NC0072575_Staff Comments_19900508

DIVISION OF ENVIRONMENTAL MANAGEMENT
May 8, 1990
Memorandum
To:
Rosanne Barons
From:
Carla Sanderson L_(T
Through:
Trevor Clements V_
Subject:
Response to Golden Poultry
NPDES Permit No. NC0072575
Request for Modification
I am responding to the letter sent March 27, 1990 from Mr. John E. Starkey
concerning a modification of the NPDES permit for Golden Poultry. Technical
Support performed an analysis for the Golden Poultry discharge in February,
1988. Several scenarios of limitations were developed for the facility to
choose from which would not further degrade the water quality in the Deep River.
The facility cho(►se a set of limits necessary for their proposed plant perfor-
mance (i.e. 53.5 #/d BOD5 and 1.27 #/d NH3N monthly averages). Since Golden
Poultry has been in operation, they have discovered that another set of limita-
tions may be more applicable for their facility's performance. Therefore, the
previous analysis has been re-evaluated for the requested set of limitations to
check for protection of the water quality in the Deep River. Below, I have
listed the set of limitations for the requested modification of the Golden
Poultry Permit:
summer Winter
Mon Ave Dal Max Mon Ave Dal Max
BODS (#/d) 40 60 80 120
NH3N (#/d) 4.2 6.3 8.4 12.6
According to the permit sheets attached with the letter from Mr. Starkey, the
limits were not listed as recommended from Technical Support in February, 1988.
The Daily Maximum limitations were listed as 2 times the monthly average in the
attached permit for both the summer and winter months. Technical Support's
recommendation for daily maximum limits were 1.5 times the monthly average.
All other limitations in the NPDES permit should remain the same. Additional
limits may be adjusted when this permit is renewed in April, 1991.
If you have any questions concerning this matter, please let me know.
cc: Dale Overcash
Tim Donnelly
WLA File

R
ta, Ca 3030 2 etr�.E ors Ga 30_
March 27, 1990
�990
Mr. Donald Safrit
Supervisor, Permits and Engineering ..i(
NC Department of Environmental Management aFrl�E
3800 Barrett Drive
Raleigh, North Carolina 27687
Re: Golden Poultry Company
Sanford, NC NPDES #0072575
Per our recent conversation, attached you will find an NPDES
permit application and a $25.00 minor modification processing fee
for the referenced facility. Our purpose in filing for the
modification is to allow adjustment of our BOD and NH3 limits.
At the time of initial permit issuance, NCDEM developed various
BOD limits and ammonia limits necessary to protect instream water
quality. A table (attached) was prepared showing various BOD/NH3
limitation combinations. Golden was allowed to choose the
specific combination and chose summer time limits of 53.5 lb/day
BOD5 and 1.27 lb/day NH3-N. Winter limits were double those
above. We selected these limits based on literature values for
other overland flow treatment systems. To date, our BOD
performance has been significantly better than anticipated,
however, our ammonia performance has not been quite as good as
anticipated.
Consequently, we are requesting the permit be modified to list
the following limits.
Summer Levels
D NH
(Olb/day) (lb/day)
40 4.2
Winter Levels VN `.'i: �fL +;J�_
BO(lb/day) (N/day) J`��c`-�t1� ��-r•;�,., •.
80 8.4
Should you have any questions or comments concerning the above or
attached, or wish to meet to discuss this matter, please call.
Sincerely,
John E. Starkey, Manager
Environmental Engineering
[phone]
JES:er
Attachment
cc: Mr. Glenn Berry Mr. Matt Hopkins File 4001cWQ
Mr. James Brown Mr. Bruce Morgan
Telex: 6827213 Fax. [phone] Phone: [phone]

PRELIMINARY RESULTS WITH LIMITS TO PROTECT INSTREAM4 .•LATER QUALITY
GOLDEN POULTRY
WASTELOOD ALLOCATIONS WITH LOADS FOR NBOD AND CBOD
NBOD
CBOD
(#/D)
(#/D)
1.5
200
3.75
180
7.5
140
18.8
120
37.5
80
COMPLIANCE
VALUES
(SUMMER DISCHARGE)
BOD5
BOD5
NH3-N
NH3-N
(#/D)
(MG/L)
(#/D)
(MG/L)
67
40.2
0.33
0.2
60
36
0.83
0.5
47
28.2
1.7
1.0
40
24
4.2
2.5
27
16.2
8.3
5.0
TABLES SHOWING THE LEVEL B MODEL RESULTS
7Q10 = 17 CFS
WASTEFLOW = 0.2 MGD (020% OF DESIGN)

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SUPPLEMENTARY INFORMATION
GOLDEN POULTRY COMPANY
NPDES PERMIT APPLICATION
1. A description of the origin, type, and flow of waste which is
proposed to be discharged. Flow shall be determined in
accordance with Rule 2H. 0206(1) of this Chapter.
Golden Poultry Company owns and operates a chicken processing
plant in Lee County. The site for the new plant is located
approximately 8 miles north of Sanford, North Carolina off
N.C.S.R. 1400. Golden owns approximately 440 acres, two
sides of the property are bounded by the Deep River. The
plant is capable of processing 182 birds per minute, and
employs approximately 400 people.
Chicken processing is a water -intensive industry. Regula-
tions issued by the United States Department of Agriculture
specify minimal water uses in several areas of the processing
operation. Even a well managed plant with a good water
conservation program will use 11 to 12 pounds of water per
pound of chicken produced. The water use schematic included
in this permit package delineates where water is used.
Wastewaters generated by the processing plant will contain
the pollutants BOD5, TSS, oil and grease, organic nitrogen
and ammonia nitrogen. The approximate strength of that
wastewater following screening will be as follows:
BOD
1500
- 2000
mg/1
TSS
700
- 900
mg/1
FOGS-
300
- 500
mg/l
Organic
Nitrogen
110
- 140
mg/l
Ammonia
Nitrogen
15
- 30
mg/l
*Fats, Oils and Greases
Average daily flow from the processing plant will be
approximately 0.75 MGD. However, depending upon market
demand, up to 1.0 MGD may be discharged by the facility.
2. A summary of waste treatment and disposal options that were
considered and why the proposed system and point of discharge
were selected; the summary should have sufficient detail to
assure that the most environmentally sound alternative was
selected from the reasonably cost effective options.
A non -discharge system was investigated for this site.
However, as is described in detail in the August 1987
engineering report, permeability of soils at the site are not
adequate to handle a slow rate infiltration system for a
discharge of this size.
t

-2-
The Deep River at the discharge point has been modelled.
Effluent limits are based on this previous modeling.
3. A narrative description of the proposed treatment works in-
cluding type and arrangement of major components, in
sufficient detail to assure that the proposed facility has
the capability to comply with the permit limits; for commonly
used treatment system or components with well established
treatment capabilities, detailed plans and specifications
need not be submitted until the application for the authori-
zation to construct; however, detailed plans and specifica-
tions shall be required with the permit application for any
system or component without well established treatment
capabilities for the nature of waste or degree of treatment
needed to meet the permit limits.
The treatment train consists of primary screening dissolved
air flotation with chemical addition, overland flow, chlori-
nation and discharge: The wastewater treatment schematic is
included in this permit package. Storage is provided between
dissolved air flotation and overland flow to be utilized as
needed. Specifications for each treatment unit is as
summarized below.
Screening - Two 4' x1 O' shaker screens ( mesh 36x40) are
utilized on the offal line; three 4'x10' shaker screens (mesh
20x2O) are utilized on the feather line.
Dissolved Air Flotation with Chemical Addition - Screened
wastewater flows to a wet well where a ferric salt is
introduced for coagulation. Next, the wastewater is pumped
into a pressurization tank. Air is injected at the pump.
The wastewater is held in the pressurization tank for a
period of 1-2 minutes at approximately 40 psig, causing
injected air to go into solution. As the wastewater is
released into the flotation cell, an anionic polymer is
introduced. This causes flocculation of solids, blood and
grease in the wastewater. As the air comes out of solution,
these pollutants float to the surface. This float fat is
skimmed off for recovery by an off -site renderer. Wastewater
discharging from the DAF system has as minimum following
quality.
BOD
500
mg/l
TSS
500
mg/l
FOG
100
mg/l
Organic
Nitrogen
100
mg/l
Ammonia
Nitrogen
20
mg/l

-3-
Sizing of the dissolved air flotation unit is 30,000 gallons,
with 700 ft2 of surface area.
Overland Flow System (and storage) - Effluent from the DAF
system flows to a wet well. Pumps controlled by level
controllers, sprays the wastewater on the appropriate
overland flow field. A basin of approximately 1 million
gallons is connected to the wet well to handle any surge
flows and to provide temporary storage in the event of any
mechanical problems. This surge basin overflows to an
approximately 4-million gallon off-line storae basin, in the
event longer periods of storage are necessary.
The overland flow system encompasses 130 acres, sufficient
area to treat 1 MGD. An automatic control system will direct
flow to the appropriate fields. A more in-depth discussion
concerning overland flow is presented in the concept design
report included in previous application packages.
Chlorination and Monitoring - Effluent from the overland flow
system is collected, disinfected, flows through a Parshall
flume with a recording device, and then discharged to the
Deep River.
4. A general location map, showing orientation of the facility
with reference to at least two geographic references
(numbered roads, named streams/rivers, etc.).
Included elsewhere in this application package.
5. A scale location plan, of the site showing location of the
proposed treatment works and the proposed point of discharge.
Included elsewhere in this application package.