NC0005126_Staff Report_19970723

NPDES DOCYWENT SCANNING COVER SHEET
NC0005126
Harmony Rendering Plant
NPDES Permit:
Document Type:
Permit Issuance
Wasteload Allocation
Authorization to Construct (AtC)
Permit Modification
Complete File - Historical
Engineering Alternatives (EAA)
Correspondence
Owner Name Change
fl---
Instream Assessment (67b)
Speculative Limits
Environmental Assessment (EA)
Document Date:
July 23, 1997
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To: Permits and Engineering Unit
Water Quality Section
Attention: ire
SOC PRIORITY PROJECT: No
Date: July 23, 1997
NPDES STAFF REPORT AND RECOMMENDATIONS
County: Iredell
NPDES Permit No.: NC0005126 (modification)
MR0 No.: 97-48
PART I - GENERAL INFORMATION
1. Facility and Address: Tyson Foods, Inc.- Harmony Plant
Post Office Box 158
Harmony, N.C. 2R634
2. Date of Investigation: January 31, 1994
3. Report Prepared By: Michael L. Parker, Environ, Engr. II
4. Person Contacted and Telephone Number: Mark Johnson, (704)
546-2602.
5. Directions to Site: From the jot. of Hwy. 901 and SR 2125
(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 lnr.Rtad 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"
Attach a USES Map Extract and indicate treatment plant site
and discharge point on map.
USGS Quad No.: D 16 NW
7. Site size and expansion area consistent with application:
Yes, There is area available for expansion, however, it may
be located within the 100 year flood plain of Hunting Creek.
Any treatment units constructed in this area will have to he
protected from flooding.
8: Topography (relationship to flood plain included): The
existing WWTP appears to have been construr.tprl hove the 100
year flood plain.
9. Location of Nearest Dwelling: Approx. 1000± feet from the
WWTP site.

Page Two
10. Receiving Stream or Affected Surface Waters: Hunting Creek
a. Classification: WS-III
b. River Basin and Suhhasin No.: vadkin 03070E
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 dischargers for a distance of several
miles below this outfall.
PART II - DESCRIPTION OF DISCHARGE AND TREATMENT WORKS
1. a. Volume of Wastewater: 1.7 MGD (Design Capacity)
h. What is the current permitted capacity: 1.7 MGD
c. Actual treatment capacity of current facility (current
design capacity): 1.7 MGD (This is an assumption as
there are no records in the MRO files that document
actual treatment capacity although Permit records as
far hack as 1979 reflect 1.7 MGD as the permitted
capacity).
d. Date(s) and construction activities allowed by previous
ATCs issued in the previous two years: N/A
P. Description of existing or substantially constructed
WWT facilities: The existing WWT facilities consist of
an aerated lagoon with mechanical aerators, effluent
disinfection (gaseous), chemical pH adjustment and flow
measurement equipment. The current DPrmit identifies
the existence of screening and a dissolved air
floatation (DAF) unit, however, these units were
determined to be in -plant processes and not related to
or considered part of the wastewater treatment plant.
f. Description of proposed WWT facilities: Tyson is
considering the addition of a clarifier to their
existing WWTP.
g Possible toxic impacts to surface waters: Tyson has
had a very erratic compliance record with toxicity
testing. An assessment for toxicity violations was made
in 1996.
2. Residual handling and utilization/disposal scheme:
a. If residuals are being land applied specify DEM Permit
No. WQ0000701
Residuals Contractor: Terra Renewal Services, Inc.
b. Residuals stabilization: Residuals are stabilized
with lime prior to field application.
3. Treatment Plant Classification: Less than 5 points; no
rating (include rating sheet). Class Ii

Page Three
4. SIC Code(s): 2077 Wastewater Code(s): 23
5. MTU Code(s): 3100.3
PART III - OTHER PERTINENT INFORMATION
1. Is this facility being constructed with Construction Grant
Funds or are any public monies involved (municipals only)?
No
2 Special monitoring or limitations (including toxicity)
requests: None at this time.
3. Important SOC/JOC or Compliance Schedule dates: N/A
4. Alternative Analysis Evaluation
Spray Irrigation:
Recycle:
Municipal Sewer:
Initial evaluations by Tyson's engineer
indicate that spray irrigation may hold
some promise for either reducing or
eventually eliminating Tyson's
discharge. Costs projections, however,
are very high since additional WWT
facilities would be necessary and the
proposed spray areas present numerous
topographic constraints. Tyson will
continue to study this option for its
feasibility.
Tyson is presently evaluating the
purchase of an evaporator, which may
eventually eliminate the need to dispose
of residuals (they will be recycled back
through the rendering process).
Unfortunately, the use of an evaporator
will also increase wastewater flow.
Tyson has accounted for the anticipated
increase in flow in this Permit
modification request,
There is currently nn municipal sewer
available to the site nor is any planned
in the foreseeable future.

Page Four
PART IV - EVALUATION AND RECOMMENDATIONS
The permittee (Tyson Foods, inc.) requests that the subject
Permit be modified from a currently permitted flow of 1.7 MGD to
0.500 MGD. Tyson also requests that NPDES stormwater Permit No.
NCG50022 be rescinded since all stormwater flows have been
directed into the existing WWTP.
This request by Tyson stems from an earlier conversation
with Tyson officials and Division staff in which Tyson officials
were questioned as to why they have chosen to maintain a
permitted flow of 1.7 MGD when normal daily flows rarely exceeded
0.300 MGD. After several toxicity testing failures (and an
assessment of civil penalties for toxicity violations), Tyson has
finally decided that a reduction in permitted flow would be
beneficial when conducting toxicity testing. The flow reduction
is expected to reduce Tyson's IWC from 7% to 1.8%, At this level,
Tyson feels they can consistently achieve effluent toxicity
compliance.
Pending receipt and approval of the WLA, it is recommended
that the Permit be modified as requested.
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Signature deport Preparer Date
Aez,
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Water Qualm/ Regional Supervisor Pate