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Home My WebLink AboutNC0005126_Renewal Application_20180919ROY COOPER NORTH CAROLINA Governor Environmental Quality -WCiiiAEL S_ REG-AN Seoretm�.- LINDA CU-LPEPPER Interim Director September 19, 2018 Matthew Herman Tyson Farms Inc 180 Cabin Creek Rd Zirconia, NC 28790 Subject: Permit Renewal Application No. NC000S126 Tyson Farms, Inc. Iredell County Dear Applicant: The Water Quality Permitting Section acknowledges the September 19, 2018 receipt of your permit renewal application and supporting documentation. Your application will be assigned to a permit writer within the Section's NPDES WW permitting branch. Per G.S. 15OB-3 your current permit does not expire until permit decision on the application is made. Continuation of the current permit is contingent on timely and sufficient application for renewal of the current permit. The permit writer will contact you if additional information is required to complete your permit renewal. Please respond in a timely manner to requests for additional information necessary to allow a complete review of the application and renewal of the permit. Information regarding the status of your renewal application can be found online using the Department of Environmental Quality's Environmental Application Tracker at: https://deq.nc.gov/permits-regulations/permit-guidance/environmental-application-tracker If you have any additional questions about the permit, please contact the primary reviewer of the application using the links available within the Application Tracker. ec: WQPS Laserfiche File w/application Sincerely, Iv- 16�3 Q11 Wren Thedford Administrative Assistant Water Quality Permitting Section x�n� .,D_E� �PII .R11� O,Ki� North Carolina Department of Environmental Quality I Division of Water Resources 1617 Mail Service Center I Raleigh, North Carolina 27699-1617 919-807-6300 NPDES PERMIT APPLICATION — SHORT FORM C — Minor Industrial Minor industrial, manufacturing and commercial facilities. Mail the complete application to: N. C. Department of Environment and Natural Resources Division of Water Quality / NPDES Unit 1617 Mail Service Center, Raleigh, NC 27699-1617 NPDES Permit Number INCO005126 Please print or type. 1. Contact Information: Owner Name Tyson Farms, Inc. Facility Name Harmony Rendering Plant dba River Valley Animal Ingredients Mailing Address PO Box 158 City Harmony State / Zip Code NC, 28634 Telephone Number (704) 546-2602 RECEIVEI)MENRIDINR Fax Number (704) 546-5944 P1=P 1 q 2018 e-mail Address Kevin.haynes@tyson.com • �g-��SA1irC�� 2. Location of facility producing discharge: permitting Section Check here if same as above ❑ `Str`eet Address or State Road: 501 Sheffield Road City: Harmony State / Zip Code: NC/28634 County: Iredell 3. Operator Information: Name of the firm, consultant or other entity that operates the facility. (Note that this is not referring to the Operator in Responsible Charge or ORC) Name Tyson Foods, Inc. Mailing Address City State / Zip Code Telephone Number Fax Number 4. Ownership Status: Federal ❑ 2020 Don Tyson Parkway Springdale AR, 72765 (479) 290-4000 State ❑ Private ® Public ❑ Page 1 of 5 C-MI 10/08 NPDES PERMIT APPLICATION - SHORT FORM C - Minor Industrial Minor industrial, manufacturing and commercial facilities. S. Standard Industrial Classification (SIC) code(s): 2077 6. Number of employees: 98 7. Describe the treatment system List all installed waste treatment components with capacities, describe the processes that generate wastewaters. If the space provided is not sufficient attach a separate sheet of paper with the system description. Wastewater generated at the rendenering plant is treated by a waste activated sludge treatment system. The treatment system was designed based on the following wastewater sources: 1) feather cooker condensate 50,000gpd; 2) Meat cooker condensate 90,000gpd. 3) Truck wash, floor drainage, venturi and packed bed - scrubbers 60,000gpd; 4) Evaporator condensate 100,000gpd; all flows are based on 6 days/week. The wastewater treatment process is a waste activated sludge Modified Ludzack Endinger (MLE) treatment process for high efficiency nitrate removal. The system components consist of an 845,000 gallon FEB with one 25 HP surface aerator and course bubble diffusers; DAF Influent Pump Station; Pretreatment DAF unit; 1,250,000 gallon Anoxic Reactor #1A with one surface aerator and mixing system, 690,000 gallon Anoxic Reactor #113 with a jet aeration and mixing system and three 25 HP surface aerators; Reactor #1 Effluent Pump Station; 645,000 gallon Nitrification Reactor #2A with a 25 HP surface aerator and fine bubble diffusers, 645,000 gallon Nitrification Reactor #213 with a jet aeration and mixing system; 350,000 gallon Polishing Tank with a mixing system and jet aeration, Flocculation Tank; 264,000 gallon Final gravity clarifier; 4 MG Lagoon; RAS/WAS pump stations; and Chlorination/Dechlorination chamber. A flow diagram of the wastewater treatment process is attached. S. Is facility covered under federal effluent limitation guidelines? No ❑ Yes If yes, specify the category? Meat and Poultry - Subpart J Renderers 9. Principal product(s) produced: Chicken and pet food ingredients Principal raw material(s) consumed: Poultry by-products Briefly describe the manufacturing process(es): Rendering of poultry by-products including feathers, offal, and blood into chicken feed and pet food ingredients. Page 2 of 5 C-MI 10/08 NPDES PERMIT APPLICATION - SHORT FORM C - Minor Industrial Minor industrial, manufacturing and commercial facilities. 10. Amount of principal product produced or raw material consumed Lists eci c amounts consumed and/or units of roduction over the last three ears Product Produced or Raw Material Consumed AVERAGE Product Produced or Raw Material Consumed PEAK per Day 1,540,906 - Raw Material Consumed 1,737,614 - Raw Material Consumed per Month 46,869,232 - Raw Material Consumed 53,866,039 - Raw Material Consumed per Year 562,430,791 - Raw Material Consumed 1572,631,767 - Raw Material Consumed 11. Frequency of discharge: Continuous Z If intermittent: Days per week discharge occurs: Intermittent ❑ Duration: 12. Types of wastewater discharged to surface waters only Discharge Flow GALLONS PER DAY Sanitary - monthly average Utility water, etc. - monthly average Process water - monthly average 181,000 Stormwater - monthly average Other - monthly average Explain: Monthly Average total discharge (all types) 181,000 13. Number of separate discharge points: 1 Outfall Identification number(s) 001 14. Name of receiving stream(s) (Provide a map showing the exact location of each outfall, including latitude and longitude): Hunting Creek — lat 35 deg. 57' 16", long 80 deg. 43' 12" Page 3 of 5 C-MI 10/08 NPDES PERMIT APPLICATION - SHORT FORM C - Minor Industrial Minor industrial, manufacturing and commercial facilities. 15. Effluent Data [for new or proposed discharges] Provide data for the parameters listed. Temperature and pH shall be grab samples, for all other parameters 24-hour composite sampling shall be used. If more than one analysis is reported, report daily maximum and monthly average. If only one analysis is reported, report as daily maximum. NOTE: Permittees requesting renewal should complete the table ONLY for the parameters .v.rrof,tit. mn»itnred. Summarize the past 3 uears of effluent data. Parameter Daily Maximum Monthly Average Units of Measurement Biochemical Oxygen Demand (BOD5) 369.4 12.58 lbs./day Chemical Oxygen Demand (COD) Total Organic Carbon Total Suspended Solids 59.5 10.08 lbs./day Ammonia as N 265.07 9.38 lbs. / day Temperature (Summer) 35.0 28.8 °C Temperature (Winter) 27.3 18.4 °C pH 7.8 7.2 su Fecal Coliform (If sanitary waste is present) Total Residual Chlorine (if chlorine is used) 10 0 ug/L 16. List all permits, construction approvals and/or applications (check all that apply and provide permit numbers or check none if not applicable): Type Permit Number Type Permit Number Hazardous Waste (RCRA) UIC (SDWA) NPDES PSD (CAA) Non -attainment program (CAA) NESHAPS (CAA) Ocean Dumping (MPRSA) Dredge or fill (Section 404 or CWA) Other 17. List any chemicals that may be discharged (Please list and explain source and potential amounts.) Page 4 of 5 C-MI 10/08 NPDES PERMIT APPLICATION - SHORT FORM C - Minor Industrial Minor industrial, manufacturing and commercial facilities. 18. Is this facility located on Indian country? (check one) Yes ❑ No 19. Applicant Certification I certify that I am familiar with the information contained in the application and that to the best of my knowledge and belief such information is true, complete, and accurate. Gregg Wikstrom Plant Manager North Carolina General Statute 143-215.6 (b)(2) provides that: Any person who knowingly makes any false statement representation, or certification in any, application, record, report, plan, or other document files 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 $25,000 or imprisonment not more than 5 years, or both, for a similar offense.) Page 5 of 5 C-M 110/08 7 ---------------- E.0610 1 0 WASTEWATER EA 0 'A'KR TANK BDREEN 6 5 4 EXISTING D.A.F. CELL 3 2 1 MEN CONDENSATE EXISTING D D L - ----------- PRETREATMENT ATED F.E.B.F E.B. EMXSMG. A T 85MG* R= TUBE EXISTING DAF NFLUENT �$<?_r. PUMP STATION WASTE AC7NATE —DICE ------ DAF EFFLUENT0 XIC"✓FLOW t 0 CONDENSATE ",'EOUAUZATIC 4 'N W, EXISTING ANOXIC FLOW EOUALIZATION Nr uITRATe RECYCLE REACTOR.; COOLING POND EFFLUENT REACTOR No.IB .75MG EW RAW 4EAT---D- N.IA AND WEI 'ErWTE lul V-NWE*ATER JUNCTION c BOX ---------------------------- - ---- . ...... ................ - ------------------------- c --------------------------------- --------------------------- kmirlAul0i ----------- EIDVING llWP lE.RAllr PUMP no --------------------------------- --------------------------E ACTNATED----- pUWP VATLOk 13 REA EXISTING Nl.E RECYCLE AEROBIC NITRIFICATION REACTOR NO 2B 645MG 'oA EXISTING �REACTOR'--C, AA FINAL CLARIFIER 3 N EX";IN. EXISTING b 001 DISCHARGE POINT B f FLOCC TANK GLYCERINE CARBON SOURCE z� ED 11 REQUIRED EXISTING CHLORINE RECMLE CHAMBER , .ER TO PUNT EWERGEKT Elf -PASS MAY BE MOLAEO FOR ICITENDED PMODS OF NOT WEATHER PRodEoml FLOW DIACIRAM REID ENGINWW-G 06, PAI EXISTING AERATED COOLING POND (FOR EMERGENCY COOLING ONLY) A Won Foodp, Inc moo A WWKFATER TRIEWNENT SYS= "N BY. a UPGRADE Mon. BY m Ow. ' Ea- TF.W 8 7 6 5 4 3 2