WQ0003449_Final Permit_19941205

State of North Carolina
Department of Environment,
Health and Natural Resources
Division of Environmental Management
James B. Hunt, Jr., Governor
Jonathan B. Howes, Secretary
A. Preston Howard, Jr., P.E., Director
Mr. Gerald W. Caughman, President
Power Sources, Inc.
9140 ArrowPoint Boulevard, Suite 370
Charlotte, NC 28273
Dear Mr. Caughman:
ffl1.9;WA
C)EHNFi
December 5, 1994
Subject: Permit No. WQ0003449
Power Sources, Inc.
Forest City Facility
Scrubber water Recycle System
Rutherford County
In accordance with your application received October 12, 1994, we are forwarding herewith Permit
No. WQ0003449, dated December 5, 1994, to Power Sources, Inc. for the continued operation of the
subject wastewater recycle system.
This permit shall be effective from the date of issuance until November 30, 1999, and shall be
subject to the conditions and limitations as specified therein. Please pay particular attention to the
monitoring requirements in this permit. Failure to establish an adequate system for collecting and
maintaining the required operational information will result in future compliance problems.
If any parts, requirements, or limitations contained in this permit are unacceptable, you have the
right to request an adjudicatory hearing upon written request within thirty (30) days following receipt of
this permit. This request must be in the form of a written petition, conforming to Chapter 150B of North
Carolina General Statutes, and filed with the Office of Administrative Hearings, P.O. Drawer 27447,
Raleigh, NC 27611-7447. Unless such demands are made this permit shall be final and binding.
If you need additional information concerning this matter, please contact Mr. Randy Kepler at
[phone].
Sincerely,
iQ .rylc
A. Pres Howard, Jr., P.E.
cc: Rutherford County Health Department
Asheville Regional Office, Water Quality. --
-Training and Certification Unit ,�.►
Facilities Assessment Unit
P.O. Box 29535, Raleigh, North Carolina 27626-0535 'telephone [phone] FAX [phone]
,do= An Equal Opportunity Affirmative Action -Employer 50% recycled/ 10% post -consumer paper

NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT COMMISSION
DEPARTMENT OF ENVIRONMENT, HEALTH AND NATURAL RESOURCES
RALEIGH
RECYCLE SYSTEM PERMIT
In accordance with the provisions of Article 21 of Chapter 143, General Statutes of North Carolina as
amended, and other applicable Laws, Rules, and Regulations
PERMISSION IS HEREBY GRANTED TO
Power Sources, Inc.
Rutherford County
MOS -19-0
continued operation of a scrubber water recycle system consisting of a 10,000 square foot concrete
recirculation/settling basin, a 300 GPM recirculation pump, and all the associated valves, piping, and
appurtenances to serve Power Sources, Inc. -Forest City Plant, with no discharge of wastes to the surface
waters, pursuant to the application received October 12, 1994, and in conformity with the project plan,
specifications, and other supporting data subsequently filed and approved by the Department of
Environment, Health and Natural Resources and considered a part of this permit.
This permit shall be effective from the date of issuance until November 30, 1999, and shall be
subject to the following specified conditions and limitations:
1. This permit shall become voidable unless the facilities are constructed in accordance with
the conditions of this permit, the approved plans and specifications, and other supporting
data.
2. This permit is effective only with respect to the nature and volume of wastes described in
the application and other supporting data.
3. The facilities shall be properly maintained and operated at all times.
4. This permit is not transferable. In the event there is a desire for the facilities to change
ownership, or there is a name change of the Permittee, a formal permit request must be
submitted to the Division of Environmental Management accompanied by an application
fee, documentation from the parties involved, and other supporting materials as may be
appropriate. The approval of the request will be considered on its merits and may or may
not be approved.
5. In the event that the facilities fail to perform satisfactorily, including the creation of
nuisance conditions, the Permittee shall tape immediate corrective action, including those
actions that may be required by this Division, such as the construction of additional or
replacement treatment or disposal facilities.

j
6. The residuals generated from these treatment facilities must be disposed in accordance with
General Statute .143-215.1 and in a manner approved by the North Carolina Division of
Environmental Management.
7. The issuance of this permit shall not relieve the Permittee of the responsibility for damages
to surface or groundwaters resulting from the operation of this facility.
8. The facilities shall be effectively maintained and operated as a non -discharge system to
prevent the discharge of any wastewater resulting from the operation of this facility.
9. Diversion or bypassing of untreated wastewater from the treatment facilities is prohibited.
10. Freeboard in the recirculation basin shall not be less than two feet at any time.
11. Any monitoring deemed necessary by the Division of Environmental Management to insure
surface and ground water protection will be established and an acceptable sampling
reporting schedule shall be followed.
12. Adequate inspection, maintenance, and cleaning shall be provided by the Permittee to
insure proper operation of the subject facilities.
13. The Permittee or his designee shall inspect the wastewater recycle facilities to prevent
malfunctions and deterioration, operator errors and discharges which may cause or lead to
the release of wastes to the environment, a threat to human health, or a nuisance. The
Permittee shall maintain an inspection log or summary including at least the date and time of
inspection, observations made, and any maintenance, repairs, or corrective actions taken by
the Permittee. This log of inspections shall be maintained by the Permittee for a period of
three years from the date of the inspection and shall be made available to the Division of
Environmental Management or other permitting authority, upon request.
14. Any duly authorized officer, employee, or representative of the Division of Environmental
Management may, upon presentation of credentials, enter and inspect any property,
premises or place on or related to the recycle system at any reasonable time for the purpose
of determining compliance with this permit, may inspect or copy any records that must be
maintained under the terms and conditions of this permit, and may obtain samples of
groundwater, surface water, or leachate.
15. The annual administering and compliance fee must be paid by the Permittee within thirty
(30) days after being billed by the Division. Failure to pay the fee accordingly may cause
the Division to initiate action to revoke this permit as specified by 15A NCAC 2H .4205
(c)(4).
16. Failure to abide by the conditions and limitations contained in this permit may subject the
Permittee to an enforcement action by the Division of Environmental Management in
accordance with North Carolina General Statute 143-215.6(a) to 143-215.6(c).
17. The issuance of this permit does not preclude the Permittee from complying with any and
all statutes, rules, regulations, or ordinances which may be imposed by other government
agencies (local, state, and federal) which have jurisdiction.
18. A set of approved plans and specifications for the subject project must be retained by the
Permittee for the life of this project.
2

19. Noncompliance Notification:
The Permittee shall report by telephone to the Asheville Regional Office, telephone number
704-251-6208, as soon as possible, but in no case more than 24 hours or on the next
working day following the occurrence or first knowledge of the occurrence of any of the
following:
a. Any occurrence at the wastewater treatment facility which results in the treatment of
significant amounts of wastes which are abnormal in quantity or characteristic, such as
the dumping of the contents of a basin or tank, the known passage of a slug of
hazardous substance through the facility, or any other unusual circumstances;
b. Any process unit failure, due to known or unknown reasons, that renders the facility
incapable of adequate wastewater treatment, such as mechanical or electrical failures of
pumps, aerators, compressors, etc.;
c. Any failure of a pumping station, sewer line, or treatment facility resulting in a by-pass
directly to receiving waters without treatment of all or any portion of the influent to
such station or facility; or
d . Any time that self-monitoring information indicates that the facility is not in compliance
with its permit limitations.
Persons reporting such occurrences by telephone shall also file a written report in letter
form within 15 days following first knowledge of the occurrence. This report must outline
the actions taken or proposed to be taken to ensure that the problem does not recur.
20. Upon classification of the facility by the Certification Commission, the Permittee shall
employ a certified wastewater treatment plant operator to be in responsible charge (ORC) of
the wastewater treatment facilities. The operator must hold a certificate of the type and
grade at least equivalent to or greater than the classification assigned to the wastewater
treatment facilities by the Certification Commission. The Permittee must also employ a
certified back-up operator of the appropriate type and grade to comply with the conditions
of Title 15A, Chapter 8A, .0202. The ORC of the facility must visit each Class I facility at
least weekly and each Class II, III, and IV facility at least daily, excluding weekends and
holidays, and must properly manage and document daily operation and maintenance of the
facility and must comply with all other conditions of Title 15A, Chapter 8A, .0202.
21. The Permittee, at least six (6) months prior to the expiration of this permit, shall request its
extension. Upon receipt of the request, the Commission will review the adequacy of the
facilities described therein, and if warranted, will extend the permit for such period of time
and under such conditions and limitations as it may deem appropriate.
Permit issued this the fifth day of December, 1995
NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION
ryys- (LL-
A. Preston oward, Jr., .E., Director
Division of nvironmental Management
By Authority of the Environmental Management Commission
Permit No. WQ0003449
3

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SCALE FOR CLASSIFICATION OF WATER POLLUTION CONTROL SYSTEMS
XA,ne of Facility:�—
owner or Contact Person: �y CL 1'7r t:= ;- i!4 k 4:- /7c x
Mailing Address: u.; yrt� ' �' ! - '= C'/+AR' 'c %L'C zti7 7 3
County:1 s._lrt'-cl_ Telephone:
Present Classification: New Facility Existing Facility
NPDES Per. No. NC00 Nondisc. Per. Nc,.WC Health Dept.Per No.
Rated by: P,AFZO Telephone: nr.ei--2;;_ `xc°!� Date: // %y 7y
Reviewed by: Health Dept. Telephone:
Regional Office Telephone:
Central Office Telephone:
•• .•- -• •
Check Class if •n (s): Subsurface Sprays. • • Application
•
Wastewater • •ne) ('
11 111 IV Total Points:
PLANT -iL! AN D PF1 AIM 2Qft21lQL780ttru ENI alsICH ARE AN INTEGRAL PART OF N DUSIRIAL Pi•D . 1Q\ SHLALL NOT BE
�•,f,�1 fa E : • V III` EAT.1 e,,rr FOR VE IJ ii &•- E OF ZQATA11. A[ SO ` E 10%4 S -1 -0 -ON S I 9 *VLY-QESE J1.
SUBSURFACE CLASSI FCATiON
(check alt units that apply)
1. septic tanks
2. pump tanks
3. siphon or pump -dosing systems
4. sand filters
5. grease trapfinterceptor
6. oillwater separators
7. gravity subsurface treatment and disposal:
B. pressure subsurface treatment and disposal;
SPRAY IRRIGATION CXP.SSIF]CATION
(check all units that apply)
1.
preliminary treatment (definition no. 32 }
2.
lagoons
3.
sept€c tanks
4,
pump tanks
5.
pumps
6.
sand fillers
7.
grease trap/interceptor
8.
oil/water separators
g.
disinfection
10.
chemical addition for nutrient/algae control
11.
spray irrigation of wastewater
In addition to the above classificat€ons, pretreatment of wastewater In excess of these components shell
be rated using the point rating system and will require an ^operator with an appropriate dual certification.
LAND APPLICATION/RESIDUALS CLASSIFICATION (Applies only to permit holder)
1. Land application of biosolids, residuals or contaminated soils on a designated site,
WASTEWATER TREATMENT FACILITY CLASSIFICATION
The following systems shall be assigned a Class I classification, unless the flow is of a significant quantity or the technology is unusually
complex, to require consideration by the Commission on a case-by-case basis: (Check if Appropriate)
1. Oil/water Separator Systems consisting only of physical separation, pumps and disposal;
2. Seplic Tank/Sand Filter Systems consisting only of septic tanks, dosing apparatus, pumps,sand filters, disinfection
and direct discharge;
3. Lagoon Systems consisting only of preliminary treatment, lagoons, pumps, disinfection, necessary chemical treatment for
algae or nutrient control, and direct discharge;
4.- ` Closed-loop Recycle Systems;
5. Groundwater Remediation Systems consisting only of olllwater separators, pumps, air -stripping, carbon adsorption, disinfection
and dispo ,.i;
6. Aquaculture operations with discharge to surface waters;
7. Water Plant sludge handling and back -wash water treatment;
8. Seafood processing consisting of screening and disposal.
9. Single-family discharging systems, with the exception of Aerobic Treatment Units, will be classified if permitted after July 1,
1993 or 4 upon inspection by the Division, it is found that the system is not being adequately operated or maintained. Such
systems will be notified of the classification or reclassification by the Commission, in writing.

The following scale is used for rating wastewater treatment facilities: (circle appropi,
ITEM POW .
( 1 )
Industrial Pretreatment Units or Industrial Pretreatment Program (see dellnhion No. 331 ...................................................4
(2)
DESIGN FLOW OF PLANT ;`: gpd (rat zppl:cabla to nn—cnntam;nated cooling waters, sludge handling faciH;" for
water purification plants, totally closed cycle systams(see definh4on No. 11), and facilities consisting only of item
(4)(d) or Items (4)(d) and (11)(d))
0 - 20,000 ......................................... ..............................................................................,................ i
20.001 - 50,000......................................................................................................................................2
50.001 - 100.000 ................ ....................................................................................................3
100,001 - 250,000 ................. .....................................................................................4
250,001 - 500,000...................................................................................................................................5
500.001 1,OOC.000................. ........................................................................8
1,000,001 - 2.000.000 .......................................... ....................................................... ..— ........ ..10
2,000.001 (and up) rate 1 point additional for each 200,000 gpd capacity up to a maximum of .................30
Design Flow (gpd)
(3)
PRELIMINARY
UNITS/PROCESSES (sae definition No.32)
(a)
BwScreens......................................................................................................................................1
or
(b)
Mechanical Screens, Slatic Screens or Comminuting Dev€ces............ .............................................................. 2
(c)
Grit Removal..............................................................................................................................................1
or
(d)
Mechanical or Aerated Grit Removal.............................................................................................................2
(a)
Flow Measuring Devito ................... ........................... ................. ........................................................ I........ t
or
(1)
Instrumented Flow Measurement................................................................................................................2
(g)
Praaeratlon...............................................................................................................................................2
(h)
Influent Flow Equaiizatlon..........................................................................................................................2
(i)
Grease or Oil Separators - Gravity.................................................................................................................2
Mechanical., ...................,.........................................................................................3
DlssolvadAir Flotation................................................................................................................................a
(I}
Prechtortnation..........................................................................................................................................5
(4)
PRlMARYTREATMENT t NUS43ROCESSES
(a)
Septic Tank (sea definition No. 43). ............................................................................................................ 2
(b)
Imhoff Tank...............................................................................................................................................5
(c)
Primary Clariliers.........................................................................................................................................5
(d)
Settling Ponds or Settling Tanks for Inorganic Non-loxk Materials (sludge handling facilities for water
pur'rfical;on plants, sand, gravel, stone, and other mining operations except recreational activities such as gem
orgold mining).........................................................................................................:..............................2
(5)
SECONDARY TREATMENT LN7&rPFKDCESSES
(a)
Carbonaceous Stage
(i) Aeration-Wlgh Purity Oxygen System...............................................................................20
Diffused Air System................................................................................:......................1 0
Mechanical Air System (lixed, floating or rotor)..................................................................8
SeparateSludge Reaerwlon.............................................................................................3
(II) Trickling Flher
HighRate.......................................................................................................................7
StandardRata...............................................................................................................5
PackedTower., ...... .............................................................. ..5
(lit) Biological Aerated Filter or Aerated Biological Filter............................................................1 0
(iv) Aerated Lagoons. ......................................................................................................... 10
(v) Rotating Biological Coniactors......................................................................................10
(vi) Sand Filters -intermittent biological..................................................................................2
Recirculatingbiological.....................................................................................................3
(vii) Stabilization Lagoons....................................................................................................5
(viii) Clarfor...........................................................................................................................5
(Ix) Single stage system for combined carbonaceous removal of BOD and nitrogenous removal by
nitrification (&a% definition No, 12)(Poinis for this hem have to be in addhicn to nems
(5)(a)(1) through (5)(a)(vlii),
u1111zIng the extended aeration process (see definition No.3a)...........................................2
utilizing other than the extended aeration process .... .................. ............................. ..... ...5
(x) Nutrient additions to enhance BOO removal......................................................................5
(X 1) Biological Culture ('Super Bugs')addition........................................................................5
(b)
Nitrogenous Stage
(1) Aeration - High Purity Oxygen System.............................................................................20
DiffusadAir System.......................................................................................................1 0
Mechanical Air System (fixed, floating or rotor)..................................................................8
Separate Sludge Reaeration.............................................................................................3
(ll) Trickling Filter -High Rate...................................................................................................7
Standard Rate...............................................................................................................5
PackedTower.............................................................................----...............................5
(111) Biological Aerated Fiffer or Aerated Biological Fher..... ................................... .................... 1 0
(Iv) Rotating Biological Conlactors.............................................................................:........1 0
(v) Sand Filter - Inierminent biological...................................................................................2
Recirculating biological.....................................................................................................3
(VI) clarfTiar...........................................................................................................................5
(8)
TERTIARY OR ADVANCED TREATMENT UNIT&PROCESSES
(a)
Activated Carbon Beds -
without carbon regeneration. ................................................................... .........................
with carbon regeneration..........................................................................»...........................16
(b)
Powdered or Granular Activated Carbon Feed -
without carbon regeneration......................................................................................... ..5
with carbon regeneration.....................................................................................................15
(c)
Alr atrlpping............................................................................................................................................ .5
(d)
Danitrificatlon Process........................................._............................ ...10
(e)
Electrodiaiysls..................................................... .........................._........................................................5
(f)
Foam Separation........................................................................................................................................5
(g)
ion Exchange............................................................................................................................................5
(h)
Land Application of Treated Effluent (see definition No. 22b) (not applicable for sand. gravel, stone
and other similar mining operations) by high rate Infiltration ... ................... .......... _.................... ................... 4
(1)
Microscreens..................................................................--..........5
Of
Phosphorous Removal by Biological Processes (See deflnhlon No. 26).........................................................20
(k)
Polishing Ponds - without aeration ..... _.................................................................... -................................2
withaeration..................................................................................................................5

:
(n)
i. �/
Reverse Osmosis .........................:.... ...................................................................................5
Sand or Mixed -Media Filters - low rate ....................................................................................... ............2
high rate......................................................................5
/ (o)
Treatment processes for removal of metal or cyanide ............... 15
(p)
treatment processes for removal of toxic materials other than metal or cyanide..............................................1 5
(7) SLUDGETRFATMFNT
a
Sludge Digestion Tank Heated (anaerobic)
Aerobic..............................................................................................................................................5
Unheated(anaerobic)................................................................................................................................3
(b)
Sludge Stabilization (chemical or therma]),,,••..............I.......
(c)
Sludge Drying Beds - Gravity......................................................................................................................2
VacuumAssisted..............................................................................................................:........:..............5
(d)
Sludge Elutriation......................................................................................................................................5
(a)
Sludge Conditioner (chemical or thermal) .....................................................................................................5
(1)
Sludge Thickener (gravity) ............................. ..........5
(g)
Dissofved Air Flotation Unit [not applicable to a unit rated as(3)(#)).............................................................8
(h)
Sludge Gas Uliflzation (including gas storage) ............................................ ........... ..............2
(i)
Sludge Molding Tank - Aerated....................................................................................................................5
Non-aerated............................................................................................................................................. 2
O)
Sludge Incinerator (not including activated carbon regeneration) .......................................... ......................10
(k)
Vacuum Filter, Centrifuge, or Filter Press or other similar dewatering devices...................................................10
(8) RESIDUALS UTILIZATION/DISPOSAL (including incinerated ash)
(a)
Lagoons..............................................................................................................................................:.....2
(b)
land Application (surface and subsurface) (see definition 22a)
by contracting to a land application operator or landfill operator who holds the land application perrnil
orlandfill permit.........................................................................................................................................2
(c)
Dedicated Landfill(burial) by the permittee of the wastewater treatment facility.............................................:.5
(9) DSPFECTCN
(a)
Chlorination..........................:..................................................................................................................5
(b)
Oachlorinalion...................................................................................................:......................................5
(c)
Ozone......................................................................................................................................................5
(d)
Radiation............................................................................ 5
(1 0) CHEMICAL ADDITION SYSTEM(S) ( see delinllon No. 9) (rat appllcabie to chemical additions rased as item (3)(1),
(5)(a)(xi),
(6)(a), (6)(b), (7)(b), (7)(e), (9a), (9)(b) or (9)(c) 5 points each,
List
.......................................................................................................................5
........................................................................................... ........I.......... ........5
...SrS............. ...........................................:........... I ......... I ........ ........................................ 5
(1 i) A+1iSCEJ1ANE0U5 PROCES
UNfTS�
(a)
Holding Ponds, Holding Tanks or Settling Ponds for Organic or Toxic Materials Including wastes -from rn ming
operations containing nitrogen or phosphorus compounds in amounts significantly greater than is common
fordomestic wastewater............................................................................................................................4
(b)
Effluent Flow Equalization (not applicable to storage basins which are inherent In lard application syslems)...... 2
(c)
Stage Discharge (not applicable to storage basins inherent In land application systems)..................................5
(d)
Pumps.......................................................................................................................................................3
(e}
Stand -By Power Supply............................................................................................................................3
(f)
Thermal Pollution Control Device................................................................................................................ 3
TOTALPOI€TiS..........................................................................
CLASSIFICATION
Glass 1 ............................................................ .................................. ............. 5-25 Points
Classll .......................... ....... ......................... .............................................. 26-50 Points
classIII ...................................................... .................................................. 51.65 Points
ClassIV ...................................... .............................. ................................. ..66 -Up Points
Y---r—rr--
Facilities having a rating of one through four points, Inclusive, do not require a cerTrfled operator.
Facihiies having an act#vated sludge process will be assigned a minimum classification of Class Il.
Fac#filles having treatment processes
for the removal of metal or cyanide will be assigned a minimum classification of Class It,
Facilities having treatment processes for the biological removal of phosphorus will be assigned a minimum class€iication of Class Ill.
-------------------------------------------------------------
.0004 DEFINITIONS
The following definitions shalt apply throughout this Subchapter.
(1) Activated Carbon Beds. A physical/chemical method for reducing soluble organic maierlal from wastewater effluent; The column -type beds used in alis
method will have a flow rate varying from two to eight garlons per minute per square loot and may be either upfiow or downflow carbon beds. Carbon may or
may not be regenerated on the wastewater treatment plant site;
(2) Aerated lagoons. A basin In which all solids are maintained in suspension and by which bio{ogical oxidalion or organic matter is reduced through artificially
acceierated transfer of oxygen on a flow-through basis;
(3) Aeration. A process of bringing about Intimate contact between air or high purity oxygen in a liquid by spraying, agitation or diffuslon;(3a) Extended
Aeration. An activated sludge process utilizing a minimum hydraulic detention time of 18 hours.
(4) Agriculturally managed site. Any site on which a crop Is produced, managed, and harvested (Crop Includes grasses, grains, trees, etc.);
(5) Air Stripping. A process by which the ammonium Ion Is first converted to dissotvad ammonia (pH adjustment) with the ammonia then raleased to Its
atmosphere by physical means; or other similar processes which remove petroleum products such as benzene, toluene, and xylene;
(6) Carbon Regeneration. The regeneration of exhausted carbon by the use of a furnace to provide extremely high temperatures which volaillize and oxidlzo the
absorbed Impurhies;
(7) Carbonaceous Slage. A stage of wastawater treatment designed to achieve 'secondary" effluent ilmhs;
(8) Centrifuge. A mechanical device In which contrffugal force is used to separate solids from liquids or to separate liquids of different densi;las;
(9) Chemical Addhon Systems- The addhlon of chemlcal(s) to wastewater at an application point for purposes of Improving solids removal, pH ad)usiment,
alkallnity control, Bic.; the capability to experiment with d4lerem chemicals and different application points to achieve a specific result will be considered one
system; the capability to add chemical(s) to dual units will be rated as one system; capabOlty to add a chemical at a different application points for different
purposes will resuft in the systems being rated as separate systems;
(10) Chemical Sludge Conditioning. The addition of a chemicaf compound such as lime, ferric chloride, or a polymer to wet sludge to coalesce the mass prior to
Its application to a dewatering device;
(11) Closed Cycle Systems. Use of holding ponds or holding tanks for containment of wastewater containing Inorganic, non-toxic materials from sand, gravel,
crushed stone or other similar operations. Such systems shall carry a maximum of two points regardless of pumping facilities or any other appurtenances;
(12) Combined Removal of Carbonaceous BOO and Nhrogenous Removal by Nitrification- A single stage system required to achieve permit effluent limits on BOD
and ammonia nillWan within the same biological reactor,
(13) Dechlorination- The partial or complete reduction of residual chlorine In a liquid by any chemical or physical process;
(14) Denitrification Process. The conversion of nlirale-nitrogen to nitrogen gas;