NCG500372_complete file-historical_20160113

Weaver, Charles
From:
Weaver, Charles
Sent:
Wednesday, January 13, 201611:21 AM
To:
'[e-mail]'
Cc:
'[e-mail]'; '[e-mail]'
Subject:
renewal of NCG500372 - Gastonia Division
Attachments: NCG50 Final 093015.pdf; Technical Bulletin - NCG500000 2015.doc
Importance: High
Attached you will find the updated version of NPDES General Permit NCG500000, effective 10/1/2015. Discard any
previous versions of the General Permit and use this version until further notice.
You do not need a reprinted Certificate of Coverage, as the one issued to you in 2012 is still applicable.
Thank you for your patience during the longer -than -expected renewal period.
If you have any questions about this matter, simply reply to this message.
Charles H. Weaver
Environmental Specialist
N.C. Division of Water Resources
N.C. Department of Environmental Quality
919-807-6391
chades.weaver(aMcdenr.nov
(physical address) 512 North Salisbury Street, Raleigh, NC 27604
(mailing address)1617 Mail Service Center, Raleigh, NC 27699-1617
0- /:!'Nothing Compares
Email correspondence to and from this address is subject to the North Carolina Public Records Law and may be disclosed
to third parties.

Weaver, Charles
From:
Vogler, Bob <[e-mail]>
Sent:
Wednesday, January 13, 201611:56 AM
To:
Weaver, Charles
Subject:
Read: renewal of NCG500372 - Gastonia Division
Attachments:
ATT00001; ATT00002.txt; ATT00003.htm
Importance: High
Your message
To: Vogler, Bob
Subject: renewal of NCG500372 - Gastonia Division
Sent: Wednesday, January 13, 201611:21:08 AM (UTC-05:00) Eastern Time (US & Canada)
was read on Wednesday, January 13, 201611:55:36 AM (UTC-05:00) Eastern Time (US & Canada).
1

(OKLEINFELDER
Bright Peopie. Right Solutions.
December 4, 2014
Mr. Mark Cassidy
Valley Proteins, Inc.
5533 York Hwy
Gastonia, NC 28052
RE: NPDES Permit Renewal Application
Valley Proteins Gastonia Division
Gastonia, Gaston County, North Carolina
Dear Mr. Cassidy:
RECEIVED
DEC 16 2014
CENTRAL FILES
DWR SECTION
As required under 15A NCAC 2H .0127(d), an application for renewal of existing coverage is
required for General Permit NCG500000. Please find enclosed four (4) copies of the Notice of
Renewal Intent (NORI) permit renewal application for your Gastonia, NC facility. The renewal
package includes necessary NORI application forms, detailed description of current treatment
provided to the wastewater before discharge, and two copies of a site map showing the pathway
of the discharge to the receiving stream.
Please sign the certification section of each copy of the NORI form, and submit two copies to
the North Carolina Department of Environment and Natural Resources (NCDENR), Division of
Water Resources (DWR), Water Permitting Section by January 30, 2015. No permit fee is
required. Each copy should be signed in blue ink. Keep one copy for your records, return one
copy to Kleinfelder, and submit two copies, post -marked on or before January 30, 2015, by
certified mail or overnight carrier to:
Mr. Charles Weaver
North Carolina Department of Environment and Natural Resources
Division of Water Resources
Water Permitting Section
1617 Mail Service Center
Raleigh, North Carolina 27699-1617
The Division of Water Resources is responsible for administering North Carolina's NPDES
Permitting and Compliance Program for wastewater that discharges directly to waters of the
state. Since the permit expires at midnight July 31, 2015, and Federal (40 CFR 122) and state
(15A NCAC 2H .0105(3)) regulations require that permit renewal application be submitted at
least 180 days prior to expiration of the current permit, the permits renewal due date is February
1, 2015.
00131914.000A/46/RAL14L10285 Page 1 December4, 2014
© 2014 Kleinfelder
3500 Gateway Centre Blvd. Suite 200, Morrisville, NC 27560 p 1919.755.5011 f 1919.756.1414

If you have any question, please call Linda Lamb with Kleinfelder at 919.755.5011, ext 102.
Sincerely,
KL€1 FELDE INC.
Da ry ssick
Project Professional
Attachment A: Notice of Renewal Intent (NORI)
Attachment B: Permit Renewal NOR[ Supplement
Attachment C: Site Map of Discharge Pathway
Cc: Mr. Bob Vogler, Valley Proteins, Winchester, VA
Linda M. Lamb, P.E.
Senior Professional
00131914.000A/46/RAL141-10285 Page 2
© 2014 Kleinfelder
December 4, 2014

ff�2
NCDENR
North Carolina Department of Environment and Natural Resources
Division of Water Resources
Pat McCrory Thomas A. Reeder John E. Skvarla, III
Governor Director Secretary
NOTICE OF RENEWAL INTENT
[Required by 15A NCAC 02H .0127(d)l; [term definition see 15A NCAC 02H .0103(19)]
Application for renewal of existing coverage under General Permit NCG500000
Existing Certificate of Coverage (CoQ: NCG500372
(Press Tab to navigate form)
1) Mailing address of facility owner/operator: (address to which all correspondence should be mailed)
Company Name Valley Proteins, Inc.
Owner Name Valley Proteins, Inc.
Street Address
City
Telephone #
Email Address
P.O. Box 3588
Winchester
State VA ZIP Code 22604 - 2586
540 - 877 - 2092 Fax # 540 - 877 - 3216
bvogler @ valleyproteins.com
2) Location of facility producing discharge:
Facility Name
Facility Contact
Street Address
City
County
Telephone #
Email Address
Valley Proteins Gastonia Division
Mark Cassidy
5533 York Highway
Gastonia
Gaston
State NC ZIP Code 28052 -
704 - 864 - 9941 Fax # 704 - 861 - 9252
mcassidy@ valleyproteins.com
3) Description of Discharge:
a) Is the discharge directly to the receiving stream?
❑ Yes
® No — Please submit a site map with the pathway to the potential receiving waters clearly marked. This
includes tracing the pathway of the storm sewer to the discharge point, if the storm sewer is the only
viable means of discharge.
b) Number of discharge outfalls (ditches, pipes, channels, etc. that convey wastewater from the property):
One 1
Page t of 3

NCG500000 Renewal Application
c) What type of wastewater is discharged? Indicate which discharge points, if more than one.
® Non -contact cooling water
❑ Boiler Blowdown
❑ Cooling Tower Blowdown
❑ Condensate
❑ Other
(Please describe "Other"):
Outfall (s) #: 001
Outfall (s) #:
Outfall (s) #:
Outfall (s) #:
Outfall (s) #:
d) Volume of discharge per each discharge point (in GPD):
#001: 300,000 GPD #002: GPD #003: GPD #004: GPD
4) Please check the type of chemical[s] added to the wastewater for treatment, per each separate discharge
point (if applicable, use separate sheet):
❑ Chlorine ❑ Biocides ❑ Corrosion inhibitors ❑ Algaecide ❑ Other ® None
If ggy box other than None is checked, a completed Biocide 101 Form and manufacturers' information on the
additive must be submitted to the following address for approval:
NC DENR / DWR / Environmental Sciences Section
Aquatic Toxicology Unit
1621 Mail Service Center
Raleigh, NC 27699-1621
5) Is there any type of treatment being provided to the wastewater before discharge? (i.e., retention ponds,
settling ponds, etc.)
® Yes - Please include design specifics (i.e., design volume, retention time, surface area, etc.) with submittal
package. Existing treatment facilities should be described in detail.
❑ No
6) Discharge Frequency:
a) The discharge is: ® Continuous ❑ Intermittent ❑ Seasonal
i) If the discharge is intermittent, describe when the discharge will occur:
ii) If seasonal, check the month(s) the discharge occurs:
❑ Jan ❑ Feb ❑ Mar. ❑ Apr ❑ May ❑ Jun ❑ Jul ❑ Aug. ❑ Sept. ❑ Oct. ❑ Nov. ❑ Dec.
b) How many days per week is there a discharge? Six
c) Please check the days discharge occurs: ® Sat. ❑ Sun. ® Mon. ® Tue. ® Wed. ® Thu. ® Fri.
Page 2 of 3

NCG500000 Renewal Application
Additional Application Requirements:
The following information must be included in duplicate [original + I copy] with this application or it
will be returned as incomplete.
➢ Site map. If the discharge is not directly to a stream, the pathway to the receiving stream must
be clearly indicated. This includes tracing the pathway of a storm sewer to its discharge point.
➢ Authorization for representatives. If this application will be submitted by a consulting
engineer (or engineering firm), include documentation from the Permittee showing that the
consultant submitting the application has been designated an Authorized Representative of the
applicant, per 15A NCAC 02H .0138(b)(1).
CERTIFICATION
I certify that I am familiar with the information contained in this application and that to the best of my
knowledge and belief such information is true, complete, and accurate.
Printed Name of Person Signing:
Title: General Manager
Mark Cassidy
(Please review 115A NCAC 02H .0106(e)/for authorized signing officials)
(Signature ofApplicant) (Date Signed)
North Carolina General Statute S 143-215.611 provides that:
Any person who knowingly makes any false statement representation, or certification in any application, record, report,
plan, or other document filed or required to be maintained under this Article or a rule implementing this Article; or
who knowingly makes a false statement of a material fact in a rulemaking proceeding or contested case under this
Article; or who falsifies, tampers with, or knowingly renders inaccurate any recording or monitoring device or method
required to be operated or maintained under this Article or rules of the Commission implementing this Article, shall be
guilty of a Class 2 misdemeanor which may include a fine not to exceed ten thousand dollars ($10,000). 18 U.S.C.
Section 1001 provides a punishment by a fine or imprisonment not more than 5 years, or both, for a similar offense.
This Notice of Renewal Intent does NOT require a separate fee.
The permitted facility already nays an annual fee for coverage under NCG500000.
Mail the original and one copy of the entire package to:
NC DENR / DWR / Water Permitting Section
1617 Mail Service Center
Raleigh, North Carolina 27699-1617
Attn: Charles Weaver
Page 3 of 3 Revised 911113

Valley Proteins
Gastonia, NC
Permit No. NCG500372
Permit Renewal NOI Supplement
Item
5. Treatment of Wastewater Before Discharge: Cooling Water Reservoir
Water is supplied to the reservoir via two pumps from Crowders Creek. The reservoir
supplies non -contact cooling water to process heat exchangers (shell and tube
condensers.) Water is pumped from the reservoir, through the condensers, and back to
the reservoir. The returning water is sprayed into the air, and falls onto the surface of
the reservoir to promote cooling. Both the spray and the surface of the reservoir provide
evaporative cooling. The reservoir discharges via rip -rap cascade into Crowders Creek,
generally along the railroad right-of-way, and enters the creek 50-100 feet upstream of
the cooling water intake. The surface area of the reservoir is approximately 2600 square
feet; the volume of the reservoir is approximately 115,000 gallons. Theoretical retention
time is 9.2 hours.
Additional Application Requirements
This application is for renewal of existing equipment, with no modification.

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\\ i NOTES: GASTONIA, NORTH CAROLINA
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ern
• NCDENR
North Carolina Department of Environment and Natural Resources
Division of Water Quality
Beverly Eaves Perdue
Governor
Mr. Mark Cassidy
Valley Proteins, Inc.
P.O. Box 3588
Winchester, VA 22604
Dear Mr. Cassidy:
Charles Wakild
Director
August 1, 2012
Dee Freeman
Secretary
Subject: Issuance under General Permit NCG500000
Certificate of Coverage (COC) NCG500372
5533 York Highway, Gastonia
Gaston County
In accordance with your application received on January 4, 2012, the Division hereby forwards this
Certificate of Coverage (CoC) to discharge under the subject general permit. We renew this CoC
pursuant to the requirements of North Carolina's General Statue 143-215.1 and the Memorandum of
Agreement between North Carolina and the US Environmental Protection Agency dated July 17, 2007
(or as subsequently amended).
If any parts, measurement frequencies or sampling requirements contained in this general permit are
unacceptable, you have the right to request an individual permit by submitting an individual NPDES
permit application. Unless such demand is made, this Certificate of Coverage shall be final and
binding.
Please note that this CoC is not transferable except after notice to the Division. The Division may
modify, or revoke and reissue this CoC. This issuance does not affect your legal obligations to obtain
other permits that may be required by the Division of Water Resources, the Division of Land
Resources, the Coastal Area Management Act, or any other Federal or Local government.
If you have any questions concerning this permit, please contact Joe R. Corporon L.G. at telephone
number [phone] or email 6cle.corporon&cderingov).
Sincerely,
[original issued electronically]
for Charles Wakild
cc: Mooresville Regional Office
NPDES General Permit Files
1617 Mail Service Canter. 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: w .ncxaterresources.org
None
rthCarolina
Naturally
An Equal Opportunity 1 Affirmative Action Employer

STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
DIVISION OF WATER QUALITY
General Permit NCG500000
Certificate of Coverage NCG500372
To discharge non -contact cooling water and similar wastewaters under the
NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM
(NPDES
In compliance with the provisions of North Carolina General Statute 143-215.1, other lawful standards and
regulations promulgated and adopted by the North Carolina Environmental Management Commission, and
the Federal Water Pollution Control Act, as amended,
Valley Proteins, Inc.
is hereby authorized to discharge wastewater from a facility located at
5533 York Highway
Gastonia
Gaston County
to receiving waters designated as Crowders Creek [stream segment [11-135], a waterbody currently classified C;
waters within subbasin 03-08-37 of the Catawba River Basin, in accordance with effluent limitations, monitoring
requirements, and other conditions set forth in Parts I, H, III and IV of the General Permit NCG500000, as attached.
This permit shall become effective August 1, 2012.
This Certificate of Coverage shall remain in effect for the duration of the General Permit.
Signed this day, August 1, 2012
fodg nal issued electronicallyl
Charles Wakild, Director
Division of Water Quality
By Authority of the Environmental Management Commission

FF%
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NCDENR
rn CAROLnw CSWPTWXW cY
F)-VSn1►t"-V01iq'UW RFSQJR:R.9
Division of Water Quality / Water Quality Section
National Pollutant Discharge Elimination System
NCG500000
Check
Pcmm t
NOTICE OF INTENT
National Pollutant Discharge Elimination System application for coverage under General Permit
NCG500000: Non -contact cooling water, boiler blowdown, cooling tower blowdown, condensate, and
similar point source discharges
(Please print or type)
1) Mailing address of ownerloperator:
Company Name Valley Proteins, Inc.
2)
3)
Owner Name Valley Proteins, Inc.
Street Address PO Box 3588
City Win _r _g _ _r State VA ZIP Code 22604-2586
Telephone No. 5 4-0 8 7 7- 2 0 9 2 Fax: [phone]
* Address to which all permit correspondence will be mailed
Location of facility producing discharge:
Facility Name Valley Proteins, Inc.
Facility Contact Michael Daniel
Street Address 5533 York Highway
City Gastonia State NC ZIP Code 28052
County Gaston
Telephone No. 704 864-9941 Fax: [phone]
Physical location information:
Please provide a narrative description of how to get to the facility (use street names, state road numbers,
and distance and direction from a roadway intersection). From Gastonia, NC go five miles south
on US321. After Robinson Rd. intersection, u-turn. Plant is on right at 5533 York Hwy.
(A copy of a county map or USGS quad sheet with facility clearly located on the map is required to be st bmitted•with-. t�h
-Y
4) This NPDES permit application applies to which of the following : f I'
❑ New or Proposed A - 4 2 G 12
❑ Modification
Please describe the modification: =niA_vATFR QUA1.1
® Renewal I�ollI r �_ Ui= CC 0�'.AP
Please specify existing permit number and original issue date: NCG5 0 0 3 72 July 23, 2007
5) Does this facility have any other NPDES permits?
❑ No
® Yes
If yes, list the permit numbers for all current NPDES permits for this facility: NCG06 0173
6) What is the nature of the business applying for this permit? By -Products, Animal
Do
Page 1 of 4
04/05

r,
NCG500000 N.0.1.
7) Description of Discharge:
a) Is the discharge directly to the receiving water? ❑ Yes ® No
If no, submit a site map with the pathway to the potential receiving waters clearly marked. This
includes tracing the pathway of the storm sewer to the discharge point, if the storm sewer is the only
viable means of discharge.
b) Number of discharge points (ditches, pipes, channels, etc. that convey wastewater from the
property): One (1)
c) What type of wastewater is discharged? Indicate which discharge points, if more than one.
® Non -contact cooling water Discharge point(s) M 001
❑ Boiler Blowdown Discharge point(s) #:
❑ Cooling Tower Blowdown Discharge point(s) #:
❑ Condensate Discharge point(s) #:
❑ Other Discharge point(s) M
(Please describe "Other")
d) Volume of discharge per each discharge point (in GPD):
#1: 300, 000 #2: #3: #4
e) Please describe the type of process (i.e., compressor, A/C unit, chiller, boiler, etc.) the wastewater is
being discharged from, per each separate discharge point (if applicable, use separate sheet):
Shell and Tube Condenser
8) Please check the type of chemical added to the wastewater for treatment, per each separate discharge
point (if applicable, use separate sheet):
❑ Biocides Name:
Manuf.:
❑ Corrosion inhibitors Name:
Manuf.:
❑ Chlorine Name:
Manuf.:
❑ Algaecide Name:
Manuf.:
❑ Other Name:
Manuf.:
s ,-1=
9) If any box in item (8) above, other than none, was checked, a completed Biocide 101 Form and
manufacturers' information on the additive is required to be submitted with the application for the
Division's review.
10) Is there any type of treatment being provided to the wastewater before discharge (i.e., retention, ponds,
settling ponds, etc.)? IN Yes ❑ No
If yes, please include design specifics (i.e., design volume, retention time, surface area, etc.) with
submittal package. Existing treatment facilities should be described in detail. Design criteria and
operational data (including calculations) should be provided to ensure that the facility can comply with the
requirements of the General Permit. The treatment shall be sufficient to meet the limits set by the
general permits.
Note: Construction of any wastewater treatment facilities requires submission of three (3) sets
of plans and specifications along with the application. Design of treatment facilities
must comply with the requirements of 15A NCAC 2H .0138. If construction applies to
this discharge, include the three sets of plans and specifications with this application.
Page 2 of 4 04/05

NCG500000 N.O.I.
11) Discharge Frequency:
a) The discharge is: 0 Continuous ❑ Intermittent ❑ Seasonalo
i) If the discharge is intermittent, describe when the discharge will occur:
ii) If seasonal check the month(s) the discharge occurs: ❑ Jan. ❑ Feb. ❑ Mar. ❑ Apr.
❑ May ❑ Jun. ❑ Jul. ❑ Aug. ❑ Sept. ❑ Oct. ❑ Nov. ❑ Dec.
b) How many days per week is there a discharge? Six (6 )
c) Please check the days discharge occurs:
® Sat. ❑ Sun. ® Mon. 13 Tue. ® Wed. El Thu. IN Fri.
12) Pollutants:
Please list any known pollutants that are present in the discharge, per each separate discharge point (if
applicable, use separate sheet): None
13) Receiving waters:
a) What is the name of the body or bodies of water (creek, stream, river, lake, etc.) that the facility
wastewater discharges end up in? If the site wastewater discharges to a separate storm sewer
system (4S), name the operator of the 4S (e.g. City of Raleigh). Crowders Creek
b) Stream Classification
C
14) Alternatives to Direct Discharge:
Address the feasibility of implementing each of the following non -discharge alternatives
a) Connection to a Municipal or Regional Sewer Collection System
b) Subsurface disposal (including nitrification field, infiltration gallery, injection wells, etc.)
c) Spray irrigation
The alternatives to discharge analysis should include boring logs and/or other information indicating that
a subsurface system is neither feasible nor practical as well as written confirmation indicating that
connection to a POTW is not an option. It should also include a present value of costs analysis as
outlined in the Division's "Guidance For the Evaluation of Wastewater Disposal Altematives".
15) Additional Application Requirements:
For new or proposed discharges, the following information must be included in triplicate with this
application or it will be returned as incomplete.
a) 7.5 minute series USGS topographic map (or a photocopied portion thereof) with discharge location
clearly indicated.
b) Site map, if the discharge is not directly to a stream, the pathway to the receiving stream must be
clearly indicated. This includes tracing the pathway of a storm sewer to its discharge point.
c) If this application is being submitted by a consulting engineer (or engineering firm), include
documentation from the applicant showing that the engineer (Or firm) submitting the application has
been designated an authorized Representative of the applicant.
d) Final plans for the treatment system (if applicable). The plans must be signed and sealed by a North
Carolina registered Professional Engineer and stamped -"Final Design -Not released for construction".
Page 3 of 4 04/05

NCG500000 N.O.I.
e) Final specifications for all major treatment components (if applicable). The specifications must be
signed and sealed by a North Carolina registered Professional Engineer and shall include a narrative
description of the treatment system to be constructed.
I certify that I am familiar with the information contained in this application and that to the best of my
knowledge and belief such information is true, complete, and accurate.
Printed Name of Person Signing: Mark Cassidy
Title: General Manager
C:�' �4= /-2 A. �
(Signature of Applicant) (Date Signed )
North Carolina General Statute 143-215.6 b (1) provides that:
Any person who knowingly makes any false statement, representation, or certification in any
application, record, report, plan or other document filed 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.)
Notice of Intent must be accompanied by a check or money order for $100.00 made payable to:
NCDENR
Mail three (3) copies of the entire package to:
NPDES Permits Unit
Division of Water Quality
1617 Mail Service Center
Raleigh, North Carolina 27699-1617
Final Checklist
This application will be returned as incomplete unless all of the following items have been
included:
® Check for $100 made payable to NCDENR
® 3 copies of county map or USGS quad sheet with location of facility clearly marked on map
IN 3 copies of this completed application and all supporting documents
❑ 3 sets of plans and specifications signed and sealed by a North Carolina P.E.
® Thorough responses to items 1-7 on this application
IN Alternatives analysis including present value of costs for all alternatives
Note
The submission of this document does not guarantee the issuance of an NPDES permit
Page 4 of 4 04/05

Valley Proteins
Gastonia, NC
Permit No. NCG500372
Permit Renewal NOI Supplement
Item
10. Cooling Water Reservoir
Water is supplied to the reservoir via two pumps from Crowders Creek. The reservoir
supplies non -contact cooling water to process heat exchangers (shell and tube
condensers.) Water is pumped from the reservoir, through the condensers, and back to
the reservoir. The returning water is sprayed into the air, and falls onto the surface of
the reservoir to promote cooling. Both the spray and the surface of the reservoir provide
evaporative cooling. The reservoir discharges via rip -rap cascade into Crowders Creek,
generally along the railroad right-of-way, and enters the creek 50-100 feet upstream of
the cooling water intake. The surface area of the reservoir is approximately 2600 square
feet; the volume of the reservoir is approximately 115,000 gallons. Theoretical retention
time is 9.2 hours.
14. Alternatives Analysis
a. Discharge to the Gastonia, NC Crowders Creek treatment plant is not feasible for
300,000 gpd of cooling water. Valley Proteins' pretreatment plant currently
discharges approximately 250,000 gpd directly to the Crowders Creek treatment
plant via a gravity Parshall flume, following the Valley Proteins lift station, stilling
well and metering station. This system would not accommodate an additional
300,000 gallons per day, and could not be reasonably replaced with equipment
to double the capacity for the purpose of routing non -contact water to
unnecessary treatment.
b. Subsurface disposal is not feasible given the soil structures present and the
wastewater volume to be treated. Subsurface exploration (soil boring) at the
Valley Proteins site confirms local soils are USCS classification "CH," described
as inorganic sandy clay. Application at hydraulic loading rates of 0.4 to 0.1 gpd /
sq. ft (North Carolina Long Term Acceptance Rates, per 15A NCAC 18A.1955),
results in a minimum required area of 750,000 sq. ft. of trench bottom. (Ref.
"Report of Subsurface Exploration and Geotechnical Recommendations, Valley
Proteins Vehicle Maintenance Facility, February 3, 2010, Kleinfelder Project
108513.31)
c. Spray irrigation is not feasible for the site for similar reasons. Poor clayey surface
soils, identified from USDA Soil Conservation Service Web Soil Survey 2.0 in
2007 of Gaston County, NC, include types CeD2 and CeB2, described as Cecil
Sandy Clay Loam: clay overlaying clay loam and sandy loam. At a suggested
hydraulic loading rate for infiltration of 0.3 gpd / sq. ft., the required surface area
would be over 23 acres of spray irrigation fields, excluding distribution systems
and buffers.

15. Additional Requirements
d and e. This application is for renewal of existing equipment, with no
modification. Engineer's sealed plans and specifications are therefore not
.required.

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CHECI EDRY: 5533 SOUTH YORK ROAD
'nOTE& GASTONIA. NORTH CAROLINA
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A_
NCDENR
North Carolina Department of Environment and Natural Resources
Division of Water Quality
Michael F. Easley, Governor William G. Ross, Jr., Secretary
Coleen H. Sullins, Director
July 23, 2007
Paul Humphries
Carolina By -Products
5533 South York Road
Gastonia, NC 28052
Subject: Renewal of coverage / General Permit NCG500000
Gastonia Division
Certificate of Coverage NCG500372
Gaston County
Dear Permittee:
In accordance with your renewal application [received on December 20, 2006], the Division is renewing
Certificate of Coverage (CoC) NCG500372 to discharge under NCG500000. This CoC is issued pursuant to the
requirements of North Carolina General Statue 143-215.1 and the Memorandum of Agreement between North
Carolina and the US Environmental Protection agency dated May 9, 1994 [or as subsequently amended].
If any parts, measurement frequencies or sampling requirements contained in this General Permit are
unacceptable to you, you have the right to request an individual permit by submitting an individual permit
application. Unless such demand is made, the certificate of coverage shall be final and binding.
Please take notice that this Certificate of Coverage is not transferable except after notice to the
Division. The Division may require modification or revocation and reissuance of the certificate of coverage.
Contact the Mooresville Reydonal Office prior to any sale or transfer of the permitted facility.
Regional Office staff will assist you in documenting the transfer of this CoC.
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, Coastal Area
Management Act or any other Federal or Local governmental permit that may be required.
If you have any questions concerning the requirements of the General Permit, please contact Jim
McKay [919 733-5083, extension 595 or [e-mail].
Sincerely,
Zoe— 72 4�
for Coleen H. Sullins
cc: Central Files
Mooresville Regional Office / Surface Water Protection
NPDES file
1617 Mail Service Center, Raleigh, North Carolina 27699.1617 One
512 North Salisbury Street, Raleigh, North Carolina 27604 NorthCarolina
Phone: [phone] / FAX [phone] / Internet: www.ncwaterquality.org a �� L L 1�N� l//�
An Equal Opportunity/AffinnativeAction Employer —50%Recycled/10%!//�/PostConsumerPaper

STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
DIVISION OF WATER QUALITY
GENERAL PERMIT NCG500000
CERTIFICATE OF COVERAGE NCG500372
TO DISCHARGE NON -CONTACT COOLING WATER, COOLING TOWER AND BOILER
BLOWDOWN, CONDENSATE AND SIMILAR WASTEWATERS UNDER THE
NATIONAL POLLUTANT DISCHARGE ELINUNATION 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,
Carolina By -Products
is hereby authorized to discharge from a facility located at
Gastonia Division
5533 S York Road
Gastonia
Gaston County
to receiving waters designated as Crowders Creek in subbasin 30837 of the Catawba River
Basin in accordance with the effluent limitations, monitoring requirements, and other
conditions set forth in Parts I, II, III and IV hereof.
This certificate of coverage shall become effective August 1, 2007.
This Certificate of Coverage shall remain in effect for the duration of the General Permit.
Signed this day July 23, 2007.
for Coleen H. Sullins, Director
Division of Water Quality
By Authority of the Environmental Management Commission

SOC PRIORITY PROJECT: Yes —No x .
If Yes, SOC No.
To: Permits and Engineering Unit
Water Quality Section
Attention: Charles Weaver
Date: June 11, 2007
NPDES STAFF REPORT AND RECOMMENDATION
County: Gaston
MRO# 07-27
Permit No. NCG500372
PART I - GENERAL INFORMATION
Facility and Address: Carolina By -Products, Gastonia Division
5533 S. York Road
Gastonia, North Carolina 28052
Date of Investigation: June 5, 2007
Report Prepared By: Samar Bou-Ghazale, Env. Engineer I
J U N 1 4 2007 L
DE.l - WA4E QIJ LnY
PO!i'ii SOUIiCE E:;,�;,�J{
4. Persons Contacted and Telephone Number: Mr. Van Jones, Manager, Tel # [phone].
Directions to Site: The facility is located on the northbound side of Highway 321
approximately 0.25 mile south of the junction of Highway 321 and SR 2416 in southern
Gaston County.
6. Discharge Point(s). List for all discharge points:
Latitude:35°10'09" Longitude:81'11'36"
Attach a U.S.G.S. map extract and indicate treatment facility site and discharge point on
map.
U.S.G.S. Quad No.: G 14 NW U.S.G.S. Name: Gastonia South, N.C.
7. Site size and expansion are consistent with application? Adequate land available for
expansion if necessary.
8. Topography (relationship to flood plain included): Facility is not located in a flood plain.
Slopes range from 3 to 8%.

9. Location of nearest dwelling: The nearest dwelling is greater than 500 feet from the
discharge location.
10. Receiving stream or affected surface waters: Crowders Creek.
a. Classification: C
b. River Basin and Subbasin No.: Catawba River Basin 03-08-37
C. Describe receiving stream features and pertinent downstream uses: The receiving
stream has good flow at the time of investigation. This stream originates within a
very industrialized area near the City of Gastonia and includes other permitted
dischargers. All other uses would be of an agricultural nature prior to the stream
entering the Catawba River (lake Wylie). A nearby municipal WWTP (Crowders
Creek WWTP) is located approximately 500 feet upstream of the discharge point.
PART II - DESCRIPTION OF DISCHARGE AND TREATMENT WORKS
1. a. Volume of wastewater to be permitted: 30,000.00 GPD
b. What is the current permitted capacity of the wastewater treatment facility?
30,000.00 GPD
C. Actual treatment capacity of the current facility (current design capacity)? N/A
d. Date(s) and construction activities allowed by previous Authorizations to
Construct issued in the previous two years: N/A
e. Please provide a description of existing or substantially constructed wastewater
treatment facilities: Existing WWT consists of a small retention pond to enhance
heat dissipation.
f. Please provide a description of proposed wastewater treatment facilities: N/A
g. Possible toxic impacts to surface waters: Biocide is not used at the facility.
h. Pretreatment Program (POTWs only): N/A
2. Sludge Handling and Disposal Scheme: N/A
3. Treatment plant classification (attach completed rating sheet): no rating
4. ' SIC Code(s): 2077
Wastewater Codes: . Primary: 14

PART III - OTHER PERTINENT INFORMATION
1. Is this facility being constructed with Construction Grant Funds or are any public monies
involved (municipals only)? N/A
2. Special monitoring or limitations (including toxicity) requests: N/A
3. Important SOC, JOC or Compliance Schedule dates: (please indicate): N/A
4. Air Quality and/or Groundwater concerns or hazardous materials utilized at this facility
that may impact water quality, air quality, or groundwater: No AQ or GW concerns not
are hazardous materials utilized at this facility.
PART IV - EVALUATION AND RECOMMENDATIONS
The applicant has requested permit renewal to continue the discharge of non -contact
cooling water. Water is pumped from Crowders Creek to a 2600 square feet reservoir. From this
reservoir water is pumped into a loop through condensers prior to returning to the reservoir. The
reservoir is used for cooling purposes.
Pending review and approval by P&E, it is recommended that the permit be reissued.
Signature of Repo rep
urface Water Protection Regional Supervisor
Date

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Gastonia Division
5533 South York Road
Gastonia, NC 28052
CAROLINA BY-PRODUCTS
A VALLEY PROTEINS COMPANY
December 12, 2006
Mr. Charles Weaver Jr.
NPDES Unit
NC Division of Water Quality
1617 Mail Service Center
Raleigh, NC 27699-1617
Subject: Certificate of Coverage NCG 500372
Carolina By -Products, Gastonia Division
Gaston County, NC
Dear Mr. Weaver:
[phone]
FAX: [phone]
Enclosed please find the application for the subject Certificate of Coverage renewal.
Should you have any questions please, let me know.
Sincerely,
Paul Humphries
General Manager
Enclosures
CC: Tom Gibson, VPI
RECYCLING. THE NATURE OF OUR BUSINESS SINCE 1928.

Reservoir
Water supplied to reservoir via 2 pumps from Crowders Creek. This reservoir is used to
supply non -contact cooling water to heat exchangers (condensers).
Water is pumped from reservoir and makes a loop through condensers back to reservoir.
Prior to returning to reservoir water is sprayed into the air. This water is deposited on the
surface of the reservoir. This spray and surface of reservoir is used for cooling
Reservoir discharges via rip -rap cascade into Crowders Creek.
Surface area of reservoir is approximately 2600 square feet. Volume of reservoir is
approximately 115, 000 gallons. Theoretical retention time is 9.2 hours.

NCDENR =
„�a-� ,
North Carolina Department of Environment an ce
Division of Water Qualitv
Michael F. Easley, Governor William G. Ross, Jr., Secretary
Alan W. Klimek, P.E., Director
NOTICE OF RENEWAL INTENT
Application for renewal of existing coverage under General Permit NCG500000
Existing Certificate of Coverage (CoQ: NCG500j7�
(Please print or type)
1) Mailing address' of facility owner/operator.
Company Name J 0-02y Pra k I rs <
Owner Name
Street Address
City
{1/iGS
s. Y'rk
�MS A, ; a State A/C ZIP Code -a80 S. -
Telephone Number
Z
g6 `%
99 N /
Fax: 17 6 `i FP6/ 9 z S -11
Email address
6 h"M,
4nr1.es
oQ- Jc.
t^s.ao�
Address to which all permit correspondence should be mailed
2) Location of facility producing discharge:
Facility Name
Facility Contact
Street Address
City
County
Telephone Number
Email address
i
n II State ZIP Code
C��Y6w
Fax:
3) Description of Discharge:
a) Is the discharge directly to the receiving stream? ❑ Yes "-10
(If no, submit a site map with the pathway to the potential receiving waters clearly marked. This includes tracing the pathway of the
storm sewer to the discharge point, if the storm sewer is the only viable means of discharge.)
b) Number of discharge outfalls (ditches, pipes, channels, etc. that convey wastewater from the property):
c) What type of wastewater is discharged? Indicate which discharge points, if more than one.
21N0n-contact cooling water
❑ Boiler Blowdown
Outfall(s) #: DO /
Outfall (s) #:
Page 1 of 3

NCG500000 renewal application
❑ Cooling Tower Blowdown
❑ Condensate
❑ Other
Outfall (a) #:
Outfall (s) #:
Outfall (s) #:
(Please describe "Other")
d) Volume of discharge per each discharge point (in GPD):
#001: O6 6aa #002: #003: #004
4) Please check the type of chemical [a] added to the wastewater for treatment, per each separate discharge
point (if applicable, use separate sheet):
❑ Chlorine ❑ Biocides ElCorrosion inhibitors ❑ Algaecide ❑ Other
H None
5) If any box in item (4) above [other than None] was checked, a completed Biocide 101 Form and
manufacturers' information on the additive must be submitted to the following address for approval:
NC DENR / DWQ / Environmental Sciences Section
Aquatic Toxicology Unit
1621 Mail Service Center
Raleigh, NC 27699-1621
6) Is there any type of treatment being provided to the wf tewater before discharge (i.e., retention ponds,
settling ponds, etc.)? 04,1es ❑ No F nc�o S ed
(If yes, please include design specifics (i.e., design volume, retention time, surface area, etc.) with submittal package. Existing
treatment facilities should be described in detail. )
7) Discharge Frequency:
a) The discharge is: P 6ontinuous ❑ Intermittent ❑ Seasonal*
i) If the discharge is intermittent, describe when the discharge will occur:
ii) *Check the month(s) the discharge occurs: 0 Jan ❑ Feb ❑ Mar. ❑ Apr 0 May ❑ Jun ❑ Jul
❑ Aug. ❑ Sept. ❑ Oct. ❑ Nov. ❑ Dec.
b) How many days per week is there a discharge? 5 "
c) Please check the days discharge occurs: M9 Sat. ❑ Sun. 2-kon. CYTue. famed. 9-Tfiu. B FYi.
S) Receiving stream[s]:
a) To what body or bodies of water (creek, stream, river, lake, etc.) does the facility discharge
wastewater? If the site discharges wastewater to a se crate storm sewer system (4S), name the
operator of the 4S (e.g. City of Raleigh). C f t w Q 1f S C!`4-u lL
b) Stream Classification:
Page 2 of 3

NCG500000 renewal application
Additional Application Requirements:
The following information must be included in triplicate [original + 2 copies] with this application or it will
be returned as incomplete.
➢ Site map. If the discharge is not directly to a stream, the pathway to the receiving stream must
be clearly indicated. This includes tracing the pathway of a storm sewer to its discharge point.
➢ Authorization for representatives. If this application will be submitted by a consulting
engineer (or engineering firm), include documentation from the Permittee showing that the
consultant submitting the application has been designated an Authorized Representative of the
applicant.
Certification
I certify that I am familiar with the information contained in this application and that to the best of my
knowledge and belief such information is true, complete, and accurate.
Printed Name of Person Signing: P 0' u- ] # n moo h r " e
Title: (`-e vura.l V Via n a C. ks
(Signature of
North Carolina General Statute 143-215.6 b (i) provides that:
l 2& he.
(.date Signed)
Any person who knowingly makes any false statement, representation, or certification in any application, record, report, plan or other document
filed 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.)
This Notice of Renewal Intent does NOT require a separate fee.
The permitted facility already pays an annual fee for coverage under NCG500000.
Mail the original and two copies of the entire package to:
Mr. Charles H. Weaver
NC DENR / DWQ / NPDES
1617 Mail Service Center
Raleigh, North Carolina 27699-1617
Page 3 of 3

State of North Carolina
Department of Environment
and Natural Resources
Division of Water Quality
Michael F. Easley, Governor
William G. Ross Jr., Secretary
Alan W. Klimek, P.E. Director
July 26, 2002
TOM GIBSON
CAROLINA BY PRODUCTS CO-GASTON
PO BOX 3588
WINCHESTER, VA 22603
1••
NCDENR
NORTH CAROLINA DEPARTMENT OF
ENVIRONMENT AND NATURAL RESOURCES
Subject: Reissue - NPDES Wastewater Discharge Permit
Carolina By Products Co -Gaston
COC Number NCG500372
Gaston County
Dear Permittee:
In response to your renewal application for continued coverage under general permit NCG500000, the Division of
Water Quality (DWQ) is forwarding herewith the reissued wastewater general permit Certificate of Coverage
(COC). This COC is reissued pursuant to the requirements of North Carolina General Statute 143-215.1 and the
Memorandum of Agreement between the state of North Carolina and the U.S. Environmental Protection Agency,
dated May 9, 1994 (or as subsquently amended).
The following information is included with your permit package:
* A copy of the Certificate of Coverage for your treatment facility
* A copy of General Wastewater Discharge Permit NCG500000
* A copy of a Technical Bulletin for General Wastewater Discharge Permit NCG500000
Your coverage under this general permit is not transferable except after notice to DWQ. The Division may require
modification or revocation and reissuance of the Certificate of Coverage. This permit does not affect the legal
requirements to obtain other permits which may be required by DENR or relieve the permittee from responsibility
for compliance with any other applicable federal, state, or local law rule, standard, ordinance, order, judgment, or
decree.
If you have any questions regarding this permit package please contact Aisha Lau of the Central Office Stormwater
and General Permits Unit at [phone], ext. 578
Sincerely,
for Alan W. Klimek, P.E.
cc: Central Files
Stormwater & General Permits Unit Files
Mooresville Regional Office
1617 Mail Service Center, Raleigh, North Carolina 27699-1617 Telephone [phone] FAX [phone]
An Equal Opportunity Affirmative Action Employer 50% recycled/ 10% post -consumer paper

STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
DIVISION OF WATER QUALITY
GENERAL PERMIT NO. NCG500000
CERTIFICATE OF COVERAGE No. NCG500372
TO DISCHARGE NON -CONTACT COOLING WATER, COOLING TOWER AND BOILER
BLOWDOWN, CONDENSATE AND SIMILAR WASTEWATERS 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,
CAROLINA BY PRODUCTS CO
is hereby authorized to discharge
NON -CONTACT COOLING WATER / CONDENSATE
water or similar wastewater from a facility located at
CAROLINA BY PRODUCTS CO-GASTON
5533 S. YORK RD
GASTONIA
GASTON COUNTY
to receiving waters designated as Crowders Creek, a class C water, in the Catawba River Basin in accordance
with the effluent limitations, monitoring requirements, and other conditions set forth in Parts I, II, III, and IV of
General Permit No. NCG500000 as attached.
This certificate of coverage shall become effective August 1, 2002.
This Certificate of Coverage shall remain in effect for the duration of the General Permit.
Signed this day July 26, 2002.
for Alan W. Klimek, P.E., Director
Division of Water Quality
By Authority of the Environmental Management Commission

State of North Carolina
Department of Environment
and Natural Resources
Division of Water Quality
James B. Hunt, Jr., Governor
Wayne McDevitt, Secretary
_. A. Preston Howard, Jr., P.E., Director
December 18, 1998
Mr. Van M. Jones
Carolina, By -Products Gastonia Division
5533 S. York Road
Gastonia, North Carolina 28052
Subject:
Dear Mr. Jones:
/••
NC ENP*
NORTH CAROUNA DEPARTMENT OF.
ENVIRONMENT AND NATuRAL RE50URCE5
General Permit NCG500000
Carolina By -Products Gastonua Division
Certificate of Coverage NCG500372
formerly Permit NC0005011
Gaston County
In accordance with your application for discharge permit received on September 29, 1998, we
are forwarding herewith the attached Certificate of Coverage to discharge under the subject NPDES
General Permit. This Certificate of Coverage is issued pursuant to the requirements of North Carolina
General Statute 143-215.1 and the Memorandum of Agreement between North Carolina and the US
Environmental Protection agency dated December 6, 1983. Issuance of this Certificate of Coverage
(NCG500372) terminates the previous permit for this facility (NC0005011)
If any parts, measurement frequencies or sampling requirements contained in this permit are
unacceptable to you, you have the right to request an individual permit by submitting an individual
permit application. Unless such demand is made, this Certificate of Coverage shall be final and
binding.
The Certificate of Coverage is not transferable except after notice to the Division. Use the
enclosed Permit Name/Ownership Change form to notify the Division if you sell or otherwise transfer
ownership of the subject facility. The Division may require modification or revocation and reissuance
of the Certificate of Coverage.
If your facility ceases discharge of wastewater before the expiration date of this permit, contact
the Regional Office listed below. Once discharge from your facility has ceased, this permit may be
rescinded. This permit does not affect the legal requirements to obtain other permits which may be
required by, the Division of Water Quality, the Division of Land Resources, Coastal Area Management
Act or any other Federal or Local governmental permit that may be required
P.O. Box 29535, Raleigh, North Carolina 27E2-C-.05S c%tc-i=sion 511 (fax) SiS 733-0719
An Equal Opportunity Affirmative Action Employer 50% recycled / 10% post -consumer paper

Carolina By -Products Gastonia Division
NCG500372
December 18, 1998
If you have any questions concerning this permit, please contact ANTONIO EVANS at
telephone number 919n33-5083, extension 584.
Sincerely,
ORIGINAL SIGNED WILLIAM C. MILLS
Y
VA. Preston Howard, Jr., P.E.
cc: Central Files
Point Source Compliance Enforcement Unit
Mooresville Regional Office
Stormwater and General Permits Unit
NPDES Unit

STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
DIVISION OF WATER QUALITY
GENERAL PERMIT NO. NCG500000
CERTIFICATE OF COVERAGE No. NCG500372
TO DISCHARGE NON -CONTACT COOLING WATER, COOLING TOWER AND BOILER BLOWDOWN,
CONDENSATE AND SIMILAR WASTEWATERS UNDER THE
NATIONAL POLLUTANT DISCHARGE ELEMNATION 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,
Carolina By -Products Resources
is hereby authorized to discharge (non -contact cooling , boiler blowdown, cooling tower blowdown, cooling waters
associated with hydroelectric operations) water from a facility located at
Carolina By -Products Resources
5533 S. York Road
Gastonia, NC
Gaston County
to receiving waters designated as Crowders Creek, Class C in the Catawba River Basin
in accordance with the effluent limitations, monitoring requirements, and other conditions set forth in Parts I, II,
III and IV hereof.
This certificate of coverage shall become effective December 18, 1998
This Certificate of Coverage shall remain in effect for the duration of the General Permit.
Signed this day December 18,1998

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