company, a corporation organized and
doing business under the laws of the State of
Delaware, and publishing a newspaper known as The
Charlotte Observer in the city of Charlotte,
County of Mecklenburg, and State of North Carolina
and that as such he/she is familiar with the
books, records, files, and business of said
Corporation and by reference to the files of said
publication, the attached advertisement was
inserted. The following is correctly copied from
the books and files of the aforesaid Corporation
and Publication.
PUBLISHED ON: 07/04
AD SPACE:
FILED ON:
NAME:
90 LINE
07/10/09
TITLE:
DATE:
In Testimony Whereof I have hereunto set my
day and ear aforesaid.
Nota
Public Notice
North Carolina EnviionmentatManagement
Commission/NPDES Unft
1617 Mail Service Center i
Raleigh. NC 27699-1617 , :. ,j;
Notice of Intent to Issue 8 NPDES Wastewater Pernat. •,
The North Cardina Environmental Management Com�toftroten
es proposto issue a NPDFS wastewater discharge peH
personls) tistyd below.
Written comments regarding the proposed ermit will be
accepted unlit 30 days after 1he publish date(ohij notico bl0
Director or the NC Division of Wa8 sir frant degree of pu
pubic hearing. should.3here be 9
interest. Please mail wmn'ients and/or info g 11 the DWQ
uests to
DWO at the above address. Interested perso
al-512 N. Salisbury Street Aalal�ggh, NCio review nfmmMion on
fife. Additional information on NPDES permits a d t o no man ay
y
be found on our websae: www. omitatqualitterg .
(919) 6W-6304.. • ?!. 1 - .�wal of permit
The Alcoa.Power Generating,:Ir :rest Cpunty; his lardy
NC0081957 i tor Narrows -thou ho�k 9 Sand � water to
die Yadkin
IS once -through•
the Yadkin River, Yadkin River Basin.;; . , . .
The Alcoa Power -Generating, Inc. requested renewal
of p: his
permit
NC0081949 to Tuckenown Powerhduse in StenN
facility discharge is once -through cooling water and sump dram
water to Yadkin River, Yadkin River Basin. •
reveal of per!nil
The A,opa:PGenerating. Ine..reStanly County; this tacday
Nf�F in076775 tor Falls Powerhouse and sump
discharge is once -through. cooling water. stormwater,
drain water to Yadkin River, Yadkin River Basin. ' .
The Alcoa Power Generating, Inc. requested renewal. of perrnit
eferto,
NC0081931 for High Rod( Powerhouse inFinvah County: this
facility discharge is once -through cooling water and etornlw. _ , .
Yadkin River, Yadkin River Basin: • .NCB, 261or.
TherTyson Foods, Inc requested renewal of permita is 05126 for
Harmony Plant in Iredell County; this facility dicharg ,
ed
industrial wastewater to Yadkin River, Yadkin River Bast. .
•
LP6361919 _ . • '.
JUL 1 0 2009
hand and affixed my seal, the
Commission Expires: _/_/_
My Commission Expires May 27, 2011

NCDENR / DWQ
FACT SHEET FOR NPDES PERMIT DEVELOPMENT
Tyson Foods, Inc.
NPDES No. NC0005126
EAcility Information
(1.) Facility Name:
Harmony Rendering Plant (formerly Holly Farms)
(2.) Permitted Flow (MGD):
0.5
(6.) County:
Iredell
(3.) Facility Class:
II
(7.) Regional Office:
Mooresville
(4.) Facility Status:
(New or existing)
Renewal
(8.) USGS Topo Quad:
D16NW
(Calahaln, NC)
(5.) Permit Status:
(i.e., New, Modification, or
Renewal)
Renewal
Stream Characteristics
(1.) Receiving Stream:
Hunting Creek
(2.) Subbasin:
030706
Yadkin
(8.) Drainage Area (mi2):
175.00
(3.) Index No.:
12-108-16-(0.5)
(9.) Summer 7Q10 (cfs)
43
(4.) Stream Classification:
WS-III
(10.) Winter 7Q10 (cfs):
71
(5.) 303(d) Listed:
NO
(11.) 30Q2 (cfs):
92
(6.) 305(b) Status:
NA
(12.) Average Flow (cfs):
175.0
(7.) Use Support:
(13.) IWC (%):
1.8
Summary
This is a MINOR renewal for a poultry rendering plant that discharges process wastewater via one
outfall. The treatment system has a design capacity of 1.7 MGD. However, at the company's
request, a permit mod in 10/97 decreased the flow limit from 1.7 to 0.5 MGD, with a resultant
decrease in the instream waste concentration (and chronic toxicity test concentration) from 7% to
1.8%. Facility discharges to Hunting Creek>South Yadkin River>Yadkin River>High Rock Lake.
Hunting Creek is not listed on the 303(d) list.
Technology Based Effluent Limit Development
The technologybased limits for Ammonia, BOD, TSS, Fey Coliform, Total Nitrogen and O
g
were established according to the 40 CFR Part 432, Subpar Moth BAT
and BPT limits apply according to Mary Rubin (EPA, Engineering and Analytical Division, 202-566-
1050). New limits are concentration based.
Toxicity Testing
Current Requirement: Quarterly Chronic Toxicity @ 1.8% JAN, APR, JUL, OCT
Recommended Requirement: Quarterly Chronic Toxicity @ 1.8% JAN, APR, JUL, OCT
The facility has been consistently passing its WET tests.

NPDES PERMIT FACT SHEET Tyson Foods, Inc.
Page 2 NPDES No. NC0005126
Compliance Summary
DMRs have been reviewed for the period January 2005 through November May 2009. Facility has a
very good compliance record. During the review period, only one NOV (notice of violation) was
issued: 02/23/05 — fecal coliforms.
A compliance inspection conducted on 01/19/09 determined that the facility is "properly operated
and well maintained".
Proposed Changes
• Monitoring Frequencies: No changes are proposed.
• Limist: The technology based limits for Ammonia, BOD, TSS, Total Nitrogen and O&G
were established according to the 40 CFR Part 432, Subpart K
State Contact
If you have any questions on any of the above information or on the attached permit, please contact
Sergei Chernikov at [phone].
Regional Office comments:
Regional office recommended renewal of the permit.
Changes in the Final Permit:
• Limits for the facility have been re -calculated in accordance with the 40 CFR part
432, Subpart J.
Page 2
Version: August 20, 2009

To: Western NPDES Unit
Surface Water Protection Section
Attention: Bob Sledge
SOC PRIORITY PROJECT: No
Date: October 15, 2008
NPDES STAFF REPORT AND RECOMMENDATIONS
County: Iredell
NPDES Permit No.: NC0005126
PART I - GENERAL INFORMATION
1. Facility and address: Tyson Foods, Inc.- Harmony Plant
Post Office Box 158
Harmony, N.C. 28634
Physical Location
501 Sheffield Road
Harmony, NC 28634
2. Date of investigation: October 15, 2008
3. Report prepared by: Michael L. Parker, Environmental Engineer II
4. Person contacted and telephone number: Mike Campbell, ORC; Dan Crowe, Plant Manager,
[phone]
5. Directions to site: From the jct. of Hwy. 901 and SR 2126 (Sheffield Rd.) southeast of the
Town of Harmony in northeastern Iredell County, travel east on SR 2126 1.4 miles. The
Tyson Foods' plant is located on the left side of SR 2126 just after crossing Hunting Creek.
6. Discharge point(s), list for all discharge points:
Latitude: 35 ° 57' 16"
Longitude: 80° 43' 12"
7. Receiving stream: Hunting Creek
USGS Quad No.: D 16 NW
a. Classification: WS-III
b. River Basin and Subbasin No.: Yadkin 030706
c. Describe receiving stream features and pertinent downstream uses: The receiving
stream has excellent flow at the point of discharge (15-20 feet wide x 1-3 feet deep).
The area is very rural with agriculture being the primary use. There are no water
intakes and/or other known dischargers for a distance of several miles below this
outfall.
PART II - DESCRIPTION OF DISCHARGE AND TREATMENT WO
1. a. What is the current permitted capacity: 0.5 MGD
OCT 2 0 2008
DENR - WATER QUALITY
SURFACE WATER PROTECTION SECTION

Page Two
b. Actual treatment capacity of current facility (current design capacity): 1.7 MGD
c. Date(s) and construction activities allowed by previous ATCs issued in the previous
two years: There have been no ATCs issued to this facility in the past two years.
d. Description of existing or substantially constructed WWT facilities: The existing
WWT facilities consist of influent screening followed by a pump station, a dissolved
air floatation (DAF) unit, polymer addition, a flow equalization basin/reactor with
diffused aeration (provides for first stage carbonaceous BOD removal), a
nitrification reactor (second stage treatment for ammonia nitrogen and final stage
carbonaceous BOD removal), an aerated sludge storage lagoon with mechanical
aeration and mixing, a final clarifier, chlorine effluent disinfection (gaseous),
dechlorination, chemical pH adjustment and flow measurement equipment.
e. Description of proposed WWT facilities: None at this time.
f. Possible toxic impacts to surface waters: This facility has a consistent compliance
record with passing their toxicity tests (IWC = 1.8%).
2. Residual handling and utilization/disposal scheme: Residuals are taken to SC for land
application. Tyson also maintains DWQ permit no. WQ0000701, which authorizes land
application on sites in NC.
3. Treatment Plant Classification: Class III
4. Compliance history: This facility has had an excellent compliance record for the past few
years.
PART III - OTHER PERTINENT INFORMATION
1. Special monitoring or limitations (including toxicity) requests: None at this time.
PART IV - EVALUATION AND RECOMMENDATIONS
The permittee (Tyson Foods, Inc.) requests renewal of the subject Permit. There have been
no changes to the existing WWTP or the subject permit since the permit was last renewed nor are
any proposed at the present time. Tyson has made significant progress in improving their effluent
quality in the past decade.
Pending receipt and approval of the draft permit, it is recommended that the Permit be
renewed as requested.
e of Report Preparer
/ 4 4 //—
Water Quality Regional Supervisor
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Reid Engineerin Company, Inc.
'411111.-
Psalm 24:1
Reid Engineering Company, Inc.
Consulting Environmental Engineers
Specializing in the Design and Operation of Water Pollution Control Systems
September 18, 2008
•
f) 1
Mr. Agyeman Adu-Poku
NCDENR DWQ PSB
1617 Mail Service Center
Raleigh, NC 27699-1617
Subject: Tyson Foods - Harmony, North Carolina
NPDES Permit Renewal - Permit No. NC0005126
Dear Mr. Adu-Poku:
Sc;-' ?
Tyson Foods requests the renewal of their NPDES permit, permit number
NC0005126, at their rendering plant in Harmony, NC.
On behalf of our client, Tyson Foods, Reid Engineering Company has prepared the
attached permit renewal application package for your review. Included in the renewal
application package is the following information:
Completed Application Form - NPDES Short Form C
�- Site Location Map
Schematic of Wastewater Flow
If you have questions or need additional information please advise.
Sincerely,
Wade Tanner, P.E.
Project Engineer
1210 Princess Anne Street • Fredericksburg, Virginia 22401 • 540-371-8500 • FAX [phone] • wwwreidengineering.com
Registered Professional Engineers in Alabama, Arizona. Arkansas, California. Delaware, Florida, Georgia, Idaho, Illinois. Indiana. Iowa. Kansas, Kentucky. Louisiana, Maine, Maryland, Massachusetts.
Michigan, Minnesota. Mississippi, Missouri. Nebraska, New Mexico. New York. North Carolina. Ohio, Oklahoma, Pennsylvania, South Carolina, Tennessee, Texas, Virginia. Washington, West Virginia

NPDES PERMIT RENEWAL
APPLICATION PACKAGE
for
TYSON FOODS, INC.
Harmony, North Carolina
September 18, 2008
Prepared by
Reid Engineering Company, Inc.
'1111.110.-
t+ SEP 2 4 2003
DE'4R;�-
PROTECTING THE ENVIRONMENT AND YOUR INVESTMENT IN POLLUTION CONTROL

NPDES PERMIT APPLICATION - SHORT FORM C - Minor Industrial
Minor industrial, manufacturing and commercial facilities.
Mail the complete application to:
N. C. Department of Environment and Natural Resources
Division of Water Quality / NPDES Unit
1617 Mail Service Center, Raleigh, NC 27699-1617
NPDES Permit Number
NC0005126
If you are completing this form in computer use the TAB key or the up - down arrows to move from one
field to the next. To check the boxes, click your mouse on top of the box. Otherwise, please print or type.
1. Contact Information:
Owner Name Tyson Foods, Inc.
Facility Name Harmony Rendering Plant dba River Valley Animal Foods
Mailing Address P.O. Box 185
City Harmony
State / Zip Code NC
Telephone Number
Fax Number
•
[phone]
[phone] '!I S E P 2 4 2 JB
e-mail Address [e-mail]
tyson.com
2. Location of facility producing discharge:
Check here if same as above ❑
Street Address or State Road
City
State / Zip Code
County
501 Sheffield Road
Harmony
NC / 28634
Iredell
3. Operator Information:
Name of the firm, consultant or other entity that operates the facility. (Note that this is not referring to the
Operator in Responsible Charge or ORC)
Name
Mailing Address
City
State / Zip Code
Telephone Number
Fax Number
Mike Campbell
501 Sheffield Road
Harmony
NC / 28634
[phone]
[phone]
Page 1 of 5 C-MI 03/05

NPDES PERMIT APPLICATION - SHORT FORM C - Minor Industrial
Minor industrial, manufacturing and commercial facilities.
4. Ownership Status:
Federal ❑ State ❑ Private ® Public 0
5. Standard Industrial Classification (SIC) code(s): 2077
6. Number of employees: 119
7. Describe the treatment system List all installed waste treatment components with capacities,
describe the processes that generate wastewaters. If the space provided is not sufficient attach a
separate sheet of paper with the system description.
Wastewater generated at the rendenering plant is treated by a waste activated sludge
treatment system. The treatment system was designed based on the following wastewater
sources: 1) feather cooker condensate 200,000 gpd; 2) Meat cooker condensate 200,000 gpd
3) Truck wash, floor drainage, venturi scrubber 80,000 gpd; 4) Evaporator condensate
100,000 gpd; all flows are based on 6 days/week.
The wastewater treatment process consists waste activated sludge Modified Ludzack Endinger
(MLE) treatment process for high efficiency nitrate removal. The system components consist of
a 845,000 allon FEB with two 25 HP surface aerators; DAF Influent Pump Station;
Pretreatment DA unit; , gallon Anoxic Reactor # wi a jet aeration and mixing
'` ys em; eactor # 1 Effluent Pump Station; 645,000 gallon Nitrification Reactor #2 with a jet
aeration and mixing system; Flocculation Tank; 264,000 gallon Final gravity clarifier; 4 MG
Waste Sludge Lagoon; RAS/WAS pump stations; and Chlorination/ Dechlorination chamber. A
flow diagram of the wastewater treatment process is attached.
8. Is facility covered under federal effluent limitation guidelines? No ❑ Yes
If yes, specify the category? Meat and Poultry - Subpart J Renderers
9. Principal product(s) produced: Chicken and pet food ingredients.
Principal raw material(s) consumed: Poultry by-products
Briefly describe the manufacturing process(es):
Rendering of poultry by-products including feathers, offal, and fat into chicken feed and pet food
ingredients.
Page 2 of 5 C-MI 03/05

NPDES PERMIT APPLICATION - SHORT FORM C - Minor Industrial
Minor industrial, manufacturing and commercial facilities.
10. Amount of principal product produced or raw material consumed
List specific amounts consumed and/or units of production over the last three years)
Product Produced or Raw Material
Consumed
(AVERAGE)
Product Produced or Raw Material
Consumed
(PEAK)
per Day
1,330,000 # RM
2,580,500 # RM
per Month
40,364,000 # RM
59,482,440 # RM
per Year
484,365,000 # RM
525,627,380 #RM
11. Frequency of discharge: Continuous ® Intermittent ❑
If intermittent:
Days per week discharge occurs: 7 Duration: 24
12. Types of wastewater discharged to surface waters only
Discharge
Flow
(GALLONS PER DAY)
Sanitary - monthly average
Utility water, etc. - monthly average
Process water - monthly average
193,500
Stormwater - monthly average
Other - monthly average
Explain:
Monthly Average
total discharge (all types)
193,500
13. Number of separate discharge points: 1 Outfall Identification number(s) 001
14. Name of receiving stream(s) (Provide a map showing the exact location of each outfalI, including
latitude and longitude
Hunting Creek - lat 35 deg. 57' 16", long 80 deg. 43' 12"
Page 3 of 5
C-MI 03/05

NPDES PERMIT APPLICATION - SHORT FORM C - Minor Industrial
Minor industrial, manufacturing and commercial facilities.
15. Effluent Data
Provide data for the parameters listed. Temperature and pH shall be grab samples, for all other parameters 24-hour
composite sampling shall be used. If more than one analysis is reported, report daily maximum and monthly average.
If only one analysis is reported, report as daily maximum.
Parameter
Daily
Maximum
Monthly
Average
Units of
Measurement
Biochemical Oxygen Demand (BOD5)
9
6.1
mg/1
Chemical Oxygen Demand (COD)
101
66.57
mg/1
Total Organic Carbon
21
Total Suspended Solids
45
14.6
mg/1
Ammonia as N
56
1.7
mg/1
Temperature (Summer)
30
23.1
C
Temperature (Winter)
11.9
14.7
C
pH
8.6
7.2
Fecal Coliform (If sanitary waste is
present)
n / a
n/a
Total Residual Chlorine (if chlorine is
used)
3.6
0.35
ug/1
16. List all permits, construction approvals and/or applications (check all that apply and provide permit
numbers or check none if not applicable):
Type Permit Number Type
Hazardous Waste (RCRA) NESHAPS (CAA)
UIC (SDWA) Ocean Dumping (MPRSA)
NPDES Dredge or fill (Section 404 or CWA)
PSD (CAA) Other
Non -attainment program (CAA)
Permit Number
17. List any chemicals that may be discharged (Please list and explain source and potential
amounts.)
Page 4 of 5 C-MI 03/05

NPDES PERMIT APPLICATION - SHORT FORM C - Minor Industrial
Minor industrial, manufacturing and commercial facilities.
18. Is this facility located on Indian country? (check one)
Yes ❑ No El
19. Applicant Certification
I certify that I am familiar with the information contained in the application and that to the
best of my knowledge and belief such information is true, complete, and accurate.
Daniel Crowe
Plant Manager
Printed name of Person Signing
Signature of Applicant
Title
6///q/gK
Date
North Carolina General Statute 143-215.6 (b)(2). provides that: Any person who knowingly makes any false
statement representation, or certification in any application, record, report, plan, or other document files or
required to be maintained under Article 21 or regulations of the Environmental Management Commission
implementing that Article, or who falsifies, tampers with, or knowingly renders inaccurate any recording or
monitoring 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 of a misdemeanor punishable
by a fine not to exceed $25,000, or by imprisonment not to exceed six months, or by both. (18 U.S.C. Section
1001 provides a punishment by a fine of not more than $25,000 or imprisonment not more than 5 years, or both,
for a similar offense.)
SEP 44
LT. it.:fUt`iTY
Page 5 of 5 C-MI 03/05

CALAHALN, N. C.
N 3552.5— W 8037.5/ 7.5
1969
AMS 4855 I NW —SERIES V842
Reid Engineering Company, Inc.
1210 Princess Anne Street
Fredericksburg, Virginia
leiranone 540-371-8500 Fax [phone]
Scale:
1"=2000'
Dote:
8-27-08
LOCATION MAP
Drown by:
GDS / WHT
Dwg No:
FIG.1
HARMONY RENDERING PLANT
TYSON FOODS, INC.
HARMONY, NORTH CAROLINA

• FACT SHEET FOR EXPEDITED PERMIT RENEWALS
Basic Information to determine potential for expedited permit renewal
Reviewer/Date
.Sv'- 61 0 K e --' i l<AJ
Permit Number
N Ooa S1 26
Facility Name
}-A- r-Ado -ek t
)L4
_
Basin Name/Sub-basin number
� _ 66
Yak �/ � ��
Receiving Stream
1-t,:h/t'i A -
Stream Classification in Permit
1n/ S -1 I i L)
Does permit need NH3 limits?
ti)
Does permit need TRC limits?
/w
Does permit have toxicity testing?
Does permit have Special Conditions?
/4,16
Does permit have instream monitoring?
A!)
Is the stream impaired (on 303(d) list)?
Z),)
Any obvious compliance concerns?
Any permit mods since last permit?
N
Existing expiration date
°MY/ 0 0
New expiration date
01.,) if / 1 l-f
New permit effective date
r
Miscellaneous Comments
sad 1-H
YES
This is a SIMPLE EXPEDITED permit renewal (administrative
renewal with no changes, or only minor changes such as TRC, NH3,
name/ownership changes). Include conventional WTPs in this group.
YES_ This is a MORE COMPLEX EXPEDITED permit renewal (includes
Special Conditions (such as EAA, Wastewater Management Plan), 303(d)
listed, toxicity testing, instream monitoring, compliance concerns, phased
limits). Basin Coordinator to make case -by -case decision.
YESI This permit CANNOT BE EXPEDITED for one of the following reasons:
• Major Facility (municipal/industrial)
• Minor Municipals with pretreatment program
• Minor Industrials subject to Fed Effluent Guidelines (lb/day limits for BOD, TSS,
etc)
• Limits based on reasonable potential analysis (metals, GW remediation organics)
• Permitted flow > 0.5 MGD (requires full Fact Sheet)
• Permits determined by Basin Coordinator to be outside expedited process
TB Version 8/18/2006 (NPDES Server/Current Versions/Expedited Fact Sheet)

•
DAF. EFFLUENT
Date: 5-27-08
DIETING DRAINAGE WASTEWATER
INFLUENT FORCE WAIN
RAW CONDENSATE WASTEWATER
PRETREATED WASTEWATER
FROM E.A.F.
1
RAW CONDENSATE WASTEWATER
LEVEL SENSOR/
INDICATOR
EXISTING
D.A.F. F.E.B.
L
25 HP 25 HP
SURFACE AERATOR FIRST STAGE F.E.B. SURFACE AERATOR
& WASTEWATER COOLING TANK
92' DIA. x 17' SWD
EMERGENCY
OVERFLOW
TANK DRAINS
DRAIN/SCUM
PUMP
STATION
FINAL CLARIFIER
D.O. SENSOR/
CONTROLLER
FOR 7 DAY/F.E.B
REACTOR No. 1
LEVEL SENSOR/ BLOWERS
ANOXIC/F.E.B.
REACTOR No.1
F.EB. EFFLUENT
RAW STATK)N
0•
F.EB. REACTOR No.1 BY-PASS
DRAIN PUMP STATION FLOW
30 HP
SURFACE
AERATOR
SLUDGE RETURN
FLOW METER
- - - *00 1-
I
r -*4- --1 ifl 1- -F.:_w-
WASTE SLUDGE '•
FLOW METER SLUDGE RETURN
PUMP STATION
FLOW
METER MAGNESIUM HYDROXIDE
SOLUTION FEED POINT
EXITING
DAF. INFLUENT
PUMPS
BLOWER
Ne.1
4-
1
N
BLOWER
No.2
r____1
EXISTING D.A.F. CELL
FOR FINAL STAGE
WASTEWATER PRETREATMENT
FLOCC TUBE
WASTE ACTIVATED SLUDGE
TO BE REMOVED & THICKENED
IN EXLSTING OAF. CELL
BLOWER BLOWER BLOWER
Ne.3 No.4 No.5
r.._..)
i--T--i t--T.-1 t--T-.i
-1- 4-
f z I
Q '4 Q Q,
DA. SENSOR/
CONTROLLER
FOR NITRIFICATION
REACTOR No.2
BLOWERS
NITRIFICATION
NITRATE
ME R 'I REACTOR No.2
r i O =r
JEr ........................................ i
TANK
DRAIN
SLUDGE RETURN FLOW
ALTERNATE TO RAS- PUMP SUCTION (EMERGENCY ONLY)
WINNE
RETURN
IOW
/ ALTERNATE BY-PASS (EMERGENCY ONLY)
CLARIFIER SCUM UNE
7
1t
r
AERATED LAGOON FOR WASTE ACTIVATED SLUDGE STORAGE
SLUDGE TO
LAND DISPOSAL
DISCHARGE TO
_ ===ir ==_= HUNTING CREEK
n n n
EXISTING CIi1LORrNATIQN ;.
/DEHL(}itIN4ION
;CHAMBER;,
CHLORINE _
SOLUTION SOWIION
jj
SULFUR DIOXIDE
BUBBLER
FLOW METER
TUBE
"COMPANY CONFIDENTIAL"
© COPYRIGHT 2005 - REID ENGINEERING COMPANY, INC.
"" FOR GENERAL NOTES & DETAILS SEE SHEET 0-1 ."
Scale:
NONE
Designed by: J.H.R.
Drawn by: JW, GS
Checked by: J.H.R.
a.
ce
SCHEMATIC OF WASTEWATER FLOW
Revision Date
Drawing No.
F1
of Sheets
Job No. TF30D
THE INFORMATION CONTAINED
HEREIN SHALL BE CONSIDERED
PROPRIETARY TO REID ENGINEERING
COMPANY, INC. ANY USE OR RE-
PRODUCTION OF THIS INFORMATION
WITHOUT THE EXPRESS WRITTEN
CONSENT FROM REID ENGINEERING
COMPANY, INC. IS HEREBY
PROHIBITED.