WQ0001105_Final Permit_20050719

Michael F. Easley, Governor
William G. Ross Jr., Secretary
North Carolina Department of Environment and Natural Resources
Alan W, Klimek, P.E., Director
Division of Water Quality
July 19, 2005
Richard C. Atwood
PCS Phosphate Company, Inc.
PO Box 48
Aurora, NC 27806
Subject: Permit No. WQ0001105
PCS Phosphate Company, Inc.
Wastewater Recycle System
Beaufort County
Dear Mr. Atwood:
In accordance with your request for renewal received April 26, 2005, we are forwarding herewith Permit
No. WQ0001105, dated July 19, 2005, 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 June 30, 2010, shall void Permit No.
WQ0001105 issued February 7, 2001, 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 150E 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 Michelle McKay at (919) 715-
6187.
Since
Alan W. Klimek, P.E.
cc: Beaufort County Health Department
Washington Regional Office, Aquifer Protection Section
APS Central Files
LAU Files
o`
NrthCarolina
Nawrally
Aquifer Protection Section 1636 Mail Service Center Raleigh, NC 27699-1636 Phone [phone] Customer Service
Internet: h2o.enr.state.nc.us 2728 Capital Boulevard Raleigh, NC 27604 FAX [phone]
An Equal OpportuniyAffirmative Action Employer— 50% Recycled110% 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 April 26, 2005, and subsequent additional information received by the Division, 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 June 30, 2010, shall void Permit No.
WQ0001105 issued February 7, 2001, 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 Perrnittee, 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 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 two recycle cooling ponds shall not be less than two feet at any time.
11. If not already installed, a waste -level gauge, to monitor waste levels in the storage pond, shall be installed
within 60 days of issuance of this permit. This gauge shaII have readily visible permanent markings
indicating the maximum liquid level at the top of the temporary liquid storage volume, minimum liquid
level at the bottom of the temporary liquid storage volume, and top of the darn elevations. Caution must be
taken not to damage the integrity of the liner when installing the gauge.
12. 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.
13. Adequate inspection, maintenance, and cleaning shall be provided by the Permittee to insure proper
operation of the subject facilities.
14. 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.
15. 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.
16. 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 211.0205 (c)(4).
17. 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.
18. The issuance of this permit does not exempt the Permittee from complying with any and all statutes, rules,
regulations, or ordinances which may be unposed by other government agencies (local, state, and federal)
which have jurisdiction, including but not limited to applicable river buffer rules in 15A NCAC 213_0200,
erosion and sedimentation control requirements in 15A NCAC Chapter 4 and under the Division's General
Permit NCG010000, and any requirements pertaining to wetlands under 15A NCAC 2B .0200 and 2H
.0500.20.

19. A set of approved plans and specifications for the subject project must be retained by the Permittee for the
life of this project.
20. Noncompliance Notification:
The Permittee shall report by telephone to the Raleigh Regional Office, telephone number [phone],
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.
Occurrences outside normal business hours may also be reported to the Division's Emergency Management
personnel at telephone number [phone], or [phone]. 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.
21. Upon classification of the wastewater treatment and spray irrigation facilities by the Water Pollution
Control System Operators Certification Commission (WPCSOCC), the Permittee shall designate and
employ a certified operator to be in responsible charge (ORC) and one or more certified operator(s) to be
back-up ORC(s) of the facilities in accordance with 15A NCAC 8G .0201. The ORC shall visit the
facilities in accordance with 15A NCAC 8G .0204 or as specified in this permit and shall comply with all
other conditions specified in these rules.
22. The twenty one (21) existing monitor wells (MW1-3A, MW1-3B, MW1-4A, MW1-413, MWl-5A, MW1-
5B, MW1-6A, MW1-6B, MWl-7A, MW1-7B, MW1-SA, and MW1-8B surrounding the recycle cooling
pond No. 1, and MW2-IAR, MW2-1BR, MW2-3A, MW2-3B, MW24A, 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)
FIuoride (F) pH
Chloride (Cl) Water Level
Total Phosphorous Sodium (Na)

The following parameters shall be monitored 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 measured 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 NC Division of Water
Quality Information Processing Unit, 1617 Mail Service Center, Raleigh, North Carolina 27699-
1617, 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.
23. Any additional groundwater quality monitoring, as deemed necessary by the Division, shall be provided.
24. 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 rernediation
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.
25. 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.
26. Thirty (30) days prior to the start of a dredging operation, the perrnittee 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.
27. 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.
28. Solids removal in Cooling Pond No. 1 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.
4

29. 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.
Permit issued this the 19'h day of July, 2005
NORTH WROLINA ENVIRONMENTAL MANAGEMENT COMMISSION
Alan W. Klimek,'P.E., Director
Division of Water Quality
By Authority of the Environmental Management Commission
Permit Number WQ0001105
5