WQ0001105_Final Permit_20071130

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Richard C. Atwood
PCS Phosphate Company, Inc.
1530 NC HWY 306 South
Aurora, North Carolina 27806
Dear Mr. :
Michael F. Easley, Governor
William G. Ross Jr., Secretary
North Carolina Department of Environment and Natural Resources
Coleen H. Sullins., Director
Division of Water Quality
November 30, 2007
Subject: Permit No. WQ0001105
PCS Phosphate Company, Inc.
Wastewater Recycle System
Beaufort County
In accordance with your request for permit modification received October 17, 2007, we are forwarding
herewith Permit No. WQ0001105, dated November 30, 2007, to PCS Phosphate Company, Inc. for the
construction and continued operation of the subject wastewater recycle system. This modification includes the
addition of a cooling pond of approximately fifty (50) acres with no change in the permitted flow for the facility.
This permit shall be effective from the date of issuance until June 30, 2010, shall void Permit No.
WQ0001105 issued July 19, 2005, and shall be subject to the conditions and limitations as specified therein.
Please pay particular attention to the monitoring requirements in this pen -nit. 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.
One set of approved plans and specifications is being forwarded to you. If you need additional
information concerning this matter, please contact Matthew Fleahman at [phone] or
[e-mail].
Sincerely
for Coleen H. Sullins
o r
Nth Carolina
Naturldly
Aquifer Protection Section 1636 Mail Service Center Raleigh, NC 27699-1636 Telephone : [phone]
Internet: www,ncwatMuality.org location: 2728 Capital Boulevard Raleigh, NC 27604 Fax 1: [phone]
Fax 2: [phone]
An Equal Opportunity/Affirmative Action Employer— 50% Recycled/l0°/a Post Consumer Paper Customer Service: [phone]

cc: Beaufort County Health Department
Washington Regional Office, Aquifer Protection Section
Robert M. Chiles, P.E. — P.O. Box 3496, New Bern, NC 28564
Technical Assistance and Certification Unit
APS Central Files
LAU Files
2

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 that is made-up of stormwater and / or
mine process generated wastewater which is defined in 40 CFR 436.181 e. The recirculating system consists of a
120 acre pond (pond No.l), 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),
construction of an additional cooling pond of approximately 50 acres, and all associated piping, valves and
appurtenances
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 October 17, 2007, 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 July 19, 2005, and shall be subject to the following specified conditions and limitations;
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 this permit, the approved pians and specifications, and other supporting materials. If thisroject is to
be completed in phases and partially certified, you -shall retain the responsibility to track further
construction approved under the same permit, and shall provide a final certificate of completion once the
entire project has been completed. Mail the Certification to the Division of Water Quality, Aquifer
Protection Section, 1636 Mail Service Center, Raleigh, NC 27699-1636.
2. The Washington Regional Office, telephone number [phone], shall be notified at least forty-eight
(48) hours in advance of operation of the installed facilities so that an in-place inspection can be made.
Such notification to the regional supervisor shall be made during the normal office hours from 8:00 a.m.
until 5;00 p.m. on Monday through Friday, excluding State Holidays.

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.
4. This permit is effective only with respect to the nature and volume of wastes described in the application
and other supporting data.
The facilities shall be properly maintained and operated at all times.
6. The following buffers shall be maintained:
a) 100 feet between treatment/storage units and any wells,
b) 50 feet between treatment/storage units and surface waters, and
c) 50 feet between treatment/storage units and property lines.
Some of the buffers specified above may not have been included in previous permits for this waste
treatment and disposal system.. These buffers are not intended to prohibit or prevent modifications,
which are required by the Division, to improve performance of the existing treatment facility. These
buffers do, however, apply to modifications of the treatment and disposal facilities that are for the
purpose of increasing the flow that is tributary to the facility, These buffers do apply to any
expansion or modification of the irrigation areas and apply in instances in which the sale of property
would cause any of the buffers now complied with, for the treatment and disposal facilities, to be
violated. The applicant is advised that any modifications to the existing facilities will require a permit
modification.
7. There shall be no public access to the wastewater treatment equipment, wastewater storage structures or to
the wastewater within the closed-loop recycle facility.
a°. An Operation and Maintenance Plan of the wastewater recycle system shall be mairftained �r the facility
and shall contain the following"
a) Description of the operation of the recycle system in sufficient detail to show what operations are
necessary for the facility to function and by whom the functions are to be conducted;
b) Description of anticipated maintenance of the system;
c) Provisions for safety measures, including restriction of access to the site and equipment, as
appropriate;
d) Spill Control provisions including:
i. Response to upsets and bypasses including control, containment, and remediation;
ii. Contact information for plant personnel, emergency responders, and regulatory agencies.
9. 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.
10. 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.
11. 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.
12. 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.
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13. 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.
14. Diversion or bypassing of untreated wastewater from the treatment facilities is prohibited.
15. Freeboard in the Cooling Ponds shall not be less than two feet at any time.
16. A waste -level gauge, to monitor waste levels in the cooling ponds, shall be provided. This gauge shall 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
dam elevations. Caution must be taken not to damage the integrity of the liner when installing the gauge.
17. A protective vegetative cover shall be established and maintained on all earthen basin embankments
(outside toe of embankment to maximum purnping elevation), berms, pipe runs, erosion control areas, and
surface water diversions. Trees, shrubs, and other woody vegetation shall not be allowed to grow on the
earthen basin dikes or embankments. Earthen basin embankment areas shall be kept mowed or otherwise
controlled and accessible.
18. 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.
19. Adequate inspection, maintenance, and cleaning shall be provided by the Permittee to insure proper
operation of the subject facilities.
20. 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.
21. 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.
22. 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).
23. 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.
24. The issuance of this permit does not exempt 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, including but not limited to applicable river buffer rules in 15A NCAC 2B.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.
25. A set of approved plans and specifications for the subject project must be retained by the Permittee for the
life of this project.
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26. 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 rnechanical 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.
2L TJpou 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, MWl-3B, MW14A, MW14B, MW1-5A, MW1-
5B, MW 1-6A, MW 1-6B, MW 1-7A, MW 1-7B, MW 1-8A, and MW 1-8B surrounding the recycle cooling
pond No. 1, and MW2-IAR, MW2-1BR, MW2-3A, MW2-3B, MW24A, MW2-4B, MW2-4C, 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 in November only:
Total Organic Carbon (TQC)
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
M

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 remediation
action in addition to the penalty provisions applicable under General Statute 143-215.6A(a)(1).
25. 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
26. 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,
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) gypsurn 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.
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
30. 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 30th day of November 2007
NORTH OL 77
AL MANAGEMENT COMMISSION
J� Coleen H
Sullins, Director
Division of Water Quality
By Authority of the -Environmental Management Commission
Permit Number WQ0001105

Permit No. WQ0001105
November 30, 2007
ENGINEER'S CERTIFICATION
Partial Final
1, , 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
Location and County
for the Permittee hereby state that, to the best of my abilities, due care and diligence was used in the observation
of the construction such that the construction was observed to be built within substantial compliance and intent of
this permit, the approved plans and specifications, and other supporting materials.
Signature
Date
7
Registration No.

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RICHLAND TOWNSHIP BEAUFORT COUNTY NORTH CAROLINA
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DATE: JULY 25, 2007 ROBERT
M. CHILES,
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