WQ0000701_Final Permit_19890912

ra STA'fe
State of North Carolina
Department of Natural Resources and Community Development
Division of Environmental Management
512 North Salisbury Street • Raleigh, North Carolina 27611
James G. Martin, Governor R. Paul Wilms
William W. Cobey, Jr., Secretary September 12, 1989 Director
Mr. Frank Taracido, Chief Engineer
Holly Farms Foods, Inc.
PO Box 88
Wilkesboro, NC 28697-0088
SUBJECT: Permit No. WQ0000701
Holly Farms Foods, Inc.
Harmony Rendering Plant
Land Application of Sludge
Sludge Storage Tank
Rowan County
Dear Mr. Taracido:
In accordance with the request received July 3, 1989, we are forwarding
herewith Permit No. WQ0000701, dated September 12, 1989, to Holly Farms Foods,
Inc. for the operation of the subject sludge land application facilities and the
construction and operation of the subject sludge storage tank.
This permit shall be effective from the date of issuance until June 30, 1990,
shall supersede Permit No. WQ0000701, which was issued on March 31, 1989, and shall
be subject to the conditions and limitations as specified therein.. This permit
modification includes the construction and operation of a 520,000 gallon sludge
storage tank and the ceasing of operation of the 425,000 gallon sludge holding
lagoon at the Richard Adam's Farm.
As stated in correspondence previously received from Holly Farms Foods, Inc.,
the request to have sludge land application sites (Bryant Church property) permitted
in Wilkes County and to construct a sludge holding lagoon on these properties has
been withdrawn. Additionally, Holly Farms Foods, Inc. has also previously Withdrawn
its request to construct a new sludge holding lagoon on the Richard Adams' property
in Rowan County and has now stated that it will. discontinue using the 42.5,000 gallon
lagoon on the Richard Adams' property.
As stated in the Director's letter of March 31., 1989, Holly Farms Foods, Inc.
is not allowed to apply sludge during; the period from May 1 to October 30 to areas
of certain fields on the Richard Adams' property which are located within the
100 -year flood plain since the particular waters which may be affected are
classified as "WS -III."
Pollution Premtion Pays
P.O. Box 17687, Raleigh, North Catalina 27611-7687 Telephone [phone]
An Eaual Onon miniry AKir ntivP A.-+:-..

If any parts, requirements, or limitations contained in this permit are
unacceptable to you, you have the right to request an adjudicatory hearing upon
written request within 30 days following receipt of this permit. This request must
be in the form of a. written petition, conforming to Chapter 1508 of. North Carolina
General Statutes, and filed with the Office of Administrative Hearings, Post Office
Drawer 11666, Raleigh, North Carolina 27604. Unless such demands are made this
permit shall be final and binding.
One set of approved plans for a new sludge storage tank is enclosed. If you
need additional information concerning this matter, please contact Mr. Randy Jones,
telephone No. 919/733-5083.
Sitz► ely,
R. Paul Wilms
cc: Rowan County Health Department
Mooresville Regional Supervisor
Groundwater Section

NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT COMMISSION
DEPARTMENT OF NATURAL RESOURCES AND COMMUNITY DEVELOPMENT
RALE IGI[
P E R M I T
For the discharge of Sewage, Industrial Wastes, or Other Wastes
In accordance with the provisions of Article 21 of Chapter 1.43, General Statutes
of North Carolina as amended, and other applicable .Laws, Rules, .and Regulations
PERMISSION IS HEREBY GRANTED TO
Holly Farms Foods, Inc.
Rowan County
FOR THE
construction and operation of a 520,000 gallon sludge storage tank, with all
appurtenances, to be located at the Harmony Rendering Plant and the subsurface
injection of sludge from the Harmony Rendering Plant to the lands identified in
condition no. 19 of this permit, pursuant to the request received July 3, 1989, and
in conformity with the project plans', specifications, and other supporting data
subsequently filed and approved by the Department of. Natural Resources and Community
Development and considered a part of this permit.
This permit shall be effective from the date of issuance until June 30, 1990,
shall supersede Permit No. WQ0000701, which was issued on March 31, 1989, and shall
be subject to the following specified conditions and limitations:
1. This permit is effective only with respect to the nature and volume of wastes
described in the application and other supporting data.
2. The facilities shall be properly maintained and operated at all times.
3. This permit is not transferable.
4. This permit shall become voidable in the event of failure of the soil to
adequately absorb the wastes and may be rescinded unless the facilities are
installed, maintained, and operated in a manner which will protect the assigned
water quality standards of the surface waters and ground waters.
5. In the event that the facilities fail to perform satisfactorily, including the
creation of nuisance conditions, the Permittee small take such immediate
corrective action as may be required by this Division, including the construction
of additional or replacement wastewater treatment or disposal facilities.
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6. 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.
7. The Permittee, at least six (6) months prior to the expiration of this permit,
shell 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.
8. Adequate facilities shall, be provided to prevent surface runoff from carrying any
disposed or stored material into any surface waters.
9. 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.
10. No type of sludge other than that from the I-Colly Farms Harmony facility or the
Wilkesboro facility shall be placed on the land application disposal site.
11. Adequate provisions shall be taken to prevent wind erosion and surface runoff
from conveying pollutants from the sludge application area onto the adjacent
property or into the surface waters.
12. Sludge shall not be applied in inclement weather or until 24 hours following a
rainfall. event of 1/2 -inch or greater in 24 hours. Emergency sludge disposal.
measures shall be approved by the Division of Environmental Management.
13. A 100 -foot buffer shall be maintained between the appropriate land owner's
property line and any applied sludge.
14. The site shall be adequately limed to a soil pH of 6.5 prior to sludge
application.
15. No crops for direct human consumption shall be raised on these sites for a period
of 18 months following sludge application.
16. Maximum slope for sludge application shall be 18% for subsurface applications.
All applications shall be by subsurface injection.
17. Adequate inspection, maintenance, and cleaning shall be provided by the Permittee
to insure proper operation of the subject facilities.
1.8. This permit shall become voidable unless the agreement between Holly Farms
Foods, Inc. and Dr. Richard Adams is in full force and effect.
19. This permit allows the land application of sludge, by subsurface injection, to
approximately 988 acres of land (less the land that is part of a buffer zone or
is located in the 100 -year flood plain) in Rowan County owned by Dr. Richard
Adams.
20. In any future transfer of this land, a notice shall be given to the new owner
that gives full details of the materials applied or incorporated at this site.
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21. Animals should not be grazed on sludge applied land within a 30 -day period
following the sludge application. Application sites that are to be used for
grazing shall, have fencing that will be used to prevent access during the 30 -day
periods after each application.
22. Public access to the land application sites shall be controlled during active
site use and for the 12 -month period on
the land application event.
23. A copy of the approved plans and specifications shall be maintained on file by
the Permittee for the life of the project.
24. Monitoring wells shall be constructed and sampling schedules arranged as required
by the Division of Environmental Management and in accordance with 15 nCAC 2C
0.100.
25. Solids, sludges, or other pollutants removed or resulting from the wastewater
storage facilities shall be contained and disposed of in such a manner as to
prevent any contamination of the surface or groundwaters of the State.
26. The following buffers shall be maintained between any subsurface applied sludge:
a) 25 feet to drainageways;
b) 100 feet to property lines; and
c) 200 feet to residences.
27. Holly Farms Foods, Inc. shall submit an annual summary of its sludge land
application activities, regarding this permit, to the Mooresville Regional Office
by January 31 of each year. The summary shall include, but not necessarily be,;`
limited to the following:
a) date sludge applied;
b) field where sludge applied;
c) method of application;
d) amount of sludge applied;
e) crop(s) grown on field; and
f) year-to-date totals in dry tons/acre, nutrient and metal loadings in
pounds per acre.
Dote: The report period shall be for the calendar year (January 1 - December 31)
and shall be submitted no later than January 31 of the following calendar
year.
28. No sludge shall be applied within 100 feet of any well, with the exception of a
monitoring well, or water supply source.
29. No sludge shall be applied to any area which is located within the 100 -year flood
plain.
30. Annual sludge applications shall not exceed the following:
a)
PAN
200 lbs. per acre
b)
Phosphate
50 lbs. per acre
c)
Potassium
100 lbs. per acre
d)
Cadmium
0.45 lbs. per acre
e)
Dry tons
9.4 dry tons per acre
f)
Hydraulic loadings (wet)
6788 gallons per acre
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31. The maximum cumulative loadings for metals shall not exceed the following:
a)
Cadmium
4.45
lbs.
per acre
b)
Copper
250
lbs.
per acre
c)
Nickel
250
lbs.
per acre
d)
head
1000
lbs.
per acre
32. In the event that the cumulative loadings of metals exceed those limits
established in condition 31, the land owner shall_ plane the following statement
in the property deed.. "Portions of this property have received wastewater
treatment plant sludge at high heavy metal application rates. Care should be
taken when food chain crops are grown due to a possible health hazard."
33. Sludge shall be applied in a manner that will. prevent runoff, ponding, and
erosion.
34. The Permittee shall submit an annual current composite sludge analysis report to
the North Carolina Department of Natural Resources and Community Development,
Mooresville Regional Office (919 North Main Street, Mooresville, NC 28115). The
sludge analysis report shall contain at least the following:
35. The owner of the land application site(s) shall be furnished with an annual
analysis of the sludge which has been applied to the sites.
36. No sludge shall. be applied to land application sites where the depth to the
seasonal high water table is Less than three feet.
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Parameters
Units
a.
Solids
%
b.
Lead
lbs/dry
ton
G.
Cadmium 1
lbs/dry
ton
d.
Nickel
lbs/dry
ton
e.
Copper
lbs/dry
ton
f.
Zinc
lbs/dry
ton
g.
Residual Chlorine
lbs/dry
ton
h.
POandand P
lbs/dry
ton
i.
TION
lbs/dry
ton
j.
NH as N
lbs/dry
ton
k.
NO3 + NO3
lbs/dry
ton
I.
0H and Grease
lbs/dry
ton
M.
pH
S. U.
n.
PCP
ppm (dry
weight)
Note: The report period shall be for
the calendar year
(January 1 - December 31)
and shall be submitted no later
than January 31
of the following calendar
year.
35. The owner of the land application site(s) shall be furnished with an annual
analysis of the sludge which has been applied to the sites.
36. No sludge shall. be applied to land application sites where the depth to the
seasonal high water table is Less than three feet.
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37. The five (5) existing monitor wells shall be sampled every March, July and
November for the following parameters:
Nitrate pH
Total .Ammonia TCC
TDS Chloride
Total Coliforms Sulfate
Water Levels *
The measurement of water level must be made prior to sampling for the remaining
parameters.
The results of the sampling and analysis shall be sent to the N.C. Division of
Environmental Management on Form GW -59 (Compliance Monitoring Report Form) every
April, August and December.
38. The use of the existing lagoon by Holly Farms Foods, Inc, must cease by
January 1, 1.990.
39. Holly Farms Foods, Inc. must submit a written status report to the Mooresville
Regional Office each month which indicates the progress toward eliminating the
existing lagoon.
40. By December 19, 1988, Holly Farms Foods, Inc. will. make a decision on the
implementation of option 1 or option 2 as described in condition no. 41.
11"
41. Depending upon the pre-treatment option which is chosen, Holly Farms Foods, Inc.
will comply with the schedules detailed below for either Option 1 or Option. 2:
OPTION 1: Installation of EPI Technology
June 30, 1989 . . . . . . . . . . . . . . Completion of Installation
September 1, 1989 . . . . . . . . . . . . 1) No Sludge Production From
Wilkesboro Complex
2) Submit Plans for On -Site Storage of
DAF Sludge at Harmony Rendering
Plant
December. 30, 1989 .
June 30, 1990 . . .
. . . . . . . . . Open Lagoon at Richard Adams Farm To
Be Emptied and Use as Storage To Be
Discontinued
. . . . . . . . . . Open Lagoon at Richard Adams Farm To
Be Filled In and Landscape To Be
Returned To Original State
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OPTION 2: DAF Cell at Wilkesboro Plant
January 30, 1989. . . . . Submit Construction Plans For
Enclosed Storage Tank To Be Located
on Richard Adams Farm
April 30, 1989 . . . . . . . . . . . . . . Begin Construction Of Storage Tank
After Receiving Approval From
NCDNR&CD
October 31, 1989. . . . . . . . . . . . Complete Construction of Enclosed
Storage Tank
December 30, 1.989 . . . . . . . . . . . . Open Lagoon at Richard Adams Farm
To Be Emptied and Use As Storage
To Be Discontinued
June 30, 1990 . . . . . . . . . . . . . . Open Lagoon at Richard Adams Farm
To Be Filled In and Landscape To Be
Returned To Original State
42. Upon completion of construction and prior to operation of this permitted
facility, a certification must be received from a professional engineer
certifying that the permitted facility has been installed in. accordance with the
approved plans and specifications.
Permit issued this the 12th day of September, 1969.
NORTH CAROLINA ENVIRONMENTAL, MANAGEMENT COMMISSION
% l '
R. Paul Wilms, Director
Division of Environmental Manag nt
By Authority of the Env�.xonmen a1 Management Commission
Permit No. WQ000070I
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ENGINEER'S CERTI7:ICATION
I, , as a duly registered Professional
Engineer in the State of North Carolina, having been authorized to observe
(periodically/weekly/full time) the construction of the project,
(Project)
(Name or Location.)
for the
hereby state that, to the best of my
(Project Owner)
abilities, due care and diligence was used in the observation of the project
construction such that the construction was observed to be built within substantial
compliance and intent of the approved plans and specifications.
Signature
Date
Permit No. WQ0000701
September 12, 1989
Registration No.