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Home My WebLink AboutNC0072575_Permit Issuance_20020423ot; WATF9 �0 pG co r Katie Kirkpatrick, Environmental Engineer Gold Kist, Inc. P.O. Box 2210 Atlanta, Georgia 30301-2210 Dear Ms. Kirkpatrick: Michael F. Easley Governor William G. Ross, Jr., Secretary Department of Environment and Natural Resources North Carolina Department of Environment and Natural Resources Gregory J. Thorpe, Ph.D., Acting Director Division of Water Quality April 23, 2002 Subject Issuance of NPDES Permit NCO072575 Gold Kist WWTP Lee County In response to your renewal request received April 3, 2001, the Division of Water Quality (the Division) has concluded its evaluation and hereby transmits your final pemvt. Thanks for your patience and cooperation with the extended state and federal reviews. After evaluating plant performance, applicable regulations, and receiving stream conditions, the Division has made only minor changes to your previous permit Additions: None. However, please note that the Effluent Limitations and Monitoring Requirements (Part I. A. (1.)) have been reformatted and sorted by Sample Location to facilitate operator use. Deletions: Instream Monitoring Requirements. The Division has waived instream monitoring requirements based upon Gold Kist's membership in the Upper Cape Fear River Association. Please be advised that, should membership in the association discontinue at any time during the term of this permit, Gold Kist must notify the Division immediately, and immediately resume instream monitoring as stipulated in this permit. If any parts, measurement frequencies, or sampling requirements contained in this permit are unacceptable, you have the right to an adjudicatory hearing upon written request within thirty (30) days after receiving this letter. Your request must be in the form of a written petition conforming to Chapter 150B of the North Carolina General Statutes, and must be filed with the office of Administrative Hearings, 6714 Mail Service Center, Raleigh, North Carolina 27699-6714. Unless such a demand is made, this permit shall be final and binding. This permit is not transferable except after notifying the Division of Water Quality. The Division may require modification, or revocation and re -issuance of this permit. Please notice that this permit does not affect your legal obligation to obtain other permits required by the Division of Water Quality, the Division of Land Resources, the Coastal Area Management Act, or other federal or local governments. If you have questions, or if we can be of further service, please contact Joe Corporon at a -mad go . o oron „acmall.net] or call (919) 733-5083, extension 597. cc. Central Files Raleigh Regional Office, Water Quality Section EPA Region 4 Technical Assistance and Certification Unit NPDES Unit Aquatic Toxicology Unit N. C. Division of Water Quality / NPDES Unit 1617 Mail Service Center, Raleigh, NC 27699.1617 Internet: h2o.enr.state.nc.us Respectful,, Qriginai Signed BY David A. Goodrich Gregory J. Thorpe, Ph.D. Phone: (919)733.5083 fax: (919) 733-0719 DENR Customer Service Center. 1800 623.7748 Permit NC00725'y5 � f ,J 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 PDES 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, Gold -Kist, Inc. is hereby authorized to discharge wastewater from a facility located at the Gold -Kist Processing Plant Zimmerman Road near Sanford Lee County to receiving waters designated as the Deep River within the Cape Fear River Basin, in accordance with effluent limitations, monitoring requirements, and other conditions set forth in Parts I, II, III and IV hereof. This permit shall become effective June 1, 2002. This permit and authorization to discharge shall expire at midnight September 30, 2006. Signed this day Ap& 23, 2002. Qriginal Signed B David X Goodrich Gregory J. Thorpe, Ph.D., Acting Director Division of Water Quality By Authority of the Environmental Management Commission c Permit NCO072575 SUPPLEMENT TO PERMIT COVER SHEET Gold -Kist, Inc. is hereby authorized to. 1. Continue discharging 1.0 MGD of treated process -contact and domestic wastewater from a treatment facility consisting of the following components: • Solids removal area (screened and separated; trucked offsite as byproduct) • 35,000-gallon equalization tank (with pumps) • Anaerobic treatment lagoon (17 M gallons -- lined and covered to capture methane) • Methane incinerator • Lined, open lagoon (17 M gallons -- maintained for treatment -system back up) • Aeration basin (Schreiber process with facilities for magnesium hydroxide additive) • Clarifier (with RAS screw pumps and wet well/splitter to aeration basin and/or lagoon) • "Fuzzy" filter • Chlorine contact chamber • De -chlorination contact chamber (with recycle pumps for process water re -use) • Flow measurement device (Parshall flume) • Step aeration device This facility is located on Zimmerman Road near Sanford at the Gold -Kist Processing Plant in Lee County. 2. Discharge from said wastewater treatment works through Outfall 001 to the Deep River (see attached map), a stream classified as Class C waters within the Cape Fear River Basin. Gold -Kist, Inc. Poultry Processing and WWTP Latitude: 350 33' 50" N State Grid/ouad: E 22 SW / Colon, NC Longitude: 79° 13' 11" W Permitted Flow: 1.0 MGD Receiving Stream: Deep River Drainage Basin: Cape Fear River Basin Stream Class: C Sub•Basin: 03-06-11 11 Facility :yT:, 3._ . q s►. Location ` not to scale North NPDES Permit No. NCO072575 Lee County Permit NCO072575 �A. (I.) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS During the period beginning on the effective date of the permit and lasting until expiration, the Permittee is authorized to discharge through Outfall 001. Such discharges shall be limited and monitored by the Permittee as specified below: PARAMETERS EFFLUENT LIMITS MONITORING REQUIREMENTS Monthly Avers a Daily Maximum Measurement Fre uenc Sample Type Sample Locationl Flow 1.0 MGD Continuous Recordin Influent or Effluent BOD, 5 day, 200C (April 1-- October 31 5.0 mg/L 10.0 mg1L' 3/Week Composite Effluent BOD, 5 day, 200C November 1 -- March 31 10.0 mg/L 20.0 mg/L Week Composite Effluent NH3 as N (April 1-October 31 1.0 mg/L 2.0 mg/L 3/Week Composite Effluent NH3 as N November 1-- March 31 2.0 mg/L 4.0 mg/L 3/Week Composite Effluent Total Suspended Solids SS 496pounds/day 922 poundsiday 3/Week Composite Effluent Oil and Grease 160pounds/day 324pounds/day 3Meek Grab Effluent Dissolved 0xyqen2 Week Grab Effluent Fecal Coliform(geometric mean 2001100 ml 4001100 ml 3Meek Grab Effluent Total Residual Chlorine RC 3 28 µglL 3/Week Grab Effluent Temperature °C 3/Week Grab Effluent H4 Week Grab Effluent Total Nitrogen (NO2 + NO3 + TKN) Quarterly Composite Effluent Total Phosphorus Quarterly Composite Effluent Chronic Toxicity, Quarterly Composite Effluent Fecal Coliform(geometric mean 6 Temperature, °C6 LConductiv' issolved Oxygen6 Variable7 Variable7 Varlable7 Variable7 Grab Grab Grab Grab Upstream & Downstream Upstream & Downstream Upstream & Downstream Upstream & Downstream Footnotes 1. Sample Locations: E — Effluent; I — Influent; U — Upstream at NCSR 1400; D — Downstream 50 feet above the City of Sanford outfall. 2. Daily average dissolved oxygen effluent concentration shall not fall below 6.0 mg/L. 3. Total Residual Chlorine (TRC) shall be monitored only if chlorine is used to disinfect. 4. pH shall not fall below 6.0 nor exceed 9.0 standard units. 5. Chronic Toxicity (Ceriodaphnia) at 9 %; quarterly during January, April, July, October; See Special Condition A. (2.) 6. Monitoring upstream (U) and downstream (D) are provisionally waived, based on the permittee's membership in the Upper Cape Fear River Association. If at any time during the term of this permit, membership in the association is terminated, the permittee shall notify the Division immediately, and immediately continue instream monitoring as stipulated in this permit. 7. Variable: sample upstream and downstream 3/week during summer months of June, July August, and September, weekly during the rest of the year. Units: mg/L = milligrams per liter µg/L = micrograms per liter ml = milliliter NH3 as N = ammonia as nitrogen pounds/day = pounds per day BOD = biochemical oxygen demand Effluent shall contain no floating solids or foam visible in other than trace amounts. Permit NC-0072575 r A. (2.) CHRONIC TOXICITY PERMIT LIMIT (Quarterly) The effluent discharge shall at no time exhibit observable inhibition of reproduction or significant mortality to Ceriodapbnia dubia at an effluent concentration of 9%. The permit holder shall perform at a minimum, uarter! monitoring using test procedures outlined in the "North Carolina Ceriodapbnia 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 Branch 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. 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. NPDES PERMIT DRAFT /FINAL FILE CONTENTS: Left side: ❑ /�Iew Tracking Slip. L Old Tracking Slip. Right side: ❑ Streamline Package Sheet Draft Permit Cover Letter. LAY Draft Permit Facility Map Fact Sheet. LL! Permit Writer's Notes r,§taff Report from Region Old Permit permit Application. L9' Acknowledgement Letter ❑ Permiaee Responses iWaste Load Allocation CHECK LIST Facility Permit No. NPDES Permit Writer: Q-. (to region, only if bamlined) (add new policy xt; summarize major c anges to permit) (order: cover, supplement, map, effluen sheets, special conditions) (E-Maps Include facility; Outfalls; U a D sample locations) (document permit writer's issues and re -issue logic) (if not in Facts Sheet -- chronology, strategy, DMR Review, RPA, etc.) (as appropriate --.not needed if streamlined) (Text, Effluent Sheets and Special Conditions) (Nevy Permit or Renewal; any additional permittee correspondence) (for Renewal Application, from NPDES Unit) (to acknowledgement letter, if any) (referenpe date; recalculated for current action?) ?, 10 C-A-f Note: Italics indicate special conditipr'irof always required or applicable. EY/ Submitted to C-9t � 44 for Peer Review: Datte-� ( 6f Peer Review completed by I 1 l .'D.ate�a/ �Lr�, ) ❑/ Permit Mailed Mail o Regional Staff MA 'UISM� !�' by CYO- Date 2,3gwL' E Regional Office Review completed by _ o C745&m Date a uL Additional Review by Er Additional Review completed by initiated by CAeWMAT DateT� �{ on: Date 1�4&Z E'�Submitted to �t (G�i4 for Public Notice on �o ,3ct�{ : Notice Date ? }��J M'- Updated Public Notice and IMS databases. Date �9axo UH �Date 5/FINAL submitted fo Dave Goodrich for signature on 1 m w w�i�e4 0 Additional Review JO'co S% A UNITED STATES ENVIRONMENTAL PROTECTION AGENCY REGION 4 o e ATLANTA FEDERAL CENTER ;Fro 61 FORSYTH STREET 102 l9< PgoltC ATLANTA, GEORGIA 30303-8960 MAR 1 4 2002 Mr. Dave Goodrich, Supervisor NPDES Unit O w Division of Water Quality North Carolina Department of Environment and PK 2 1 Natural Resources " 1617 Mail lService CenteroFt+a -wNkl P( Raleigh, RC 699-1617 aINS out- SUBJ: NPDES Permit for Gold Kist WWTP Permit No. NCO072575 Dear Mr. Goodrich: In accordance with the EPA/NCDENR MOA, we have completed our review of the draft permit referenced above. We request that we be afforded an additional review opportunity only if significant changes are made to the permit prior to issuance, or if significant comments to the permit are received. Otherwise, please send us one copy of the final permit when issued. If you have any questions, please call Ms. Dee Stewart at (404) 562-9334. Sincerely, J. Scott Gordon, Chief Permits, Grants and Technical Assistance Branch Water Management Division Internet Address (URL) • http://www.epa,gov Recycled/Recyclable . Printed with Vegetable Oil Based Inks on Recycled Paper (Minimum 30% Postconsumeo Re: [Fwd: Gold Kist -- DRAFT Permit Review] Subject: Re: [Fwd: Gold Kist -- DRAFT Permit Review] Date: Tue, 24 Jul 2001 14:08:46 -0400 From: Randy Jones <randyJones @ncmail.net> To: Joe Corporon <Joe.Corporon@ncmail.net> CC: Ted Cashion <ted.cashion@ncmail.net>, Ken Schuster <Ken.Schuster@ncmail.net> Joe, Ted Cashion reviewed the subject draft permit and had the following comments: - NH3 as N should be noted as ammonia as N, not nitrate as N; - Nap did not show discharge location clearly. We will also send the hard copy down to you. Thanks, Randy �ACc`zo�Z 5S Ted Cashion wrote: > see comments, permit draft looks ok. send to jow if you concur. tc > > ------------------------------------------------------------------------ > Subject: Gold Kist -- DRAFT Permit Review > Date: Mon, 23 Jul 2001 15:35:45 -0400 > From: Joe Corporon <joe.corporon@ncmail.net> > To: Ted Cashion <Ted.Cashion@ncmail.net> > Ted, please review attached files and comment as necessary. > Thanks, > --Joe > ------------------------------------------------------ > Name: Gold -Kist DRAFT cover letter.doc > Gold -Kist DRAFT cover letter.doc Type: Winword File (application/msword > Encoding: base64 > Download Status: Not downloaded with message > Name: Gold -Kist DRAFT EFF.doc > Gold -Kist DRAFT EFF.doc Type: Winword File (application/msword) > Encoding: base64 > Download Status: Not downloaded with message > Name; Gold -Kist DRAFT Permit.doc > Gold -Kist DRAFT Permit.doc Type: Winword File (application/msword) > Encoding: base64 > Download Status: Not downloaded with message > Name; Gold -Kist Map.ppt > Gold -Kist Map.ppt Type: Microsoft PowerPoint Show (applicationlvnd.ms-p• > Encoding: base64 > Download Status: Not downloaded with message > Name: Gold -Kist --Fact Sheet.doc > Gold -Kist --Fact Sheet.doc Type: Winword File (application/msword) > Encoding: base64 > Download Status: Not downloaded with message 1 of 1 9/5/01 8:13 AM GOLD Kw INC. 244 Perimeter Center Parkway, N.E. (30346-2397) • P.O. Box 2210, Atlanta, GA 30301-2210 • (770) 393-5000 August 27, 2001 Mr. Joe R. Corporon NPDES Unit Division of Water Quality North Carolina DENR 1617 Mail Service Center Raleigh, North Carolina 27699-1617 RE: Proposed NPDES Permit Gold Kist Processing Plant Sanford, North Carolina Dear Mr. Corporon: �s AUG �Q'V 13Tvp_Vi Gold Kist has reviewed the proposed NPDES permit and finds no significant deviations from the current operating permit. With the understanding that no additions have been made to the permit, Gold Kist offers the following comments regarding with the proposed permit: Effluent Limitations and Monitoring Requirements The daily maximum for Total Suspended Residue (TSR) should read as 992 lbs/day versus 922 lbs/day. Limits for Fecal coliform (geometric mean) should be monthly average of 200/100 ml and daily maximum of 400/100 ml. The proposed permit erroneously lists the daily maximum as a weekly average. Sampling frequency for instream parameters should read as once per week versus three per week during June, July, August and September. Fact Sheet for NPDES Permit Development The introduction incorrectly states the expiration date of the current permit as April 30, 2001 versus September 30, 2001. The primary SIC code for the facility information should read 2015 versus 2115. Page Two RE: Proposed NPDES permit — Sanford If you have any questions, please call me at (770) 393-5032. Sincerely, Koju Katie Kirkpatrick, P.E. Environmental Engineer cc: Mr. Allen Merritt Mr. Bruce Morgan Mr. Don Poe Ms. Barbara Goetz File (Sanford 3.2) (So sr UNITED STATES ENVIRONMENTAL PROTECTION AGENCY J� 4'�s, REGION 4 A z ATLANTA FEDERAL CENTER ao a 61 FORSYTH STREET zz o ATLANTA, GEORGIA 30303 4[ Pq(11E AUG -13ZUet-- Mr. Kerr T. Stevens, Director r- Division of Water Quality i North Carolina Department of Environment and Natural Resources 1617 Mail Service Center Raleigh, North Carolina 27699-1617 o W SUBJ: NCO072575 - Gold Kist, Inc. Processing Plant WO O 1 Dear Mr. Stevens: We have received the North Carolina Department of Environment and Natural Resources (NC DENR) National Pollutant Discharge Elimination System (NPDES) draft permit for the referenced industrial facility. At this time, EPA is unable to complete its review of this draft permit because the related permit application does not sufficiently characterize the effluent quality of the proposed discharge. Therefore, the information provided is inadequate to determine whether the draft permit meets the guidelines and requirements of the Clean Water Act. Section 123.25(a) of Title 40 of the Code of Federal Regulations (C.F.R.) provides that permit applications used by the State must require, at a minimum, the same information required in the pertinent EPA application forms. The information as required by EPA Standard Form 2C was not provided (see Enclosure). EPA requests that the State or permittee provide this expanded effluent testing data for each applicable outfall for which permit coverage is sought. This request is made pursuant to 40 C.F.R. § 123.44(d)(2) and the NC/EPA State NPDES Program Memorandum of Agreement (MOA) and thus constitutes an interim objection to issuance of this permit. Upon receipt of the complete application materials, EPA will complete its review. If you have any questions, please do not hesitate to contact me or Ms. Caroline Ejimofor of my staff, at 404-562-9309 or eiimofor.caroline@epa.eov. Sincerely, Enclosure Banister, Director aeement Division I .IAY.VLINA ENVIRONMENTAL MANAGEMENT COMMISSION/ NPDES 1617 Mail Service Center, Raleigh, NC 276"-1617 OF INTENT TO ISSUE A STATE. NPDES WASTEWA. TER PERMIT On the basis of thor. ough staff review and; applicatian of NC General Statute 12321, Public Law 93 500 and other, lawful standards and regula. tions, the North Cara. ling Environmental Management Com- mission proposes to issue a National Pol !Imant Discharge. Elimination System. (NPDES) wastewater. discharge permit to the person(s) listed below effective 45 days frorn the publish. date ofthis notice. 'NPDES Permit Num- ber N00072675, Gold Kist, Inc., P.O. Box' 2210, Atlanta, GA 30301 has applied for a permit renewal for a facility located in Lee County discharg- ing treated wastewa- ter into Deep River in the Cape Fear Riv- er Basin. Currently BOD, nitrogen, Total Suspended Residue, oil and grease, fecal coliform, and Total Residual Chlorine are water quality lim- ited. This discharge may affect future allo- cations in this por- tion of the receivin stream. Written comments re- garding the proposed permit will be accept. ed until 30 days after the publish date o this notice. All com- ments received prior - to that date are con. sidered in the final determinations re- garding the proposed permit. The Director of the NC Division of Water Quality may de-lde to hold a pub- lic meeting for the propose(' pfrmit should the Division receive a significant. d-eeree of nublic iuter- Lee County North Carolina Bill Horner III, Publisher of 0Ile �5atifarb lbralb, a newspaper published in Lee County in the state of North Carolina, being duly sworn, deposes and says: that the attached advertisement of notice, in the action entitled . �)(X, 14;c ` - is (see I A, I - I . � I was duly published in the aforesaid newspapers once a week for I consecutive weeks, beginning with the issue dated the 21 day of and ending with the issue dated the 2 1 day of RECEIVED /,�0 Bill Horner 111, PubliiihAr Sworn to and subscribed before me otary , My commission expires: 'AUG--0-2 200P ONSUDWOFFICE this % day of Y-7 Received of the cost of the above publication. By: 7/25/01 Permit Number Facility Name Permit Writer Publish Date Final to Supervisor NC0024210 High Point, East Side Rodriguez 8/31/01 NG0028118 Fu ua -Varina, Town Kenneth Creek WTP Rodriguez 8/31/01 NC0072575 Gold Kist,lnc. Cor oron 8/31/01 SOC WQ 94-026 Diversicare Assisted Living Services IManual 8/31/01 Re: [Fwd: Gold Kist -- DRAFr Permit Review] Subject: Re: [Fwd: Gold Kist -- DRAFT Permit Review] Date: Tue, 24 Jul 2001 14:08:46 -0400 From: Randy Jones <randy.j ones@ ncmail.net> To: Joe Corporon <Joe.Corporon@ncmail.net> CC: Ted Cashion <ted.cashion@ncmail.net>, Ken Schuster <Ken.Schuster@ncmail.net> Joe, Ted Cashion reviewed the subject draft permit and had the following comments: - NH3 as N should be noted as ammonia as N, not nitrate as N; - Map did not show discharge location clearly. We will also send the hard copy down to you. Thanks, Randy Ted Cashion wrote: K,\C C-�079213-�S > see comments, permit draft looks ok. send to jow if you concur. tc > ------------------------------------------------------------------------ > Subject: Gold Kist -- DRAFT Permit Review > Date: Mon, 23 Jul 2001 15:35:45 -0400 > From: Joe Corporon <joe.corporon@ncmail.net> > To: Ted Cashion <Ted.Cashion@ncmail.net> > Ted, please review attached files and comment as necessary. > Thanks, > --Joe > ---- --------------------------------------------------- > Name: Gold -Kist DRAFT cover letter.doc > Gold -Kist DRAFT cover letter.doc Type: Winword File (application/msword > Encoding: base64 > Download Status: Not downloaded with message > Name: Gold -Kist DRAFT EFF.doc > Gold -Kist DRAFT EFF.doc Type: Winword File (application/msword) > Encoding: base64 > Download Status: Not downloaded with message > Name: Gold -Kist DRAFT Permit.doc > Gold -Kist DRAFT Permit.doc Type: Winword File (application/msword) > Encoding: base64 > Download Status: Not downloaded with message > Name: Gold -Kist Map.ppt > Gold -Kist Map.ppt Type: Microsoft PowerPoint. Show (applicationlvnd.ms-p, > Encoding: base64 > Download Status: Not downloaded with message > Name: Gold -Kist --Fact Sheet.doc > Gold -Kist --Fact Sheet.doc Type: Winword File (application/msword) > Encoding: base64 > Download Status: Not downloaded with message 1 of 1 7/24/01 3:49 PM DENR / DWQ / NPDES Unit FACT SHEET FOR NPDES PERMIT DEVELOPMENT NPDES Permit No. NCO072575 INTRODUCTION Gold -Kist, Inc., formerly Golden Poultry (herein Gold -Kist or the permittee), requires a National Pollutant Discharge Elimination System (NPDES) permit to dispose treated wastewater to the surface waters of the state. The permittee's 5-year NPDES permit expired April 30, 2001 and they have requested renewal from the Division of Water Quality (the Division). This Fact Sheet summarizes background information and rationale used by the Division's NPDES Unit to determine permit limits and monitoring conditions. This document also contains references to information sources relevant to this permit renewal (superscripted numbers in order of appearance, see References). FACILITY RECORDS REVIEW Facility Description. Gold -Kist (Table 1) is a live chicken processing facility utilizing a Grade III activated sludge wastewater treatment plant (WWTP) to treat process -contact slaughter -house wastewater. This plant's permitted flow of 1.0 MGD presently also includes about 25,000 gallon per day of employee sanitary sewerage. Wastewater exits the slaughter house via two 14-inch diameter lines (one for viscera/meat and one for feathers). Process water is screened of solids, drained to a holding tank, then pumped to a covered, anaerobic treatment lagoon. Effluent from the anaerobic lagoon includes gasses (disposed to a methane incinerator) and liquid, further treated in an aeration basin (Schreiber), a clarifier (with activated sludge return), a "fuzzy" filter, and chlorination/de- chlorination chambers. A Parshall flume measures flow and a step aerator provides final treatment. Table 1. Gold -Kist, Inc. Facility Information A licant/Facilit Name Gold -Kist, Inc. A licant Address P.O. Box 2210, Atlanta, Georgia 30301-2210 Facility Address 484 Zimmerman Road, Sanford, North Carolina, 27330 Permitted Flow (MGD) 1.0 Type of Waste Industrial process wastewater, Primary SIC Code 2115 W W Code Prim. 23; Treatment Unit Code Facility/Permit Status Class III, Minor / Renewal Drainage Basin / County U Cape Fear River Basin / Lee Count Miscellaneous Receiving Stream IX4Deep River Regional Office Raleigh Stream Classification C State Grid / USGS To o Quad E 22 SW/ I Colon, NC 303(d) Listed? Not listed Permit Writer 1 Joe Rorporon Subbasin ' 03-06-11 Date: 09Ju101 Drainage Area (sq. mi.)' 1122 aijjjjjjjjqW Lat. 350 33' S0" Long. 79° 13' 11" Summer 7Q10 (cfs) 17 Winter 7Q 10 (cfs) 32 30Q2 (cfs) Average Flow (cfs) 1240 IWC (%) 9 % Fact Sheet Renewal -- NPDES Permit N00072575 Page I Division records for Gold -Kist (previously permitted as Golden Poultry) date from 1987. The current permit expires on September 30, 2001. The Division received documentation to renew (Standard Form C) on April 3, 2001. 1 Poultry plants are currently not classified as Primary Industries and are therefore not required to submit Priority Pollutant Analyses (PPA). Waste Load Allocation (WLA). The Division prepared the last WLA for the receiving stream in February 1996 and developed effluent limits and monitoring requirements considering an in -stream waste concentration (IWC) of 9 %.T The Division views these limits and monitoring requirements appropriate for renewal considering similar past and present production levels (currently—173,000 chickens per day) with no relevant modifications to the plant/treatment system, or changes in the receiving stream. Verifying Existing Stream Conditions. This facility discharges to the Deep River, a Class C waterbody within the Cape Fear River Basin-5 Although portions of the Deep River upstream (Subbasin 30608) are listed as "impaired" [DWQ 303(d) list], the stream segment containing this discharge (Subbasin 30611) is not listed.5,6 CORRESPONDENCE Staff Report. Raleigh Regional Office (RRO) conducted an annual facility inspection and prepared a Staff Report dated May 11, 2001. The RRO staff noted minor compliance issues and recommended implementation of permanent sludge disposal methods instead of returning sludge to the anaerobic lagoon. The RRO found the facility generally in good operating condition and recommended that the NPDES Unit renew the permit. Renewal Application. With renewal, the permittee has requested consent from the Non -discharge Unit to re-route and separate employee sanitary sewerage (20,000 to 30,000 GPD) from process wastewater. This request requires a modification of the facility's Non -discharge permit WQ0014565. By separating sanitary waste from process waste, the facility will create the option to reuse additional treated wastewater for chicken processing. COMPLIANCE REVIEW Notices of Violation (NOVs). DMR data indicated a chlorine violation on January 23, 2001. The Division issued an NOV (January 1999) for fecal coliform violations in September 1998 ($1,547 assessed fines). No other NOVs have been issued since that event. DMRs do indicate non-compliance related to ammonia (May 2000) and BOD5 failures (Jan 1999), however no discharge occurred. Although BOD5 exceeded the Daily Maximum (10 mg/L) for 7 days within a 17-day period, the permittee diverted effluent to the anaerobic lagoon preventing discharge. Therefore, wastewater did not reach the receiving stream and no violation occurred. Chronic Whole Effluent Toxicity (WET) Test. Quarterly monitoring results for chronic WET testing beginning in January 1996 indicate "pass" through March 2001(17 quarters). Fact Sheet Renewal -- NPDES NC0072575 Page 2 Effluent and In -stream Data Review. Effluent. The Division reviewed 29 months (January 1999 through May 2001) of Discharge Monitoring Reports (DMRs).10 Reports appear regular, thorough, and complete. Total discharge of treated wastewater through Outfall 001 for this time period averaged about 0.635 MGD or 64% of permitted capacity. Effluent dissolved oxygen (DO) is routinely discharged at levels above 8 mg/L. Total Residual Chlorine (TRC), temperature, fecal coliform, BOD, Total Suspended Residue (TSR), pH, oil and grease are all compliant (see NOVs for exceptions). Instream Dissolved Oxygen, Temperature and Fecal Coliform. Gold Kist, Inc. discontinued instream monitoring in May 2000,10 as privileged by its membership in the Upper Cape Fear Basin Association who continue to sample and monitor the Deep River for its members. Instream DO and temperature data prior to May 2000 appear reasonable and seasonally appropriate. Summer dissolved oxygen values (upstream and downstream) appear marginal with respect to the Stream Standard minimum of 5 mg/L. Although upstream and downstream DO regularly averaged monthly above 5.0 mg/L, summer single -day minimums were reported as low as 3.5 mg/L. Instream data for fecal coliform, DO, and temperature appear similar in samples taken upstream compared to downstream, suggesting that this facility's discharge does not adversely impact the Deep River. PERMITTING APPROACH Federal technology -based limits (under 40CFR) for chicken processing are in progress but have not been promulgated by EPA (Draft due in November 2001 — Final, Spring 2002). The Division judges previous permit limits and monitoring requirements to be appropriate for renewal considering recent data supplied by the permittee indicating no significant changes in production (currently — 173,000 chickens per day) or changes in the condition of the receiving stream -I'll SUMMARY OF PERMITTING APPROACH Recommended Additions: NONE Recommended Deletions: Instream Monitoring Requirements appear in the renewed permit, but compliance is hereby waived provided that the permittee maintain membership in the Upper Cape Fear River Association. Should membership in the association terminate, or should stream monitoring by the association discontinue, the permittee shall notify the Division immediately and compliance with stream monitoring shall continue immediately, according to the renewed permit. Fact Sheet Renewal -- N PDES NCO072575 Nee C PROPOSED SCHEDULE OF ISSUANCE Draft Permit to Public Notice: Permit Scheduled to Issue: NPDES UNIT CONTACT If you have questions xef#ding any contact Joe Corpor at ( 9) 733 50 NAME: ENCES July 25, 2001. September 3, 2001 Kabove information or on the attached permit, please .597. Die: 1. 2001. NPDES Permit Application Standard Form C, Gold -Kist Inc., due Nov. 30, 2000, received April 3, 2001. 2. 2000. NPDES Regional Staff Report and Recommendations for the Renewal, for Gold -Kist, Inc., NPDES Permit No. NC0072575, Raleigh Regional Office, November 2. 3. 2000. Active NPDES Permits List, North Carolina Division of Water Quality, NPDES Unit, on the web at http:/h2o.enr.state.nc.us/NPDES/NPDESweb.html. 4. 1996. NPDES Permit No.N00072575. Issued to Golden Poultry, now Gold -Kist, Inc., expired April 30, 2001. Copies obtained through The Division of Water Quality, Central Files, Archdale Building, 512 N. Salisbury St., Raleigh, North Carolina. 5. 1999. Catawba Basinwide Water Quality Plan. North Carolina Division of Water Quality, Water Quality Section. 6. 2000. 303(d) List of North Carolina Impaired Waters - Draft. North Carolina Division of Water Quality, Water Quality Section. Copies obtained through Planning Branch, Archdale Building, 512 N. Salisbury St., Raleigh, North Carolina. 7. 1995. NPDES Waste Load Allocation Work Sheet, NPDES Permit No. NC0072575, for Gold - Kist, Inc., (reviewed by Carla Sanderson), February 27. 8. 2001. NPDES Whole Effluent Toxicity Test Results, January 1996 through May 2001, DENR, Environmental Services Branch, Aquatic Toxicology Unit, June 20. 10. 1998-2000. Discharge Monitoring Reports (DMR) for Effluent (DEM Form MR-1) and instream monitoring (DEM Form MR-3), NPDES NCO072575 for Golden Poultry, now Gold - Kist, Inc. 11.2001 Site Visit Inspection of the Wastewater Treatment Facilities, conducted by Bruce Morgan (Gold Kist Engineer) and Katie Kirkpatrick (Gold Kist Environmental Engineer) for Joe Corporon (NPDES Unit), July 18. Fact Sheet Renewal -- NPDES NC(H)72i75 Pays 4 5 7-5 )- REGIONAL OFFICE COMMENTS NH3 AS N SHOULD BE NOTED AS AMMONIA AS N, NOT NITRATE AS N MAP DID NOT SHOW DISCHARGE LOCATION CLEARLY ar: � y'O C S i nm O ma N o l� NAME: �DATE: o REGIONAL SUPER 0 NPDES SUPERVISOR: DATE: Fact Sheet Renewal — NPDES NC0072575 Page 5 r'A P15WA NCDENi No" CAROUNA DePARTMCNT o. ENVIRONMENT AND NATIItAL Resouw-C4 TELEPHONE RECORD Date: ! v�'� �S Project: ► Timed -+S k, = 6T eln� � -Z -S ❑ Return Mr./ Mrs. `Cl t�Vt1f��L�epresenting: 2160 all to Address � ❑ Call from Subject: B Telephone: ( v--S u `w 3 Z q>u-,t yCT?3- 1 / S,rr N 5 PR P(AAC- v NE ED FOLLOW-UP CTION(S)R l W tj /c FAX: Vc5 c BY WHOMMHEN c�.0-fNsj i-cNL cc: Signed Whole Effluent Toxicity Testing Self -Monitoring Summary June 18, 2001 FACILITY REQUIREMENT YEAR 1AN FEB MAR APR MAY JIIN JUL AUG SEP OCT NOV DEC Golden Finds, Pam chr Iim: 9.01/. 197 Pass Pass Pass Pam NCOO72575/1101 Begin:01IN6 Frcpuenry: Q P/F + Jan Apr Jul Oct NonComp:SingJe 108 Pass - - Pus - - Pass - - Pam - - County: Lee Region: RRO StAlaccre CPFI I 1999 Pass - - Pas - - Pass - - Pass - - PF: 1a Soda SUN Pena Pao P. Pass 7QI0: 17.0 IWC(%)9.1 Door 2001 Pans - - Pan Galdsbnro WW1R Perm do Iran S.B%:ifpf 14.2 chr Jim 75%;ifpr 17.6 chr lim 9.1 1997 Pass - - Pan - - Pass - - Pam - - NC00239491W1 Begmell/I/21100 FresPa Q Jsn Apr Jul Oct + NNCNN:Sbtglc 1990 Pass - - Pan - - Pass - - Pass - -- Coon7 Wayne Region: WARD Sultanate NEU05 I999 Pass - - Pm - - Pass - - Pass - -- PF: 10.8 Special 2000 Pass - - Pass - - Pass - - Pass - -- 7QIO:271.1 IWC(%)5.g Order. 2001 Pot - - Pass Goldsboro WWTP Perot chr lam: 21% 107 - - - - - - - - - - -- - NC00239491002 Begin:I l/l/2000 Ftcquenry:Q tun Apr Jul Oct + NonComp:Single INS - - - - - - - - - -- -- Cowry: Weys. Region: WARD Subbarin: NEU05 1999 - - - -- - - - - - -- -- -- PF: 4.0 SPneial 2000 - - - - - - - -- - - -- -- 7Q10:271.1 IWC(%)2.2 ado: 2001 H - - H Graham WNTP Perm chr lam: 14% 107 - - Pun - - Pass - - Pau - - Pass NCN21211/001 Begm:3/1/1"t, Frequcnry: Q P/F + Mar Jun Sap Dec 14m Conge Single INS - - Pass - - Pass - - Pau - - Pass County: Alatnwa Region: WSRO Subbrave CPF02 INS - - Pass - - Fail Pon -- Pans - - Pau PF: 3.5 tricot 20^0. Plan Fag >$6 >56 Pm - - Pecs 7QI0: 34 IWC(%):14 Oder: 2031 - - Pan - GnnlleFalls W Penn chr It. 11%(4/laWl New Pomp IW7 - - Paar - - Pan - - pass - - Pau NCOI218WWI Begin:7/1/1995 Frequency: Q PIP + Marlun Sep Dee NanCotttp:Sv.& 1998 - - Pan - - Pan - - Pass - - Pass Consul, C.Idwcll Region: ARO Subbarin: CTB32 INS - - Pun - - Pam - - Pass - - Pass PF: 9.90 3Pxnl 2" - - Pass Pans Pass - - Pass 7QI0: 93 IWC(°al'.II Omar 2001 - - Pass - Greeosbom N Range Cr W537p Penn chr 0m: 90% 1997 Pass - - Fad Pass - Pass - - Pass - - VC01124325/001 Begm: 4,1'1996 FtNuwry:0 P/F , Jw Apr Jul Ocl NonComp:Singlc INS Far Fall Pass Pass - - Pau -- - Pact - - County, Gmlbml Raga'. WSRO Subbion: CPF02 Is" Pass - - Pau - - Pan - - >1.0 -- - 7QIO 0911 IW('I". ) 91, mia 20I 949 - - »CO Creation, Osborne W WTP Penn chr Iim: 90% Y 1997 Fall Fad Pon Pa. - - Paea -- - Pass - - NCO0473841001 Begln11111996 Frequency: 01 + Jan Apr Jul Oct Norcona,Single 1998 Pass - - Foul Pass - Pau Pazs County0milinJ Rcgian: WSRO Subbarin; CPF02 190 Pam - - Pau - - Fa1P1N -- -- >100 -- - PF: 22.o St ial 200O >,, - - IN - - >1N - - 9C.9 - - 7010.2.1 IWC0013.7 Oder: 2001 94.9 - - >100 Greenville WWTP Perm chr Iim: 20% r 1997 - - Pason) - - Paul - - pal - - Pxic1s) NC0023931/001 Begin:lJ0001 Frequanry:Q Mar Jun Sep Dee + NmCma P:Smglc INS - - Fux.) Paaa(z) - Pai l - - rands) - - Paent) Cowry: Pin Region: WARD Subbarin: TAR05 INS - - pass(.) - - Passlzl - - Lain pawed.) - pass(-) PF: 17.5 Spica) 2000 - - Fall 693 -80 >Bp - - >N - - >80 7QI0:109 IWC(%)20 Onto 2Nt - - Gmscr lnduaaea Inc. Pam chr Iran: 64L 1997 - Pon - - Pass - - Pm - - Pau - NCN41391/001 Begin:1/111999 Frcgaenq: Q P/F + Feb May Aug Nov + No.Comp:Sulgh, I990 - Pm - - Pau - - Pao - - Paz - Counry: Port Region: ARO Subbarin: BM06 1999 - Pass - - Pass - - Pass - - Pau - PF: 0.45 San, 2000 - pass - - Pass - - Pass - - Pass - 7QIW 10.8 IWC(%):6.07 Oda: 2001 - Pass - - Grover lnduatrlt, I.e. Parmchrlim: LBO/. 1997 - - Pam - - Pass - -- Pas. Pans NCOOS39841001 BeglnA/1/2000 Fromacy:Q Mar lute Sep Dee + NNComp:Smglc INS - - Pan - - Pet - - Pairs Pass Cowry: Cleyelwd Region: MRO Subbarin: BRD05 INS - - Pau - - Pass - - Pas. - - at PF: 0.38 5raial 2000 - Pw9 Pau - - Pau -- - Pun -- -- Pa.. 7QlM 32 IWC(%):I.B adm: 2601 - - Fell >10 Guilford Mills East Porn chr Iim: 27% 1997 16.26 - - 49 - - 52.54 - - 32.53 NC00023051001 Begirell/I/1996 Frequency:QP/F + Jw Apr JulOc, NonComp:Single INS <65 32.510.6 - 15.91 52,54 Inn 32,56 52.54.>60 52.5 MO - Fell C,umy: Duple Region: WIRO Subbarin: CPF22 1999 Pam - - Pau - - Pans - - Pan - - PF: 1.5 Spatial 2" Fat 32.9 On Pau - - Fell <13.5 <335 US - -- 7010:6.5 IWC%)47 Cater 2001 Fad <115,03.5t 16.4,164f <ISS LEGEND: PERM - Palma Requiament LET • Admini,lrau.a Lena - Target Frequcrcy - Monnonng 0cqucrcy: Q Quarterly, M- Monthly; BM- Bimonthly; SA. Semiannually; A. Annually: OWD� Only wbcn di cl arging: D. Discontinued monitonng requirement Began Full m nsh regotaJ 7QIO - Receiving nrcam Ime flew aileron (clo + - quanerly monitoring increases to monthly Stuart fi lure or NR Month that teeing most occur - ex. )an. Apr. Jul. Oct NonComp - Cumrnl Compliance Regulations PF= I'emuaedflr,,M(IDI IWC"--Imue.mxasleaancemonoa PT - PaxdFadtat AC=Acute CIR-Chronic Dale.Nmamm I - Fathcud Morrow. • Cerumphan.'.my-Myudshnntp;CIA -('hmme value;P- Mortality ofsutad Pereare at hlghastamanlrmion;at- Peetarmlby DWQ Aquatic Tax Unit;tat -Bad test Rernmiµ Neulom Duo non aguucd. NR-N...... ed Pod6ty Aatyng Status: I - Inaetma. N - Newly lssuwl(To wtuuet).N- Anlye but not discharging: a -More data available for month in question:• - ORC signature naded 23 CAPE FEAR RIVER BASIN Name of Stream Subbasin Stream Index Number Map Number Class DEEP RIVER CPF09 17-(4) D19NW2 WS-IV CA ' DEEP RIVER CPF08 17-(30.5) D19SE2 C DEEP RIVER CPF09 17-(10.5) D19SE2 C DEEP RIVER CPF10 17-(10.5) D19SE2 C DEEP RIVER CPF10 17-(25.7) F20NE2 C HQW DEEP RIVER CPF10 17-(28.5) F21NW2 WS-V HQW DEEP RIVER CPF10 17-(32.5) F21NE1 WS-IV DEEP RIVER CPF10 17-(36.5) E21SE5 WS-IV DEEP RIVER CPF11 17-(36. 5) E21SE5 WS-IV DEEP RIVER CPF11 17-(38.3) E22SW4 WS-IV CA DEEP RIVER CPF11 17-(38.7) E22SW4 C DEEP RIVER CPF11 17-(43.5) E22SW3 WS-IV DEEP RIVER (including High Poji�7 Lake at CPF5 17-(1) C19SW8 WS-IV CA normal pool elevation) Daniels Creek CPF07 18-10-(2) F22NE5 C Daniels Creek (Watsons Lake) CPF07 18-10-(1) F22NE3 B Dane Creek CPF17 18-64-7 J25SE8 C Sw Dark Branch CPF22 18-74-20.7 G27SW9 C Sw Davis Branch CPF16 18-45-1-1 124SW3 C Davis Creek CPF16 18-50-5-2 I24SE6 C Deep Branch CPF13 18-20-15 F23SW1 C Deep Branch CPF14 18-23-16-10-5 F22SW8 WS-III Deep Creek CPF02 16-14-8-(1) C21NE4 WS-II NSW Deep Creek CPF02 16-14-8-(2) C21NW9 WS-II NSW CA Deep Creek CPF14 18-23-17 G22NW9 WS-III Deep Creek CPF17 18-88-8-3-1-1 L27SW2 SA Deer Branch CPF13 1B-20-13-1 F22SE7 C Deer Valley Branch CPF20 18-68-18-11 J26NE1 C Sw Denis Creek CPF17 18-88-9-2-3 L26NE5 SA Dero Creek CPF23 18-74-32 I27NE7 C Sw Devane Branch CPF19 18-68-6 I25NE2 C Sw Dews Creek CPF17 18-81-9 R26SE3 C Sw Dicks Branch CPF22 18-74-19-5 G26NE7 C Sw Dock Creek CPF23 18-74-60 J27SW5 C Sw Doctors Creek CPF22 18-74-29-3 H26SW8 C Sw Dodsons Lake CPF09 17-16-2 D20NW9 WS-III Dogwood Lake CPF08 17-8-1 C19SW9 WS-IV Dollar Branch (Marsh Branch) CPF19 18-68-1-10-3 H25NE2 C SW Doncho Creek CPF16 18-54 J25NW2 WS-IV Doshers Creek CPF17 18-88-10 L26NE9 SC Double Branch CPF16 18-62 J26SW1 WS-IV Sw Double Branch CPF20 18-68-17-3 125SW2 C Sw Double Run CPF17 18-66-6 J26SE4 C Sw Drunken Run (north) CPF16 18-53 I25SWB C Drunken Run (south) CPF16 18-53.7 J25NW3 WS-IV Dry Branch CPF13 18-20-13-7 F22SE3 C Dry Branch CPF15 18-31-13 G22SW7 C Dry Branch CPF20 18-68-18-4 I26SE1 C SW Dry Branch CPF22 18-68-18-4 I26SE1 C Sw Dry Creek CPF02 16-13 C21NW7 C NSW Dry Creek CPF04 16-34-(0.3) D21SE7 C NSW Dry Creek CPF04 16-34-(0.7) D21SEB WS-IV NSW Dry Creek CPF10 17-26-5-6 F20NW9 WS-III Dry Creek CPF07 18-17-(1) F23NE6 C Page 8 of 30 .-W�s �lcc J Q. Co -,, y-c/ L- c A6ST, MIL FT-1 R O fs�� : APB - ss . U - uvp ` ;1005-1 _ o n� ru ocx ap W C►�Q�C�1�aA AAkr— cW` n May 15, 2001 MEMO To: Joe Corporon Through: Ken Schust Randy Joness 0.From: Ted Cashion t Subject: Memo Staff Report for Permit Renewal Gold Kist Inc. NPDES Permit No. NC0072575 Lee County Please accept this as the staff report for the subject facility. There have been no changes at the facility since the permit was issued to discharge 1.0 mgd from the Schreiber process plant. Attached is a copy of the inspection letter that was completed as a result of this action. The facility is well operated and maintained. We recommend the permit be reissued in accordance with the basinwide plan. If questions please call. h:\staffrpt\goldkist.sr State of North Carolina Department of Environment and Natural Resources Raleigh Regional Office Michael F. Easley, Governor William G. Ross, Jr., Secretary May 11, 2001 Mr. Ralph Upton Division Manager Gold Kist Inc, 484 Zimmerman Road Sanford, NC 27330 Subject: Compliance Evaluation Inspection Gold Kist W WTP NPDES Permit No. NCO072575 Lee County Dear Mr. Upton: NCDEHR NORTH CAROUI 0EP TMENT OF ENVIRONMENT A o N/ RA RmsO RCEs The subject inspection was performed May 1, 2001 by myself. The cooperation of Mike Beal, backup ORC and Bruce Morgan, ORC, was appreciated. Findings during the inspection were as follows: 1. The treatment plant is currently permitted at 1.0 mgd and consists of the following units: 17 MG anaerobic lagoon, emergency pond (used only when effluent is noncompliant), Schrieber process aeration basin, magnesium hydroxide addition, traveling bridge circular clarifier, fuzzy filter, chlorine contact chamber, dechlorination chamber, parshall flume, effluent flow measurement, and step aeration. All equipment appeared to be operating satisfactorily. 2. Sludge is currently disposed of in the anaerobic lagoon. Gold Kist will need to implement a permanent method of sludge disposal. Please respond as to what measures the facility will pursue. 3. There are no generators onsite. Mr. Beal stated that if power is lost, the processing plant will shut down and no wastewater would be discharged to the wastewater facility. 4. A high water alarm was tested, and both audible and visual alarms operated satisfactorily. The flow meter was calibrated September 2000, compliant with the Division's requirement of, at a minimum, annual calibration. 1628 Mail Service Center, Raleigh, NC 27699-1628 Telephone (919)571-4700 FAX (919)571-4718 An Equal Opportunity Affirmative Action Employer 50% recycled/10% post -consumer paper Mr. Upton Page 2 6. The effluent composite sampler is programmed to collect flow proportional samples (300 ml/10,000 gallons) as required. 7. The effluent appeared clear and free of excess solids. 8. The pH meter is being calibrated as required. However, the chlorine meter is not being calibrated with standards. The chlorine meter must be calibrated each day values are reported on the DMR. At least 3 standards must be analyzed; a low, mid range, and high value (ex. 0.1 mg/l, 1.0 mg/l, 2.0 mg/1). The standards used must bracket the expected results. A blank must also be analyzed, and the result recorded. The meter readings must be within +10% of the actual value for each standard. Readings of each of the standards must be recorded to verify meter accuracy. Also, chlorine was reported as "0" several times. As discussed during the inspection, if no chlorine is detected, the result would be reported as less than the detection limit of the meter, which would be the lowest standard used when calibrating the meter (i.e. <0.1 mg/1). Please contact the Division's Laboratory Certification Unit at 919-733-3908 for guidance on the detection limit of your particular instrument and method. A color wheel is not an approved method for DMR reporting purposes. You are required to obtain an exemption from the Laboratory Certification Unit for pH and chlorine analyses. Please contact this Unit at 919-733-3908 for the requirements for this exemption if not already obtained. 9. A cursory review of of laboratory data and DMR data showed consistent reporting of results. 10. The permit will expire September 30, 2001. An application to renew the permit has been submitted. 11. A review of DMR data for the period February 2000 - January 2001 showed 1 daily maximum violation for chlorine that occurred on January 23, 2001. BOD was reported twice for the week of October 1, 2000; 3/week is required. Lab error was reported on the DMR. Total phosphorus was not reported for May 2000; 1/month is required. The laboratory did not perform the test as required. No other limit or monitoring violations occurred. 12. Mr. Beal stated the facility is considering re -use of the effluent in the processing plant where allowed. Mr. Upton Page 3 13. Toxicity results of "pass" have been consistently reported. 14. There were several days where sampling was not conducted. It was determined that the facility did not discharge on those days because the effluent would have been noncompliant. Instead, the effluent was diverted to the emergency pond and re-routed through the plant for additional treatment. Please repond in writing to item 2 by June 1, 2001. If you have questions concerning this report please contact me at 919.571.4700 ext. 250. Sincerely, I Ted A. Cashion Environmental Chemist cc: EPA Lee Co. Health Dept. h:\inspect\goldkist.cei G= Kin INC. 244 Perimeter Center Parkway, N.E. (30346-2397) • P.O. Box 2210, Atlanta, GA 30301-2210 • (770) 393-5000 March 30, 2001 N.C. Department of Environment and Natural Resources Division of Water Quafity/NPDES Unit 1617 Mail Service Center Raleigh, North Carolina 27699-1617 RE: NPDES Application Form — Permit Renewal Gold Kist Processing Plant Sanford, North Carolina Permit No. NCO072575 To Whom It May Concern: p EC `'OM[ APR - 3 2001 D DENR-WATER QUALITY POINT SOURCE BRANCH Please find enclosed one original and three copies of a completed Standard Form C. The form is submitted for renewal of permit no. NCO072575 issued to the Gold Kist Processing Plant located in Sanford, North Carolina. Also, all supplemental information required by Standard Form C such as production information, location maps and process flow diagrams are included in the submittal package. In addition to the renewal package, a copy of the non -discharge permit modification package is included. Gold Kist is currently pursuing the elimination of sanitary wastewater from the biological system and re-routing the sanitary flow to the non - discharge application system. The removal of sanitary water from the biological system will allow the facility to pursue water reuse options utilizing treated effluent within facility operations. Gold Kist intends to chlorinate the sanitary water prior to land application. Once the non -discharge permit and system modification is complete, a letter will be issued to the NPDES unit indicating the removal of this flow from the influent to the biological system. If you have any questions, please call me at (770) 393-5032. Sincerely, Kam �'- Katie Kirkpatrick Environmental Engineer J SUPPLEMENTAL DOCUMENTATION Gold Kist Inc. — Sanford, North Carolina NPDES Permit No. NCO072575 Present Operating Status The Sanford Gold Kist facility utilizes approximately 1 million gallons of potable water each process day to produce a wholesome sanitary dressed poultry product. In the production process, this potable water becomes contaminated with feathers and offal, blood, viscera, fecal material, etc. These constituents, obviously, represent pollutants, and are normally expressed in terms of BOD (Biochemical Oxygen Demand), COD (Chemical Oxygen Demand), TSS (Total Suspended Solids), TKN (Total Kjeldahl Nitrogen), Ammonia, FOG (Fats, Oils and Greases) and fecal coliform. In order to remove these pollutants from the wastewater and satisfy the conditions of the NPDES permit, Gold Kist is equipped with several wastewater treatment processes. The wastewater treatment flow schematic is attached (Attachment 1) and is briefly described below: Wastewater exits the processing plant via two 14" diameter fines (one line for viscera/meat, one line for feathers) and enters the offal/pretreatment building. Once in the offal building, these lines discharge onto either the feather shaker screens of the meat shaker screens. These screens remove most of the larger sized solids from the waste stream. The removed solids are conveyed via inclined screw augers to offal trucks. These trucks carry the feathers and meat to an animal by-products plant, where they are recycled into feather meal, poultry meal and animal fat. Screened wastewater from both the feather side and the offal side is combined in a single 35,000 gallon wet well. The water is then pumped to a pump station and thence to the anaerobic lagoon. Prpyi•usl , the facility had utilized a pressurized system including a DAF (Dissolved Air Flotation) tank. onseeuenTv_ m the DAF tank. oils and solids were separate om the wastewater by floatine th a oils to k raked this material to a holding bin for additional dewatering via a belt filter the installation of the new to the anaerobic The anaerobic lagoon allows further reduction of pollutants in the waste stream through bacterial and chemical reactions occurring in the lagoon. Anaerobic means in the absence of oxygen, and there are bacteria, which can — and indeed prefer — to live in an environment without oxygen. These bacteria use the pollutants in the waste streams as a food source. Thus, BOD is broken down t smaller organic compounds, methane gas and carbon dioxide an more anaerobic bacterial cells. Please note the anaerobic lagoon has minimal impact on total 01 k'eldahl nitro en although much of the or anic nitrogen ---will be converted over to an ammonia nitrogen orm. The anaerobic lagoon is desi ed to reduce BO to 400 mgJl, and hold TKN at 120 m 1. Disc arge from the lagoon flows by gravity to the aeration asin provided by Schreiber. The aeration basin is intended to pick up treatment where the anaerobic lagoon left off. Instead of an oxygen -free environment, sufficient oxygen is supplied to aerobic bacteria (either directly via blowers or via nitrate oxygen) to completely oxidize BOD to carbon dioxide, water and additional cellular mass. Further sufficient oxygen is supplied to oxidize TKN to nitrate (and cellular mass). The oxygen level is carefully controlled to also allow nitrate to revert to nitrogen gas, and in the process releasing oxygen for use by aerobic bacteria degrading BOD or TKN. Discharge from the aeration basin flows by gravity to the clarifier. The purpose of the clarifier is to separate a clear supernatant for discharge from the bacterial cells. Consequently, the clarifier is a quiescent tank where the heavier bacterial cells settle, and the clear supernatant overflows the weirs to be directed to the Fuzzy Filter. Most of the bacterial cells which settle are conveyed via screw pumps back to the aeration basin, to provide sufficient bacteria back to the process to continue virtually complete BOD and TKN removal. To keep the process in balance (i.e. to prevent an oversupply of bacteria) a protion of the settled cellular mass in the clarifier is pumped back to the anaerobic lagoon. This process is called wasting and it allows the system to stay in balance without an unhealthy buildup of bacterial solids. The cells wasted to the anaerobic lagoon are degraded and digested in the lagoon. Clear supernatant effluent from the clarifier flows by gravity to the Fuzzy Filter. This unit is an upflow-fluidized bed, which contains fiber spheres as the filter media. The fiber spheres are constrained by a fixed plate at the top of the unit. As the clarified effluent passes through this media, solids are filtered out. This allows a very high level of suspended solids removal, and "polishes out" many of the remaining suspended solids in the clarifier effluent. Filtered effluent discharged from the Fuzzy Filter enters the chlorination/dechlorination chamber. The purpose of this unit is disinfection of effluent from any pathogens present. Chlorine is injected at the headworks of this unit to allow the disinfection. At the discharge of the unit, sulfur dioxide is injected to remove residual chlorine prior to release to the Deep River. Following disinfection, effluent flow is recorded. Then, the flow is directed by gravity across concrete reaeration steps, a cascade aeration system, to bring dissolved oxygen levels up. The facility's permit contains a minimum DO requirement; the cascade aeration system allows for increasing oxygen level in the effluent prior to final discharge. The fully treated, reaerated effluent is then released to the Deep River. The facility is also equipped with 3 emergency storage lagoons — two nonaerated (16 MG and 3.9 MG) and one aerated (1.2 MG). The purpose of these lagoons is two -fold. First, the lagoons — and in particular the 16 MG nonaerated lagoon — act as effluent flow control. The facility's permit limits discharge to 1 MGD1. A flow totalizer in the disinfection chamber automatically activates pumps to divert final effluent to the 16 MG lagoon when the 1 MGD limit is broached. This water will either be land applied or retreated through the process. The second purpose of the lagoons is to allow storage of wastewater and hence reduce or cease discharge when any event occurs that could cause noncompliance. When effluent quality has been restored, discharge can be reinitiated. Stored wastewater will either be land applied or retreated through the process. ' Although the facility is only permitted for 1MGD monthly average flow, it is designed for a flow of 1.5 MGD. Design Capacities See Attachment 2 for design information. (Table 1, Table 3, page 5-53) Potential Facility Changes Upgrades and/or expansions are not planned for the facility during the next five years. Schematic of Wastewater Flow See Attachment 1 for wastewater flow diagram. Also included is a block diagram for process flow through the processing plant. Location May See Attachment 3 for USGS map. Production Data See Attachment 4 for the last three years' production data for the facility. Priority Pollutant Analysis Poultry processing plants are not classified as Primary Industries and therefore, not required to submit a priority pollutant analysis. 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P P!C EC% Y6�1 ISiE � �LYGE PUY� �R�OL EF5'I% YiCR:ii1D ' GSGS,i'� I AFR1 D I yMi I Po"6` � w+D — I1 Ulb'I„YG � i I 14�SW`.6`X P.,11F5 �I �9 sPaGUTr its w�>,b VALVE fV srlelo a--cx..w:.E D9C w.ua cmc ® av YEral ® nrxavPL wo-.m FF.3E Ol4 dFt1C flL�° YE'EF. ® RQAT SVtICX �'.:� Pi631RE DLQ�CGc R') C�j C31fhTfXM� P.tt F-:J1;1E WPLAfxJIEX :'--) PJYP PIPING DIA. f�^_— WASTEWATER IN I — ` � S T E I',v� tlQC6lT6':11 PJYP_ (Exsrn+°) '0 tltR1Y4DQ4 'HMO �00��80 �c�oncoo_� S Qt 67 Z o-Z L7 +J a z 8 :D C3 OV Z � Z f�1' w rZ. r4t� eZ < Jd ` JJ L7 H r -- `_, tes _ \, _ -Y�Y EXI�I� sr� 3sm o WV1 <.'1 '4111 ENCT al sIa EXISTING I IuifY ws O i IFW N.2ETS <Sl w 5(54S= l IDENIM Fin PUFS 4?1 PHIT[KLIkYIi❑_ � , SIIkTFfii / rave � +�u MICH _—III Ii UENT A i>BdfMIC, z p, AR rave t:y v� rrTxn+c ansT�t ocvtn+e�� I P�IE.'TWAnm T a TFS.FN cu m V&W il.6J IEIiE L ��pO \J N' Kc'[F]t I RtVEFP E--L� CAECA hEPA1rml i Fuws ?% j F1NPL tl.gRiFITR I , YITMI VFSTEVAM Efl m in S!]FYISPR IMP" FiM s (W / ilASIV PUPS S.ki'LT PIdPSFf ZI 1 S7a"fEll j m fv�9 MWES., F(_a' blAa x Y uwl:� TFFATWWT STsT - w we glot4a(?�r:4> ' POTABLE WATER 190002000 GPD 5,000 GPD 45,000 GPD 40,000 GPD od 40,000 GPD 3509000 GPD 80,000 GPD 90,000 GPD 90,000 GPD 15,000 GPD 225,000 GPD 182 BIRDS/MIN 16-20 ARS/DAY 5-6 DAYS/WEEK RECEIVING KILLING BLEEDING SCALDING DEFEATHERING WHOLE BIRD WASH EVISCERATING FINAL BIRD WASH CHILLING CUT-UP DEBONING PACKING/PACKAGIN CLEAN-UP � 20,000 GPD SANITARY ICE PACKING AND PRODUCT MOISTURE ADDITION 30,000 GPD EVAPORATION 15,000 GPD BLOOD TO RENDERER OFFAL TO RENDERER 935900 SCREENING GPD STORAGE LAGOON SANITARY TREATMENT SYSTEM ANAEROBIC BASIN I � AERATION I � � BASIN ADVANCED I I BIOLOGICAL � ~SYSTEM I I CLARIFIER I I I TERTIARY I I I I FILTER I I NON - DISCHARGE SYSTEM � DISINFECTION � DISCHARGE 001 APPROX. <0.70 MGD ANNUAL AVG. IRRIGATION POND PROCESS FLOW GOLD KIST POULTRY PLANT SANFORD, NORTH CAROLINA Gold Kist - Sanford Table 'I Anaerobic Lagoon Sizing and Performance ITEM VALUE Basis/ Comment Loading, Ibs/day BOD 18765 Flow, MGD x BOD, ppm x *8.34 Design Load, lb BOD/day/1000 ft3 10 Typical 10-20, excess for future Required Volume, gallons 14045603 Calculated Retention Time, Days 9.4 Volume/Flow Depth, Low Water Level, ft 18.7 Design Decision Width/Length Ratio 0.46 Design Decision Side Slope 2:1 Design Decision Length@ Low water level,ft 524 Calculated Width@ Low water level,ft 242 .46 x Length Length@ bottom, ft 449 Calculated Width@ bottom, ft 167 Calculated Storage Depth, ft 4.3 Design Decision Storage Volume, MG 4,187,388 Calculated Total Lagoon Volume, gal 18,232,990 Calculated Length@ High Water Level, ft 541 Calculated Width@ High Water Level, ft 259 Calculated Freeboard, ft 2 Design Decision Total Depth, ft 25 Design Decision Length, inside bank, ft 549 Calculated Width, inside bank, ft 267 Calculated Process Removal Efficiency,BOD,% 73 Design Estimate, Typical 70-85% Lagoon Effluent BOD,ppm 400 Lagoon Effluent BOD Loading, lb/day 5004 Gold Kist - Sanford Table 3 Schreiber Simultech Design Analysis Item Schreiber Design BOD Removal Eff., % 98.75% BOD Load, lb/day 5004 TKN Removal Eff., % 95.83% TKN Load, lb/day 1501 02 Requirement, Ibs/lb BOD 1.2 TKN Requirement, lbs/lb TKN 4.6 BOD AOR, lb/day 6005 TKN AOR, lb/day 6906 Denitrification Credit 0.00% Total AOR, lb/day 12910 Total AOR, Ib/hr 538 Temperature, °C 20 Elevation, ft 55 Average Basin Depth,ft 16 Alpha 0.7 Beta 0.95 - Theta 1.024 Operating DO, mg/I 2 C-SC, mg/I (constant) 9.09 _. C-DC, mg/I (saturation @ site) 10.5 02 Transfer Adjustment Factor 0.61 Total SOR, lb/day 24779 _ Total SOR, Ib/hr 1032 Aeration Type Diffused 02 Transfer lb SOR/ hp-hr 5.1 _ Theoretical Aeration Horsepower 203.6 Installed Aeration Horsepower 240 (4@60 ea.) Aeration Basin Diameter,ft 160 _ Aeration Basin Water Depth,ft 16 Aeration Basin Volume, gal 2.406,697 Aeration Basin Detention Time, days 1.6 " Aeration Basin Detention Time, hrs 38.5 MLSS, ppm 4000 MLSS in System, Ibs 80,287 - Food/Microorganism Ratio 0.062 Aeration Basin Volume, fe 321,536 Aeration Basin Loading, lb BOD/1000 ft3 15.6 Sludge Production, lb/lb BOD removed 0.4 Sludge Production, lb/lb TKN removed 0.15 . Total Sludge Production, lb/day 3426 Sludge Age, days 36.1 WAS Solids Content, % 0.85 _ WAS Volume, gal/day 48,326 0 V.8 CHLORINATION/DECHLORINATION SYSTEM CAUTION: BOTH CHLORINE AND SULFUR DIOXIDE ARE TOXIC GASES. EXERCISE EXTREME CAUTION WHEN WORKING AROUND THE GAS CYLINDERS AND HANDLING EQUIPMENT. NEVER ENTER A BUILDING WHERE YOU SUSPECT A GAS LEAK MIGHT HAVE OCCURRED. EVACUATE THE IMMEDIATE AREA UNTIL THE GAS HAS DISSIPATED. To insure effluent from the facility contains no pathogenic bacteria, it must be disinfected with chlorine prior to discharge. Further, because of concern regarding the toxicity of chlorine itself, the effluent stream is also dechlorinated using sulfur dioxide gas, which strips the chlorine from solution. Components of the chlorination/dechlorination system are: • Chlorinator and sulfanator • Chemical water supply pumps • Chlorine and sulfur dioxide bottles • 35,000 gallons chlorination chamber • 11,000 gallons dechlorination chamber V.8.A. Chlorination/Dechlorination System Design Information The following summarize this system design data: 50 lb/day chlorine feed capacity 50 lb/day sulfur dioxide feed capacity 35,000 gallon chlorine contact volume 47 minutes chlorine contact time 10:1 L/W ratio in chlorine contact chamber V.8.B Chlorination/Dechlorination System Operation Filtered effluent enters the first chlorination channel at the northwest corner of the chamber. (See Figure 11). A chlorine solution is injected simultaneously at this point. The effluent then travels through remaining two channels. In the third channel. there are two submersible "Re -Use" . Goulds Model 11 RAH-C pumps, 1770 RPM, Curve 1168-4 (400 GPM @ 200' TDH). These pumps supply- chlorinated effluent water to various uses at the treatment and processing facility. 5-53 PRODUCTION DATA Gold Kist Inc. Sanford, North Carolina Pounds of Chicken Produced MONTH 1998-1999 1999-2000 2000-2001 March 14,816,550 18,453,735 19,960,782 April 18,175,542 23,256,978 24,873,680 May 16,666,652 19,802,563 21,118,157 June 16,559,422 18,320,927 19,927,791 July 21,151,042 25,182,201 23,166,521 August 16,656,053 19,337,769 19,625,608 September 16,073,305 20,127,567 18,522,854 October 22,973,576 25,903,490 23,872,781 November 16,599,334 19,353,107 18,048,571 December 16,272,247 1 22,943,241 18,615,147 January 24,203,189 19,524,739 February 18,744,944 1 19,569,349 17,502,527 Average 1891209470 Total 2173445,642 21,3719176 2093969597 25694549116 244,7599158 J r ! Gou) Kisr INc. 244 Perimeter Center Parkway, N.E. (30346-2397) • P.C. Box 2210, Atlanta, GA 30301-2210 • (770) 393-5000 November 14, 2000 Ms. Shannon Thornburg Environmental Engineer Division of Water Quality North Carolina Department of Environment and Natural Resources 1617 Mail Service Center Raleigh, NC 27699-1617 Re: Non -Discharge Permit Modification Permit No. WQ-0014565 Gold Kist Poultry Processing Plant Sanford, NC Dear Ms. Thornburg: Transmitted herewith is an executed permit modification application and four copies for the above referenced facility. The permit modification includes the addition of approximately 10,000 gallons a day of domestic wastewater and a tablet chlorination treatment system to the non -discharge permit WQ-0014565. As we discussed in our recent telephone conversation, I have omitted pages 5 and 6 of this application. The information requested on these pages can be found in the original permit application. Also included is a check in the amount of $325.00 to cover the permit processing fee. At present, the domestic waste stream is routed to the activated sludge treatment plant. The facility would like to recycle the treated water from the activated sludge plant back into the plant for feather flush water and other various plant uses. USDA regulations prohibit treated domestic wastewater to be used in this manner. We propose to re-route the domestic wastewater from the discharge of the existing septic tank through a tablet chlorination station and into the holding pond for the irrigation system where it would be mixed with treated process wastewater. It would pass through the aeration pond prior to being applied to the fields. No significant impact to the non -discharge spray irrigation treatment system is anticipated with the addition of this wastewater stream. Please see attached drawing • ,q r Y Ms. Thornburg Page 2 Thank you for all you help in this matter. If you have any questions or need additional information, please contact me at (770) 303-5205. Sincerely, 'Y""' M LUV Thomas M. Walsh Environmental Engineer Attachments cc: Mr. Glenn Berry w/o attach Mr. Bruce Morgan w/attach Mr. Scott Reynolds w/attach File: Sanford (3.3)