WQ0001105_Final Permit_19970219

State of North Carolina
Department of Environment,
Health and Natural Resources
Division of Water Quality
James B. Hunt, Jr., Governor
Jonathan B. Howes, Secretary
A. Preston Howard, Jr., P.E., Director
Mr. Steve R. Phillips,
Superintendent Environmental Affairs
PCS Phosphate Company, Inc.
Post Office Box 48
Aurora, North Carolina 27806
Dear Mr. Phillips;
LTI.K?F,A
EDOEHNF1
February 19, 1997
Subject: Permit No. WQ0001105 Amendment
PCS Phosphate Company, Inc.
Aurora, N.C. Phosphate Facility
Cooling Ponds Facility
Wastewater Recycle System
Beaufort County
In accordance with your application received December 10, 1996, we are forwarding herewith
Permit No. WQ0001105 dated February 19, 1997, to PCS Phosphate Company, Inc. for the continued
operation of the subject wastewater recycle system. This permit amendment is to allow for the dredging of
solids from the cooling ponds, and depositing the solids on an active gypsum stack. Please be informed
that a permit modification must be obtained before the use of any other solids disposal option.
This permit shall be effective from the date of issuance until June 30, 2001, shall void Permit No.
WQ0001105 issued July 15, 1996, 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. John Seymour at
[phone] extension 546.
Sincerely,
� W-6- aC-- /0.—
A. Preston Howard, Jr., P.E.
cc: Beaufort County Health Department
Washington Regional Office, Water Quality Section
Washington Regional Office, Groundwater Section
Groundwater Section Central Office, Mr. Bob Cheek
Training and Certification Unit (no rating change)
Facilities Assessment Unit
P.D. Box 29535, Raleigh, North Carolina 27626-0535 Telephone [phone] FAX [phone]
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
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 (fond 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 10, 1996, 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 June 30, 2001, shall void Permit No.
WQ0001105 issued July 15, 1996, 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 Water Quality 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, including dredged materials to be
deposited on an active gypsum stack, must be disposed in accordance with General Statute
143-215.1 and in a manner approved by the North Carolina Division of Water Quality.
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. Any monitoring deemed necessary by the Division of Water Quality 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
Water Quality or other permitting authority, upon request.
14. Any duly authorized officer, employee, or representative of the Division of Water Quality
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 of Water Quality 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 the approved plans and specifications for the subject recycle system must be
retained by the Permittee for the life of this project. These plans must include the facilities
which shall prevent surface runoff form 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 919/ 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.;
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 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 (MW1-3A, MW1-3B, MW14A, MW1-413,
MW1-5A, MW1-513, MW1-6A, MW1-6B, MW1-7A, MW1-7B, MW1-8A, and MW1-8B
surrounding the recycle cooling pond No. 1, and MW2-1AR, MW2-1BR, MW2-3A,
MW2-3B, MW2-4A, 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 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 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 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 BOJINDARY 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 BQUNDARY 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 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 Pennittee 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.
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. During dredging activities the permittee shall submit to the Division's Washington Regional
Office Water Quality Supervisor a monthly analysis, of a composite sample taken from
various layers and locations of the materials dredged from the cooling ponds. This analysis
shall include the following parameters:
CaO SO4 Crystalized H2O
Free H2O P205 F
A1203 Fe203 M90
Zn Ni Cr
Cd Si02 % Solids
26. 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

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 the 19th day of February, 1997
NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION
Preston Howard, Jr., P.E., Director
Division of Water Quality
By Authority of the Environmental Management Commission
Permit Number WQ0001105

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