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HomeMy WebLinkAboutNC0089621_NC0089621-CEI 2024_20240531 DocuSign Envelope ID:9206E8AE-15AO-41 B2-A5DD A89008857E26 ROY COOPER Govemor ELIZABETH S.BISER S—tary RICHARD E.ROGERS,JR. NORTH CAROLINA Director Envkvinmenra!Quallty May 31,2024 Novonesis NA, Inc. Tue Micheelsen,Regional President 77 Perrys Chapel Church Road Franklinton,NC 27525 Subject: Compliance Evaluation Inspection Novozymes NA, Inc. W WTP NPDES Permit NCO089621 Franklin County Dear Mr. Micheelsen: On May 8,2024,Danny Smith from the Raleigh Regional Office(RRO)of the Division of Water Resources(DWR)conducted a Compliance Evaluation Inspection(CEI)of the treatment facilities located at the Novozymes NA,Inc. facility in Franklinton,North Carolina. The purpose of this inspection was to ensure compliance with the subject NPDES permit. During the inspection,the presence and cooperation of Scott Creech-Team Supervisor,Operator in Responsible Charge(ORC), Kenneth Ball Technical Coordinator-Backup ORC(bORC),Jelena El Barigi-Technology Specialist,Jackie Batts-Progress Engineer,and Brooks Williams-Production Coordinator were helpful and appreciated. The Novozymes WWTP is located at 77 Perrys Chapel Church Road in Franklinton,North Carolina. The facility is a Grade IV Biological Water Pollution Control System with a permitted effluent wastewater flow of 2.0 MGD. Through NPDES permit NCO089621,the owner,Novonesis NA, Inc.,is authorized to discharge the treated wastewater through Outfal1001 to receiving waters designated as Cedar Creek,a waterbody classified as class C Nutrient Sensitive Waters(NSW)within the Tar-Pamlico River Basin. This NPDES Compliance Evaluation Inspection consisted of the following: • Review of the NPDES permit, • Review of the owner/facility information, • Review of December 2023-March 2024 monitoring data and compliance history; • On-site inspection of the wastewater treatment facility;and • On-site inspection of the discharge outfall. Findings during the pre-inspection file review were as follows: 1. Permit Renewal.The current NPDES permit was issued effective November 1,2020,and will expire July 31, 2024.A DWR file review confirmed the receipt of a permit renewal application on January 29,2024. 2. Permit Name/ownership change form. On February 7,2024, DWR received a name change request subject facility. The new owner's name is Novonesis and the new owner's signing official name and title is Tue Micheelsen,Regional President. D;7 North Carolina Department of Environmental Quality I Division of Water Resources igg Raleigh Regional Office 13800 Barrett Drive I Raleigh,North Carolina 276M �/ 919.7914200 DocuSign Envelope ID:9206E8AE-15A0-41 B2-A5DD-A89008857E26 1VOvozyrtmes iva, inc. CEI - NCO089621 Page 2 of 5 3. ORC designations.Novozymes NA, Inc.'s operator designations includes Scott O'Harold Creech ORC,Kenneth B. Ball bORC and Jonathan Brooks Williams bORC. All designated operators have a Grade 4 Certification and all have an active certification status. 4. Startup notification.A DWR file review confirmed the receipt of a letter dated November 27,2023, "Notification of the startup"for the Novozymes W WTP(NC0089621). 5. DMR review.A review of the Basinwide Information Management Systems(database)for the review period December 2023 through March 2024,confirmed no permit limit exceedances or failures to monitor have occurred. 6. Special Condition A. 2. Special Condition A.(2.)of the subject permit requires the permittee to perform instream monitoring of Dissolved Oxygen,pH,Conductivity,Potassium,Turbidity,and total Hardness. (Note: The upstream and downstream locations and monitoring frequencies for the above-mentioned analytes are listed in the permit text.) The permit states that the"If the permittee is a member of a monitoring coalition program,sampling of the instream parameters maya be waived as long as the monitoring coalition agrees to sample the required instream parameters at the frequency and location specified in the permit." Novozymes is conducting the upstream and downstream monitoring and maintaining this data as required by the permit. 7. Fees. The required Annual Administering and Compliance Monitoring Fee for the current billing period has been paid. There are no overdue fees. Findings during the inspection were as follows: 8. ORC Logbook. A log for the recording/documentation of daily plant operations is maintained. Daily operator log information is collected,scanned daily and is available for reference and use. 9. Lab Certifications. The Novozymes WWTP laboratory(certification number 5789)conducts the analyses for dissolved oxygen,pH,temperature,conductivity,and turbidity. Except for toxicity, Eurofins conduction analyses on all remaining analytes. ETT performs the chronic toxicity analysis. A cursory inspection of the meter calibration logs and standards,showed the laboratory to be compliant with record-keeping requirements. The YSI meter is sent out annually for meter calibration, including temperature. 10. Analytical result. The inspector reviewed/compared the reported January 2024 and February 2024 eDMR data against the bench lab data and analytical results. (Note: Start-up at the facility began in November 2023 and first process wastewater discharge occurred on December 5,2023.) For parameters listed as limits on the permit monitoring page,a review of the eDMR data revealed that for some analytes, analysis is repeated on more than one occasion for a given daily composite sample. In these instances,the highest result is reported/depicted on the eDMR. DE North Caroline Deparamnt of Environmental Quality I Division of water Resources Raleigh Regional Office 1 3800 Barrett Drive I Raleigh,North Carolnra 27609 a'.` r �� 919 791 4200 DocuSign Envelope ID:9206E8AE-15AO-41 B2-A5DD-A89008857E26 novozymes ica, inc. CEI- NCO089621 Page 3 of 5 Effluent sample results not listed on limits page. The effluent data review from Eurofins included final effluent sample results for several additional parameters(e.g.Arsenic, Sodium,COD, orthophosphate,dissolved silica). These additional parameters are not listed on the NPDES permit limit and monitoring page and the respective results were not reported on the eDMR. It is understood that a common practice for many WWTPs is to collect effluent data(process control information)beyond that as required by effluent limit page. There is no problem or concern with this practice. However,all final effluent samples results are required to be reported. When final effluent samples are collected and analyzed the following is required: 1) an appropriate EPA method is to be used for analysis, and 2)the final effluent results are required to be reported (submitted with eDMR). Please, re-submit(amend)your eDMRs for each applicable monthly report(eDMR). Include all final effluent data. (Specifically, the data you will need to address in the amended eDMRs are the sample results for the finale uent that were collected and not previously reported.) If you have any questions regarding this matter,please do not hesitate to contact Danny Smith or me at(919) 791-4200. 11. During the walk-through of the wastewater plant,the inspector observed the following: Initial treatment. -Grit removal, Influent flow meter, Primary Clarifier,Emergency Diversion Tank, Pre-Acidification Tank and Anaerobic Pretreatment. Activated sludge. - Wastewater flow to the activated sludge bioreactors is typically split 50150.Activated sludge bioreactors consist of two(2)tanks(each tank is 1 million gallons). There is also activated sludge tank,anoxic zone tank,and anaerobic zone tank. Membrane and Reverse Osmosis - Two(2)Membrane Bioreactors(Ultrafiltration) - Break tank(This tank is located prior to the RO units to ensure appropriate flow/inhibits surges) - Two(2)Reverse Osmosis units, RO reject tank and RO permeate tank. - Effluent flow meter(This meter is located downstream from permeate tank). Units were operable. System and operations area were clean and well maintained Sunnlemental Carbon. Facility has capacity to add supplemental carbon(acetic acid),as needed to the activated sludge bioreactor,activated sludge tank,and anoxic zone tank. Chemical additions/feeds.Chemical feeds/additions capacities include lime,caustic,sulfuric acid, and ferrous sulfate. Secondary Clarifier, Storage Lagoons: Discussion during the inspection revealed that Secondary Clarifier and Storage Lagoons are not specifically used in the NCO089621 discharge. These units D North Carolina Department of Environmental Quality I Division of Water Resources Raleigh Regional Office 1 3800 Barrett Dnve I Raleigh,North Carolina 27609 a �� 9197914200 DocuSign Envelope ID:9206ESAE-15A0-4182-A5DD-A89008857E26 Novozymes nA, inc. CEI- NCO089621 Page 4 of S are typically in use with Novozymes's permitted non-discharge wastewater treatment and industrial waste pretreatment system. Reject and waste activated sludge. The reject and waste sludge material is sent ack to through Novozymes' on-site Spent Residuals Biomass(SBM)process for disposal(non-discharge land application). Cascade aeration. Remote from Novozymes' main campus, located across Hwy 56 and adjacent to storage pond#3,is the cascade aeration system for the subject treatment system. Cascade aeration is performed and final effluent monitoring is conducted/collected at this location. As appropriate, secured access is provided. Both the treatment unit and the effluent sampler is fenced and locked. Cascade aeration should be added to the treatment system components list in the next permit renewal. (Mr. Creech explained that he thought that this item was addressed/included in the current permit renewal application) Outlet dissipater and Outfall 001. After the cascade aeration,the effluent pipe continues underground towards Cedar Creek. This outfall pipe(001)stops short of receiving stream. The effluent flow courses up through a screened off"wet-well/riser"onto a riprap apron level spreader. This dissipater pad allows the wastewater to diffuse flow to the stream,such that the effluent flow does not erode and scour the stream bank,stream bed or riparian zone(streamside area). It is recommended that this riprap outlet apron be identified as a treatment system component in next permit renewal. The outfall and dissipator pad were functioning well with no evident signs of streamside erosion, stream bank or stream bed rills or erosion occurring. 12. Flow measurement. The effluent flow meter calibration/documentation is conducted once a year. The effluent flow meter was checked/confirmed on October 12,2024,by Vigilantplant. No issues of concern were observed with the flow measurement. 13. Sampling. As required by the subject permit,influent and effluent sampling is achieved either by grab or composite sampling. The effluent composite sampler is set up to collect flow-proportional samples over a 24-hour period. The inspection revealed that an NIST calibrated thermometer is not in use for the effluent composite sampler(refrigerator). Please install a thermometer(NIST calibrated) to ensure that composite samples are properly collected and stored. Also,please maintain a log of the temperature readings to document proper sample collection. 14. Power. No backup generator(s)are in use to for WWTP plant operations. It was explained that the plant uses a dedicated transmission line. Facility operations are on a priority list for Duke Energy. 15. Outfall 001. The inspector observed the effluent discharge from the outfall pipe to Cedar Creek to be clear with no observable solids or foam. No observable detrimental impacts to the receiving waters from the effluent discharge were observed. D_E Q North Carolina Department of Environmental Quality I Division of Water Resources Raleigh Regional Office 1 3900 Barrett Drive I Raleigh.North Carolina 27609 �� 919 791 4200 DocuSign Envelope ID:9206E8AE-15A0-4182-A5DD-A89008857E26 Novozymes NH, inc. CEI - NCO089621 Page 5 of 5 The overall condition of the subject facility was compliant with the NPDES permit requirements as observed on the day of the inspection. If you have questions or comments about the inspection,this report or the requirements to take corrective action(if applicable),please contact Danny Smith at 919- 791-4248(dannv,smilh(&dcu.nc.gvv)or me at(919)791-4232(vanessa.manuebiideg.nc_aov). Sincerely, l)owBgnad W.CUo�In t,S& 1E, MUtti� BMGE6AMi"F. Vanessa E. Manuel,Assistant Regional Supervisor Water Quality Regional Operations Section Raleigh Regional Office Division of Water Resources,NCDEQ Attachment: EPA Water Compliance Inspection Report Cc: Laserfiche Ik North Carolina Departrnent of Environmental Quality I Division of Water Resources ERaleigh Regional office 13800 Barter Drive I Raleigh,North Carolina 27609 ' r 919.791 4200 DocuSign Envelope ID:9206E8AE-15A0-4182-A5DD-A89008857E26 United States Environmental Protection Agency Form Approved. EPA Washington,D.C.20460 OMB No.2040-0057 Water Compliance Inspection Report Approval expires 8-31-98 Section A:National Data System Coding(i.e.,PCS) Transaction Code NPDES yr/molday Inspection Type Inspector Fac Type 1 [� I 2 I! I 3 Nc0088621 11 121 24/05/08 J17 181�j 191 S I 201 I 21111111 1111111111111111111111111 11111111111 r Inspection Work Days Facility Self-Monitoring Evaluation Rating 131 QA -------------------Reserved---------- 67 70 U 71 I 1 72 L N ] 73I � I74 71 1 1 1 1 1 1 180 Section B: Facility Data l-1 L_L__I Name and Location of Facility Inspected(For Industrial Users discharging to POTW,also include Entry Time/Date Permit Effective Date POTW name and NPDES Derrnit Number) 10:OOAM 24/05/08 20111101 Novozymes NA,Inc. Exit Time/Date Permit Expiration Date 77 Perrys Chapel Church Rd Franklinton INC 27525 02:30PM 24/05/08 24/07/31 Name(s)of Onsite Representative(s)Mtles(s)/Phone and Fax Number(s) Other Facility Data /// Name,Address of Responsible OfficieVriitle/Phone and Fax Number Contacted Steve A Stadelman,PO Box 576 Franklinlon NC No 275250576//919-494-339019194943463 Section C:Areas Evaluated During Inspection(Check only those areas evaluated) Permit 0 Flow Measurement Operations&Maintenar ■Records/Reports Self-Monitoring Progran Sludge Handling Dispo: Facility Site Review M Compliance Schedules Effluent/Receiving Wate Laboratory Section D: Summary of Finding/Comments(Attach additional sheets of narrative and checklists as necessary) (See attachment summary) Name(s)and Signature(s)of Inspector(s) Agency/Office/Phone and Fax Numbers Date 13 w31gmd by: Stephen D Smith S" DWR/RRO WQ1919-791-4200/ 5/31/2024 3BIare. Signature of Managei u9$6 '0i6 Agency/Office/Phone and Fax Numbers Date VAIat,SSot '�. NlAtn�Ut� 5/31/2024 EPA Form 3560-3(Rev 9-94)Previous editions are obsolete. Page# t DocuSign Envelope ID:9206E8AE-15A0-41B2-A5DD-A89008857E26 NPDES yr/molday Inspection Type NO0089621 I11 1 24/05/08 17 18 I�, Section D: Summary of Finding/Comments(Attach additional sheets of narrative and checklists as necessary) Page# 2 DocuSign Envelope ID:9206E8AE-15A0-4162-A5DD-A89008857E26 permit: NCO089621 Owner-Facility: Novozymes NA, Inc. Inspection Date: 05/08/2024 Inspection Type: Compliance Evaluation Compliance Schedules Yes No NA NE Is there a compliance schedule for this facility? ❑ ■ ❑ ❑ Is the facility compliant with the permit and conditions for the review period? ❑ ❑ ❑ Comment: facilty does not have a compliance schedule Operations & Maintenance Yes No NA NE Is the plant generally clean with acceptable housekeeping? 0 ❑ ❑ ❑ Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable 0 ❑ ❑ ❑ Solids, pH, DO, Sludge Judge, and other that are applicable? Comment: Facilitty collect samples for pocess control. - see letter. Permit Yes No NA NE (If the present permit expires in 6 months or less). Has the permittee submitted a new 0 ❑ ❑ ❑ application? Is the facility as described in the permit? ❑ ❑ ❑ #Are there any special conditions for the permit? ■ ❑ ❑ ❑ Is access to the plant site restricted to the general public? ■ ❑ ❑ ❑ Is the inspector granted access to all areas for inspection? M ❑ ❑ ❑ Comment: There are few items to remove fromthe componets list in the pemrit and few items the inspector recommends adding (see letter) to components lists. The treatment system effectively matches the pemrit. Record Keepina Yes No NA NE Are records kept and maintained as required by the permit? 0 ❑ ❑ ❑ Is all required information readily available, complete and current? ■ ❑ ❑ ❑ Are all records maintained for 3 years(lab. reg. required 5 years)? M ❑ ❑ ❑ Are analytical results consistent with data reported on DMRs? 0 ❑ ❑ ❑ Is the chain-of-custody complete? ❑ ❑ ❑ ■ Dates, times and location of sampling ❑ Name of individual performing the sampling ❑ Results of analysis and calibration ❑ Dates of analysis ❑ Name of person performing analyses ❑ Transported COCs ❑ Are DMRs complete: do they include all permit parameters? ■ ❑ ❑ ❑ Page# 3 DocuSign Envelope ID:9206E8AE-15A0-4182-A5DD-A89008857E26 Permit: NCO089621 Owner-Facility: Novozymes NA,Inc. Inspection Date: 05/08/2024 Inspection Type: Compliance Evaluation Record Keepinsa Yes No NA NE Has the facility submitted its annual compliance report to users and DWQ? ❑ ❑ ■ ❑ (If the facility is=or> 5 MGD permitted flow) Do they operate 24/7 with a certified ❑ ❑ ■ ❑ operator on each shift? Is the ORC visitation log available and current? ■ ❑ ❑ ❑ Is the ORC certified at grade equal to or higher than the facility classification? ■ ❑ ❑ ❑ Is the backup operator certified at one grade less or greater than the facility ■ ❑ ❑ ❑ classification? Is a copy of the current NPDES permit available on site? ■ ❑ ❑ ❑ Facility has copy of previous year's Annual Report on file for review? ❑ ❑ ■ ❑ Comment: Novozvmes in an industrial facility. Effluent Pipe Yes No NA NE Is right of way to the outfall properly maintained? ■ ❑ ❑ ❑ Are the receiving water free of foam other than trace amounts and other debris? ■ ❑ ❑ ❑ If effluent (diffuser pipes are required) are they operating properly? ■ ❑ ❑ ❑ Comment: Flow Measurement- Effluent Yes No NA NE #Is flow meter used for reporting? ■ ❑ ❑ ❑ Is flow meter calibrated annually? ■ ❑ ❑ ❑ Is the flow meter operational? ■ ❑ ❑ ❑ (If units are separated) Does the chart recorder match the flow meter? ❑ ❑ ■ ❑ Comment: Chemical Feed Yes No NA NE Is containment adequate? ■ ❑ ❑ ❑ Is storage adequate? ■ ❑ ❑ ❑ Are backup pumps available? ❑ ❑ ❑ ■ Is the site free of excessive leaking? ■ ❑ ❑ ❑ Comment: Primary Clarifier Yes No NA NE Is the clarifier free of black and odorous wastewater? ■ ❑ ❑ ❑ Is the site free of excessive buildup of solids in center well of circular clarifier? ■ ❑ ❑ ❑ Page# 4 DocuSign Envelope ID:9206EBAE-15AO-41 B2-A5DD-A89008857E26 Permit: NCO089621 Owner-Facility: Novozymes NA,Inc. Inspection Date: 05/08/2024 Inspection Type: Compliance Evaluation Primary Clarifier Yes No NA NE Are weirs level? ❑ ❑ ❑ Is the site free of weir blockage? ❑ ❑ ❑ Is the site free of evidence of short-circuiting? ❑ ❑ ❑ ■ Is scum removal adequate? ❑ ❑ ❑ ■ Is the site free of excessive floating sludge? ❑ ❑ ❑ Is the drive unit operational? ❑ ❑ ❑ ■ Is the sludge blanket level acceptable? ■ ❑ ❑ ❑ Is the sludge blanket level acceptable? (Approximately %of the sidewall depth) ❑ ❑ ❑ Comment: Secondary Clarifier Yes No NA NE Is the clarifier free of black and odorous wastewater? ❑ ❑ ❑ Is the site free of excessive buildup of solids in center well of circular clarifier? ❑ ❑ ❑ 0 Are weirs level? ❑ ❑ ❑ Is the site free of weir blockage? ❑ ❑ ❑ 0 Is the site free of evidence of short-circuiting? ❑ ❑ ❑ ■ Is scum removal adequate? ❑ ❑ ❑ Is the site free of excessive floating sludge? ❑ ❑ ❑ Is the drive unit operational? ❑ ❑ ❑ ❑ Is the return rate acceptable (low turbulence)? ❑ ❑ ❑ ❑ Is the overflow clear of excessive solids/pin floc? ❑ ❑ ❑ ❑ Is the sludge blanket level acceptable? (Approximately %.of the sidewall depth) ❑ ❑ ❑ ❑ Comment: Effluent Sampling Yes No NA NE Is composite sampling flow proportional? ■ ❑ ❑ ❑ Is sample collected below all treatment units? 0 ❑ ❑ ❑ Is proper volume collected? 0 ❑ ❑ ❑ Is the tubing clean? M ❑ ❑ ❑ #Is proper temperature set for sample storage(kept at less than or equal to 6.0 ■ ❑ ❑ ❑ degrees Celsius)? Is the facility sampling performed as required by the permit(frequency, sampling type ■ ❑ ❑ ❑ representative)? Page# 5 DocuSign Envelope ID:9206E8AE-15A0-41 B2-A5DD-A89008857E26 Permit: NC0089621 Owner-Facility: Novozymes NA,Inc. Inspection Date: 05/08/2024 Inspection Type: Compliance Evaluation Effluent Samplings Yes No NA NE Comment: note: NIST calibrated thermometer is not in use for effluent composite sampler (refrigerator). This item is addressed in letter. Upstream I Downstream Sampling Yes No NA NE Is the facility sampling performed as required by the permit(frequency, sampling type, 0 ❑ ❑ ❑ and sampling location)? Comment: Page# 6