WQ0001105_Final Permit_20010207

State of North Carolina
Department of Environment
and Natural Resources
Division of Water Quality
Michael F. Easley, Governor
William G. Ross Jr., Secretary
Kerr T. Stevens, Director
February 7, 2001
William T. Cooper Jr., Vice President/General Manager
PCS Phosphate Company, Inc.
PO Box 48
Aurora, NC 27806
Dear Mr. Cooper:
4 7•
10
NCDENR
NORTH CAROLINA DEPARTMENT OF
ENVIRONMENT AND NATURAL RESOURCES
Subject: Permit No. WQ0001105
PCS Phosphate Company, Inc.
William T. Cooper Jr., Vice President/General Manager
Wastewater Recycle System
Beaufort County
In accordance with your application received December 12, 2000, we are forwarding herewith Permit No.
WQ0001105, dated February 7, 2001, to PCS Phosphate Company, Inc. for the continued operation of the subject
wastewater recycle system.
This permit shall be effective from the date of issuance until December 31, 2005, shall void Permit No.
WQ0001105 issued February 19, 1997, 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, 6714 Mail Service Center, Raleigh, NC 27699-6714. Unless such
demands are made this permit shall be final and binding.
If you need additional information concerning this matter, please contact Sue Homewood at [phone]
extension 502.
Sincere ,
Z.—Kerr T. Stevens
cc: Beaufort County Health Department
Washington Regional Office, Water Quality Section
Technical Assistance and Certification Unit
Non -Discharge Compliance/Enforcement Unit
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

NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT COMMISSION
DEPARTMENT OF ENVIRONMENT 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
PCS Phosphate Company, Inc.
Beaufort County
FOR THE
continued operation of a dual pond 180 million GPD recirculating system which consists of a 120 acre pond (pond
No.1), a 60 acre pond (Pond No. 2), bentonite slurry walls on the perimeter of Cooling Ponds No. 1 and No. 2 to
prevent migration of groundwater contaminants, the routine materials dredging of solids from the cooling ponds
and depositing the solids on an active gypsum stack, and all -associated appurtenances for the recirculation and
cooling of water from the gypsum stacks, the acid plant, the fertilizer plant, the purified acid plant, the super
phosphoric acid plant and the shipping area (acid tank farm and acid tanks and rail cars), to serve the PCS
Phosphate Company, Inc., Aurora, N.C. Facility with no discharge of wastes to the surface waters, pursuant to the
application received December 12, 2000, and in conformity with the project plan, specifications, and other
supporting data subsequently filed and approved by the Department of Environment and Natural Resources and
considered a part of this permit.
This permit shall be effective from the date of issuance until December 31, 2005, shall void Permit No.
WQ0001105 issued February 19, 1997, and shall be subject to the following specified conditions and limitations:
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 Water Quality
(Division) 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 take 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_

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 Division.
7. The issuance of this permit shall not relieve the PenY,ittee of the responsibility for damages to surface or
groundwaters resulting from the operation of this facility. Since this is a NC permitted non -discharge process
wastewater system, 40 CFR 418.12(b) does not apply.
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 two recycle cooling ponds shall not be less than two feet at any time.
IL _ Any monitoring deemed necessary by the Division 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 Petmittee 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 or other
permitting authority, upon request.
14. Any duly authorized officer, employee, or representative of the Division 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 .0205 (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 in accordance with North Carolina General Statute 143-215.6A to 143-
215.6C.
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. These plans must include the facilities that shall prevent surface runoff from carrying any
disposed or stored material into any surface waters.
19. Noncompliance Notification:
The Permittee shall report by telephone to the Washington Regional Office, telephone number (252) 946-
6481, 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.;
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 five (5)
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. The twenty one (21) existing monitor wells (MWI-3A, MWI-313, MW1-4A, MW14B, MWI-5A, MW1-5B,
MWI-6A, MW1-6B, MW1-7A, MWI-7B, MW1-8A, and MWI-8B surrounding the recycle cooling pond
No. 1, and MW2-IAR, MW2-1BR, MW2-3A, MW2-3B, MW2-4A, MW2-4B, MW24C, MW2-5B, and
MW2-5C surrounding recycle pond No. 2) must be sampled every May and November for the following
parameters:
Sulfate (SO4) Total Dissolved Solids (TDS)
Fluoride (F) pH
Chloride (Cl) Water Level
Total Phosphorous Sodium (Na)
The following parameters shall be monitored for in November only:
Total Organic Carbon (TOC)
Heavy Metals (by Inductively Coupled Plasma -Method 200.7)
Volatile Organic Compounds
(VOC) Using Method 6230D (Capillary - Column),
"Standard Methods For The Examination of Water
and Wastewater", 17th ed., 1989
The measurement of water level must be made prior to sampling for the remaining parameters. The depth
to water in each well shall be treasured from the surveyed point on the top of the casing.
The measuring points (top of well casing) of all monitoring wells shall have been surveyed to provide
relative elevations of the measuring point for each of the monitoring wells.
One copy of the results of the sampling and analysis must be received by the Groundwater Section, Permits
and Compliance Unit, P.O. Box 29578 Raleigh, N.C. 27626-0578, and one copy shall be sent to the
Division's Washington Regional Office, address 943 Washington Square mall, Washington, North Carolina
27889, on or before the last working day of every June and December.
21. Any additional groundwater quality monitoring, as deemed necessary by the Division, shall be provided.

22. The COMPLIANCE BOUNDARY for the disposal system is specified by regulations in 15A NCAC 2L,
Groundwater Classifications and Standards. The Compliance Boundary is for the disposal system
constructed after December 31, 1983 is established at either (1) 250 feet from the waste disposal area, or (2)
50 feet within the property boundary, whichever is closest to the waste disposal area. An exceedance of
Groundwater Quality Standards at or beyond the Compliance Boundary is subject to immediate remediation
action in addition to the penalty provisions applicable under General Statute 143-215.6A(a)(1).
In accordance with 15A NCAC 2L, a REVIEW BOUNDARY is established around the disposal systems
midway between the Compliance Boundary and the perimeter of the waste disposal area. Any exceedance of
standards at the Review Boundary shall require remediation action on the part of the permittee.
23_ Upon classification of the facility by the Water Pollution Control Systems Operators Certification
Commission (WPCSOCC), 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 WPCSOCC. The Permittee must also employ a certified back-up operator of the appropriate
type and grade to comply with the conditions of 15A NCAC 8G .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 15A NCAC 8G .0202.
24. Thirty (30) days prior to the start of a dredging operation, the permittee must notify the Division's
Washington Regional Office of it's intentions in writing. This written notification shall include the extent of
the intended dredging and the specific gypsum pile on which the solids will be disposed.
25. Dredging of gypsum solids from the cooling ponds is approved using either methods of wet dredging to the
active gypsum stack or by dry excavation and truck hauling to the reclamation gypsum stack. The ultimate
disposal of gypsum from the PCS Phosphate (Aurora) gypsum stacks is through the gypsum/clay blend
system into a mine reclamation area.
26. Solids removal in Cooling Pond No. I shall be limited to a depth of 7.5 feet msl and solids removal in
Cooling Pond No. 2 shall be limited to a depth of 7.0 feet msl.
27. No wastewater other than that approved by this permit shall be disposed of in the cooling ponds or allowed to
enter the recycle system. A permit amendment is required from the Division of Water Quality to add any new
sources of wastewater_
28. 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 th�Vb day of February, 2001
NORTH Q' OLINA E R7O ENTAL MANAGEMENT COMMISSION
1
Kerr T. Stevens, Director
Division of Water Quality
By Authority of the Environmental Management Commission
Permit Number WQ0001105