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HomeMy WebLinkAboutWQ0003396_Final Permit_20091218X= ...MCDET North Carolina Department ct Environment and Natural Resources Division of Water Qualii . Beverly eves Perdue C0ieen I'.. SillinS Goverror Dhct.Y December 18, 2009 Carolyn Underwood — Environmental Manager Uniboard USA, LLC 985 Corinth Road Moncure, North Carolina 27559 Dear Ms. Underwood: Dee Freema—,, Secrelee' Subject: Permit No. WQ0003396 Uniboard USA, LLC - Moncure Closed -Loop Recycle/ Conjunctive Reclaimed Water I Wastewater Irrigation System Chatham County In accordance with your permit major modification request received October 14, 2009, and subsequent additional information received November 12, 2009 and December 2, 2009, we are forwarding herewith Permit No. WQ0003396, dated December 18, 2009, to Uniboard USA, LLC for the construction and operation of the subject wastewater treatment and closed -loop recycle system for the new medium density fiberboard (MDF) mill, the conjunctive reclaimed water utilization system for the existing: particleboard (PB) mill, the construction and operation of the modified wastewater storage lagoon (Pond #5), and continued operation of the wastewater irrigation facilities associated with the existing PB mill. The modifications to the subject permit are as follows: A closed loop recycle system to serve the new MDF mill has been added to the permit. A new reclaimed water utilization stream. (generated in the new MDF mill and utilized for electrostatic precipitator make up water in the existing PB mill) has been, added to the permit. • Modifications to the wastewater storage lagoon (Pond #5) have been approved to allow construction of a lagoon divider that will split the storage lagoon into two portions (Side C and Side D) resulting in operational changes. On August 5, 2009, Session Law 2009-406, entitled "An Act to Extend Certain Govermn.ent Approvals Affecting the Development of Real Property Within the State," was enacted by the General Assembly and signed into law. The Act, known as the Permit Extension Act of 2009, extends the expiration date of certain government approvals and permits. Non -discharge permit WQ0003396, issued AC. �:Er. PROTECTIC'. EE�TION 163 Lcnatio: 2728 iar.wi Boulevard. Raielrih. i •xtl Garelina 276C4 OtIP pnme: ' :�-7a i-3221 i FA'` ':: 9 , D-715-0588: FAX 2: i . 71. , V '_ustcme--Service: 1-877-623-5748 ,. 'Mr www.ncuateraualit4�.or4 hrc�-thCaR`olin.- " i27 F °' Ms, Carolyn Underwood December 18, 2009 Page 2 of 4 by the Division of Water Quality falls within the scope of this Act and is therefore being extended until October 31, 2015. Please note per your permit, a renewal application must still be submitted six months in advance of this extended expiration date. This permit shall be effective from the date of issuance until October 31, 2015, shall void Permit No. WQ0003396 issued November 4, 20M, and shall be subject to the conditions and limitations as specified therein. Failure to establish an adequate system for collecting and maintaining the required operational information shall result in future compliance problems. Please pay special attention to the following permit conditions that are new/revised since the last permit issuance.: • Condition 1.4. requires that staff gauges be provided for monitoring freeboard in both sides C and D of Lagoon #5. • Conditions 11.7 —11.11 outlines requirements for the reclaimed water distribution piping to the PB mill • Condition H.16. — setbacks have been added for the new closed loop recycle system equipment for the MDF mill and the conjunctive reclaimed water utilization areas at the PB mill. • Condition I1I.14. prohibits diversion of stormwater from mill areas into Lagoon #5. • Condition 1II.18. requires that an education program be developed and implemented to inform employees about the proper use of reclaimed water for ESP make up in the PB mill. • Condition 11I.19. outlines operational requirements for Sides "C" and "D" of Pond #5 in accordance with the O & M Plan submitted to the Division on December 2, 2009. • Condition IV.3. specifies that influent flow to be monitored at Lagoon #5 will consist of process flow from the PB mill and the first flush of sand filter backwash from the MDF mill. This flow may be estimated using pump run times. • Condition IV A. requires that flow be monitored to the reclaimed water system at the PB mill. • Attachment A lists monitoring requirements and limitations for PPI 001 (WWTF effluent), PPI 002 (influent to Lagoon #5), and PPI 003 (reclaimed water utilization at PB mill). Please pay particular attention to the monitoring requirements in Attachment A, for they may differ from the previous permit issuance. • Attachment A — Note that PPI 001 requires that all effluent parameters be sampled following final treatment and prior to irrigation, Fecal coliform shall no longer be sampled at the effluent from the domestic package plant. Ms. Carolyn Underwood December 18. 2009 Page 3 of 4 • Attachment A —PPI 003 requires continuous monitoring of flow and turbidity for reclaimed water utilized at the PB mill. No turbidity limit is currently required for this industrial use which has no public access. Please note that if future permit modifications allow new uses of the reclaimed water, a maximum turbidity limit of 10 NTU may apply per 15A NCAC 02T .0906. If any parts, requirements or limitations contained in this permit are unacceptable, the Permittee has the right to request an adjudicatory hearing upon written request within 30 days following receipt of this permit. This request shall be in the form of a written petition, conforming to Chapter 150B of the North Carolina General Statutes, and filed with the Office of Administrative Hearings at 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 Lori Montgomery at (919) 715-6187 or lori.montgomeryC ncdenngov. Sincerely, Q✓Coleen H. Sullins cc: Chatham County Health Department Raleigh Regional Office, Aquifer Protection Section Dean Ritts, PE, CEM — ERM, 1130 Situs Court Suite 240, Raleigh, NC 27606 Technical Assistance and Certification Unit Permit File WQ00003396 Notebook File WQ00003396 Ms. Carolyn Underwood December 18, 2009 Page 4 of 4 THIS PAGE BLANK NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES RALEIGH CLOSED -LOOT' RECYCLE / CONJUNCTIVE RECLAIMED WATER / WASTEWATER IRRIGATION 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 Uniboard USA, LLC Chatham County FOR THE construction and operation of a 1.9.6 million gallon per day (MGD) wastewater treatment and closed loop recycle facility to serve the new medium density fiberboard (MDF) will consisting of the following equipment to treat and recycle scrubber blow down and various process wastewaters: one (1) 600-gallon oil/water separator; one (1) 500-gallon calcium hydroxide mix tank with agitator and a 3.8 gallon per minute (GPM) metering pump; one (1) 4,000-gallon scrubber conditioning tank with agitator and dual (2) 21.3 GPM tank transfer pumps; one (1) 500.-gallon "dirty water" buffer tank; one (1) 350 GPM capacity waste water screen with 3 mm spacing; one (1) 500-gallon screened water buffer tank with dual (2) 129.6 GPM transfer pumps; one (1) 100,000-gallon screened water tank with agitator and dual (2) 119.6 GPM transfer pumps; one (1) 500-gallon "overflow" tank with dual 4.4 GPM transfer pumps; a flocculent and coagulant dosing system prior to the screw press; one (1) Huber screw press; one (1) 500-gallon screw press buffer tank with agitator and dual (2) 153.6 GPM screw press out feed pumps; three (3) 340-gallon storage tanks and a flocculent, coagulant, and neutralizer dosing system prior to one (1) pipe flocculator; one (1) dissolved air floatation (DAF) clarifier; one (1) 4,000-gallon sludge tank with mixer and dual (2) 6 GPM sludge tank transfer pumps; a flocculent and coagulant dosing system to serve one (1) Hubero' sludge screw press with conveyor to send dewatered and pressed wood chip sludge to the fuel pile; one (1) 500-gallon sludge screw press buffer tank with agitator and dual (2) 9 GPM buffer tank transfer pumps; one (1) 500-gallon DAF outfeed buffer tank with dual (2) 188.8 GPM out feed transfer pumps; two (2) 1.000-galIon mill water pressure tanks; three (3) 100 GPM capacity dual media sand filters; one (1) 30,000-gallon mill water storage tank; two (2) 87.1 GPM trill water transfer pumps (#1 and #2) to recycle mill water to the MDF plant for wastewater treatment make up and general cleaning uses, and to send reclaimed water to the existing particle board (PB) mill for electrostatic precipitator make up water; a recycle water flow meter for MDF recycle water; two (2) 54.4 GPM mill water transfer pumps (#3 and 44) to feed one (1) reverse osmosis water filtration system for MDF dryer scrubber and press scrubber make up water; one (1) 500-gallon backwash surge tank with dual (2) 24.1 GPM backwash surge pumps for sending reverse osmosis reject and sand filter backwash to Side C of Pond #5, one (1) 500-gallon "overflow" tank with two (2) 4.4 GPM overflow tank transfer pumps to send first flush of sand filter backwash and mill water emergency overflow to "Side D" of the wastewater storage lagoon (Pond #5); two (2) squeeze water screens; one (1) 6,800-gallon squeeze water tank with agitator; two (2) 8? GPM plug screw flush water pumps; two (2) 32.7 GPM excess squeeze water pumps; WQ0003396 Version 2.2 Shell Version 090806 Page 1 of 13 one (1) squeeze water heat exchanger; one (1) 9,000-gallon squeeze water storage tank; two (2) 30.9 GPM squeeze water pumps; and various sump pumps (not individually listed) for transporting wastewater from various MDF mill process areas to the wastewater treatment and closed loop recycle equipment; construction and operation of a conjunctive use reclaimed water utilization system consisting of: a reclaimed water flow meter to measure reclaimed water transferred from the MDF mill recycle system to the existing PB mill for use as electrostatic precipitator make up water; two (2) 87.1 GPM mill water transfer pumps (411 and #2) as described above; all related piping, valves, and appurtenances; construction and operation of wastewater storage lagoon (Pond #5) modifications consisting of: installation of an earthen lagoon divider to separate Pond #5 into "Side C" — 6.79 million gallons (MG) — to store rainwater, sand filter backwash from the MDF mill, and reverse osmosis reject water for use as makeup water to MDF mill and the PB mill; and "Side D"- (6.73 MG) — to store process wastewater from the existing PB mill, first flush of sand filter backwash from the new MDF mill, and occasional emergency overflow from MDF mill water recycle system; one (1) 48.1 GPM MDF mill water make up pump (can also transfer water from lagoon Side C to Side D if necessary); continued operation of a 126,000 GPD wastewater treatment and surface irrigation facility consisting of: a 13.52 MG clay lined wastewater storage lagoon (Pond #5); a grit settling pond (Pond 94) to receive wastewater from Pond #5, plant site wastewater, and wash down water; a grit settling pond (Pond #1) to receive backwash from the Roberts-Boze clarifier at the PB mill; a domestic wastewater package treatment plant consisting of a bar screen, a 7,000-gallon aeration tank, a 1,167-gallon secondary clarifier; a 1,047-gallon sludge holding tank, dual (2) 36 cubic feet per minute (CFM) blowers, and a 185-gallon chlorine contact chamber equipped with tablet feed; an aerobic treatment :pond (Pond #2) to receive treated effluent from the domestic package treatment plant, in addition to the wastewater from Ponds #1 and 4; a secondary settling pond (Pond #3) to receive the wastewater from Pond 92; a 500 GPM pump station to transfer treated effluent from Pond #3 to the spray irrigation fields; an 800 GPM pump station to recycle effluent from Pond #3 for use as PB plant process or wash down water and to transport effluent from Pond #3 back to the wastewater storage Pond #5 if irrigation is not possible; a center pivot irrigation system consisting of sprinkler nozzles averaging 11.5 GPM divided into nine (9) spray irrigation zones with a total irrigation area of 39.49 acres to serve Uniboard USA, LLC, with no discharge of wastes to surface waters, pursuant to the application received October 14, 2009, and subsequent additional information received by the Division of Water Quality, and in conformity with the project plans, 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 froze the date of issuance until October 31, 2015, shall void Permit No. WQ0003396 issued November 4, 2008, and shall be subject to the following specified conditions and limitations: WQ0003396 Version 2.2 She]] Version 090806 Page 2 of 13 I. • SCHEDULES 1. In accordance with 15A NCAC 02T .0116, upon completion of construction and prior to operation of the MDF mill closed -loop recycle facility and the PB mill conjunctive reclaimed water utilization system, a certification (attached) shall be submitted from a licensed North Carolina Professional Engineer certifying that the permitted facility has been installed in accordance with this permit, Division approved plans and specifications, and other supporting documentation, including the location of all monitoring wells as applicable. If this project is to be completed in phases and partially certified, the Pennittee shall retain the responsibility to track further construction approved under the same permit, and shall provide a final certificate of completion once the entireproject has been completed. Mail the Certification to the Division of Water Quality, Aquifer Protection Section, 1636 Mail Service Center, Raleigh, NC 27699-1636. In accordance with 15A NCAC 02T .0116, upon completion of wastewater storage lagoon modifications and prior to operation of the modified lagoon, a certification. (attached) shall be submitted from a licensed North Carolina Professional Engineer certifying that the permitted facility has been installed in accordance with this permit, Division approved plans and specifications, and other supporting documentation, including the location of all monitoring wells as applicable. If this project is to be completed in phases and partially certified the Permittee 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, The Raleigh Regional Office, telephone number (919) 791-4200, shall be notified at least 48 hours in advance (excluding weekends and holidays) of operation of the closed loop recycle system, the conjunctive reclaimed water utilization system, and/or the modified wastewater storage lagoon such that an in -place inspection can be made. Notification to the Aquifer Protection Section's regional supervisor shall be made from 8:00 a.m. until 5:00 p.m. on Monday through Friday, excluding State Holidays. 4. A gauge to monitor.waste levels in both Sides "C" and "D" of the wastewater storage lagoon (Pond #5) shall be installed prior to operation of the modified lagoon. Caution shall be taken not to damage the integrity of the liner (if present) when installing the gauge. 5. No later than six months prior to the expiration of this permit, the Permittee shall request renewal of this permit on official Division forms. Upon receipt of the request, the Division will review the adequacy of the facilities described therein, and if warranted, will renew the permit for such period of time and under such conditions and limitations as it may deem appropriate. Please note Rule 15A NCAC 02T .0105(d) requires an updated site map to be submitted with the permit renewal application. K PERFORMANCE STANDARDS The subject wastewater irrigation facilities shall be effectively maintained and operated at all times so there is no discharge to surface waters, nor any contravention of groundwater or surface water standards. In the event the facilities fail to perform satisfactorily, including the creation of nuisance conditions due to improper operation and maintenance, or failure of the irrigation areas to adequately assimilate the effluent, the Permittee shall take immediate corrective actions including Division required actions, such as the construction of additional or replacement wastewater treatment or disposal facilities. WQ0003396 Version 2? Shell Version 090806 Page 3 of 13 2. The subject closed -loop recycle facilities (MDF mill) and conjunctive reclaimed water utilization system (PB mill) shall be effectively maintained and operated at all times so there is no discharge to the surface waters, nor any contravention of groundwater or surface water standards. In the event that the facilities fail to perform satisfactorily, including the creation of nuisance conditions due to improper operation and maintenance, the Permittee shall take immediate corrective actions including Division required actions, such as the construction of additional or replacement wastewater treatment or recycle facilities. 3. This permit shall not relieve the Permittee of their responsibility for damages to groundwater or surface water resulting from the operation of this facility. 4. All wells constructed for purposes of groundwater monitoring shall be constructed in accordance with 15A NCAC 02C .0108 (Standards of Construction for Wells Other than Water Supply), and any other jurisdictional laws and regulations pertaining to well construction. 5. Effluent limitations shall not exceed those specified in Attachment A. 6. Application rates, whether hydraulic, nutrient or other pollutant, shall not exceed those specified in Attachment B. 7. The following shall be requirements for the reclaimed water distribution and utilization facilities associated with the use of MDF mill recycle water for ESP make-up in the PB mill: a, All reclaimed water valves, storage facilities and outlets shall be tagged or labeled to warn the public or employees that reclaimed water is not intended for drinking. Where appropriate, such warning shall inform the public or employees to avoid contact with reclaimed water. b. All reclaimed water piping, valves, outlets and other appurtenances shall be color -coded, taped or otherwise marked to identify the source of the water as being reclaimed water. i. All reclaimed water piping and appurtenances shall be either colored purple (i.e., Pantone 522) and embossed or integrally stamped or marked "CAUTION: RECLAIMED WATER — DO NOT DRINK" or be installed with a purplb (i.e., Pantone 522) identification tape or polyethylene vinyl wrap. The warning shall be stamped on opposite sides of the pipe and repeated every three feet or less. ii. Identification tape shall be at least three inches wide and have white or black lettering on purple (i.e., Pantone 522) field stating "CAUTION: RECLAIMED WATER — DO NOT DRINK." Identification tape shall be installed on top of reclaimed water pipelines, fastened at least every 10 feet to each pipe length and run continuously the entire length of the pipe. iii. Existing underground distribution systems retrofitted for the purpose of distributing reclaimed water shall be taped or otherwise identified as noted above. This identification need not extend the entire length of the distribution system, but shall be incorporated within 10 feet of crossing any potable water supply line or sanitary sewer line. c. All reclaimed water valves and outlets shall be of a type, or secured in a manner, that permits operation by authorized personnel only. d. Above -ground hose bibs (i.e., spigots or other hand -operated connections) shall not be present. Hose bibs shall be located in locked below -grade vaults that shall be clearly labeled non -potable. As an alternative to the use of locked below -grade vaults with standard hose bibs services, hose bibs, which can only be operated by a special tool or connected to a special hose connection, may be placed in non -lockable underground services boxes clearly labeled non -potable. WQ0003396 Version 22 Shell Version 090806 Page 4 of 13 The Permittee shall maintain an active cross -connection control program for the reclaimed water system that provides ESP make-up in the PB mill. The cross -connection control program shall meet the following minimum requirements: a. No direct cross -connections shall be allowed between the reclaimed water and potable water systems. b. If both reclaimed water and potable water are supplied to a reclaimed water utilization area (the wet ESP unit in the PB mill), a reduced pressure principle backflow preventer, an approved air gap separation or other Division of Enviromnental Health approved device shall be installed at the potable water service connection to the use area (the wet ESP unit). The installation of the reduced pressure principle backflow prevention device shall allow proper testing. c. If potable water is used to supplement a reclaimed water utilization system, the Permittee or potable water supplier shall approve and regularly inspect the air gap separation. 9. Reclaimed water distribution lines shall be located 10 feet horizontally from and 18 inches below any water line where practicable. Where these separation distances cannot be met, the piping and integrity testing procedures shall meet water main standards in accordance with 15A NCAC 18C. 10. Reclaimed water distribution lines shall not be less than 100 feet from a well unless the piping and integrity testing procedures meet water main standards in accordance with 15A NCAC 18C, but in no case shall they be less than 25 feet from a private well or 50 feet from a public well. 11. Reclaimed water distribution lines shall meet the separation distances to sewer lines in accordance with Rule .0305 of Subchapter 02T. 12. The compliance boundary for the wastewater irrigation system shall be specified in accordance with 15A NCAC 02L .0107(b). This disposal system was individually permitted on or after December 30, 1983.. therefore, the compliance boundary is established at either 250 feet from the effluent disposal area, or 50 feet within the property boundary, whichever is closest to the effluent disposal area. An exceedance of groundwater standards at or beyond the compliance boundary is subject to remediation action according to 15A NCAC 02L .0106(d)(2) as well as enforcement actions in accordance with North Carolina General Statute 143-215.6A through 143-215.6C. 13. In accordance with 15A NCAC 02L .0108, the review boundary for the wastewater irrigation system is established midway between the compliance boundary and the effluent disposal area. Any exceedance of groundwater standards at the review boundary shall require action in accordance with 15A NCAC 02L .0106, 14, The Permittee shall apply for a permit modification to establish a new compliance boundary prior to any sale or transfer of property affecting a compliance boundary. 15. In accordance with 15A NCAC 02L .0107(d), no wells, excluding Division approved monitoring wells, shall be constructed within the compliance boundary except as provided for in 15A NCAC 02L .0107(g). WQ0003396 Version 2.2 Shell Version 090806 Page 5 of 13 16. The facilities permitted herein shall be constructed according to the following setbacks: a. The setbacks for wetted areas (permitted prior to September 1, 2006) shall be as follows (all distances in feet): i. Any habitable residence or place of public assembly under separate ownership: 400 ii. Surface waters: 100 iii. Any well with exception of monitoring wells: 100 iv. Any property line: 150 v. Public right of way: 50 b. The setbacks for wastewater treatment units (permitted prior September 1, 2006 — this includes Lagoon # 1, 2, 3, 4, and 5) shall be as follows (all distances in feet): i. Any well with the exception of a Division approved groundwater monitoring well: 100 ii. Any property line: 50 c. The setbacks for storage and treatment units associated with the MDF mill closed -loop recycle system (permitted after September 1, 2006) shall be as follows (all distances in feet): iii. Any habitable residence or place of public assembly under separate ownership: 100 iv. Any private or public water supply source: 100 v. Surface waters: 50 vi. Any well with the exception of a Division approved groundwater monitoring well: 100 vii. Any property line: 50 d. The setbacks for reclaimed utilization sites (ESP make up at existing PB mill permitted after September 1, 2006) shall be as follows (all distances in feet): i. Surface waters not classified SA: 25 ii, Surface waters classified SA:. 100 iii. Any well with exception to monitoring wells 100 III. OPERATION AND MAE\TTENANCE REQUIREMENTS 1. The facilities shall be properly maintained and operated at all times. 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. The Permittee shall maintain an Operation and Maintenance Plan pursuant to 15A NCAC 02T .0507, .0913, and .1007, which at a minimum shall include operational functions, maintenance schedules, safety measures and a spill response plan. 2. Upon the Water Pollution Control System Operators Certification Commission's (WPCSOCC) classification of the subject non -discharge facilities, in accordance with 15A NCAC 08G .0200 the Permittee shall designate and employ a certified operator in responsible charge (ORC) and one or more certified operator(s) as back-up ORC(s). The ORC or their back-up shall visit the facilities in accordance with 15A NCAC 08G .0200, and shall comply with all other conditions specified in the previously cited rules. 3. A suitable year round vegetative cover shall be maintained on the irrigation areas at all times, such that crop health is optimized, allows for even distribution of effluent, and allows inspection of the irrigation system. 4. Adequate treasures shall be taken to prevent effluent ponding in or runoff from the irrigation sites listed in Attachment B. WQ0003396 Version ". Shell Version 090806 Page 6 of 13 5. Irrigation shall not be performed during inclement weather or when the ground is in a condition that will cause ponding or runoff. 6. All irrigation equipment shall be tested and calibrated at least once per permit cycle. Calibration records shall be maintained at the facility for a period of no less than five years, and shall be made available to the Division upon request. 7. Only effluent from Uniboard USA, LLC shall be irrigated on the sites listed in Attachment B. 8. No automobiles or machinery shall be allowed on the irrigation sites except during equipment installation or while maintenance is being performed. 9. Public access to the irrigation sites and wastewater treatment facilities shall be prohibited. 10. Public access to the reclaimed water utilization sites shall be controlled during active site use. Such controls may include the posting of signs showing the activities being conducted at each site. 11. Public access to the wastewater closed -loop recycle system shall be prohibited. 12. The residuals generated from the wastewater treatment facilities shall be disposed or utilized in accordance with 15A NCAC 02T .1100. The Permittee shall maintain a residual management plan pursuant to 15A NCAC 02T .0508, .0914, and .1008. 13. Diversion or bypassing of untreated or partially treated wastewater from the treatment facilities is prohibited. 14. Diversion of stormwater from mill areas into Lagoon #5 is expressly prohibited. 15. Freeboard in Lagoon # 1, 2, 3, 4, and 5 (Sides C and D) shall not be less than one (1) foot at any time. 16. A gauge to monitor waste levels in the lagoons shall be provided in Pond #4 and #5 (Sides C and D). The gauges shall have readily visible permanent markings indicating the following elevations: 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 the lowest point on top of the dam. 17. A protective vegetative cover shall be established and maintained on all earthen embankments (i.e., outside toe of embankment to maximum allowable temporary storage elevation on the inside of the embankment), 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 dikes or embankments, Earthen embankment areas shall be kept mowed or otherwise controlled and accessible. IS. An education program shall be developed and implemented to inform employees about the proper use of reclaimed water for ESP make up in the PB mill. Educational material shall be provided to all employees in the facilities utilizing reclaimed water, and these materials shall be maintained consistent with the reclaimed water uses. All educational materials shall be made available to the Division upon request. WQ0003396 Version 2.2 Shell Version 090806 Page 7 of 13 19. Side "D" of the storage lagoon (Pond 45) shall serve as primary wet -weather storage for the wastewater treatment and surface irrigation system. Under normal operating conditions, rainwater accumulated in Side "C" of Pond #5 may be used as make-up water to the MDF and/or PB mills. If necessary to maintain the required one foot freeboard level, wastewater from Side "D" may be transferred to Side "C" via operation of a valve on the separator dike. Wastewater entering Side "C" shall be handled according to one of the following options: Once water levels have been lowered in Side "D" through irrigation, wastewater temporarily stored in Side "C" shall be transferred back to Side "D" via gravity or pumping, and shall comply with monitoring requirements for PPI 001 listed in Attachment A of this permit prior to irrigation; or • Wastewater temporarily stored in Side "C" may be utilized as make up water to the MDF and/or PB mills as water quality allows. IV. MONITORING AND REPORTING REQUIREMENTS 1. Any Division required monitoring (including groundwater, plant tissue, soil and surface water analyses) necessary to ensure groundwater and surface water protection shall be established, and an acceptable sampling reporting schedule shall be followed. 2. Per 15A NCAC 02H .0800, a Division certified laboratory shall conduct all laboratory analyses for the required effluent, groundwater or surface water parameters. Influent flow {process flow from the PB mill and first flush of sand filter backwash from the MDF mill} to Lagoon #5 shall be continuously monitored, and daily average flow values shall be reported on Form NDMR. 'Flow may be estimated using pump run times and time of discharge from the wet ESP at the PB mill. 4. Flow distributed to the conjunctive reclaimed water system at the PB mill shall be continuously monitored, and daily flow values shall be reported. on Form NDMR. The Permittee shall install and maintain an appropriate flow measurement device to ensure the accuracy and reliability of flow measurement consistent with accepted engineering and scientific practices. Selected flow measurement devices shall be capable of measuring flows with a maximum deviation of less than ten percent from true flow; accurately calibrated at a minimum of once per year; and maintained to ensure the accuracy of measurements is consistent with the selected device's accepted capability. The Permittee shall maintain records of flow measurement device calibration on file for a period of at least five years. At a minimum., documentation shall include: a. Date of flow measurement device calibration, b. Name of person performing calibration, and c. Percent from true flow. 5. The Permittee shall monitor the effluent from the subject facilities at the frequencies and locations for the parameters specified in Attachment A. WQ0003396 Version 2.2 Shell Version 090806 Page 8 of 13 6. The Permittee shall maintain adequate records tracking the amount of effluent irrigated. At a minimum, these records shall include the following information for each irrigation site listed in Attachment B: a. Date of irrigation; b. Volume of effluent irrigated; c. Site irrigated; d. Length of time site is irrigated: e. Continuous weekly, monthly, and year-to-date hydraulic (inches/acre) loadings; f. Continuous monthly and year-to-date loadings for any non -hydraulic parameter specifically limited in Attachment B; g. Weather conditions; and h. Maintenance of cover crops, 7. The Permittee shall maintain adequate records tracking the amount of reclaimed water distributed or utilized in the PB mill. At a minimum, these records shall include the following information: a. Date of distribution or utilization; b. Volume of reclaimed water distributed or utilized (i.e., monthly total); and 8. Freeboard (i.e., waste level to the lowest embankment elevation) in wastewater Lagoons #4 and #5 shall be recorded weekly. Weekly freeboard records shall be maintained at the facility for a period of no less than five years, and shall be made available to the Division upon request. Three copies of all monitoring data (as specified in Conditions IV.3., IV.4., IV.5., and IV.6.) on Form NDMR for each PPI and three copies of all operation and disposal records (as specified in Conditions IV.7., IV.8, and IV.9. on Forms NDAR-1 for every site in Attachment B shall be submitted on or before the last day of the following month.. If no activities occurred during the monitoring month, monitoring reports are still required documenting the absence of the activity. All information shall be submitted to the following address: Division of Water Quality Information Processing Unit 1617 Mail Service Center Raleigh, North Carolina 27699-1617 10. A record shall be maintained of all residuals removed from this facility. This record shall be maintained at the facility for a period of no less than five years, and shall be made available to the Division upon request. At a minimum, this record shall include: a. Name of the residuals hauler; b. Non -Discharge permit number authorizing the residuals disposal, or a letter from a municipality agreeing to accept the residuals; c. Date the residuals were hauled; and d_ Volume of residuals removed. 11. A maintenance log shall be maintained at this facility. This log shall be maintained at the facility for a period of no less than five years, and shall be made available to the Division upon request. At a minimum, this log shall include: a. Date of calibration of flow measurement device(s); b. Visual observations of the plant and plant site; and c. Record of preventative maintenance (e.g., changing of equipment, adjustments, testing, inspections and cleanings, etc.). WQ0003396 Version 2.2 Shell Version 090806 Page 9 of 13 12. A reclaimed water user inspection log shall be maintained for the ESP makeup at the PB mill. This, log shall be maintained at the facility for a period of no less than five years, and shall be made available to the Division upon request. At a minimum, this log shall include: a. Visual observations of the reclaimed water user facilities; and b. Record of preventative maintenance (e.g., pump and valve maintenance, cross connection control, etc.). 13. Monitoring wells shall be sampled at the frequencies and for the parameters specified in Attachment C. All mgoing, well construction forms, well abandonment forms and monitoring data shall refer to the permit number and the well nomenclature as provided in Attachment C and Figure 3 14. Two copies of the monitoring well sampling and analysis results shall be submitted on a Compliance Monitoring Form (GW -59), along with attached copies of laboratory analyses, on or before the last working day of the month following the sampling month. The Compliance Monitoring Form (GW- 59) shall include this permit number, the appropriate well identification number, and one GW-59a certification form shall be submitted with each set of sampling results. All information shall be submitted to the following address: Division of Water Quality Information Processing Unit 1617 Mail Service Center Raleigh, North Carolina 27699-1617 15. An annual representative soils analysis (i.e., Standard Soil Fertility Analysis) shall be conducted on each irrigation site listed in Attachment B. These results shall be maintained at the facility for a period of no less than five years, and shall be made available to the Division upon request. At a minimum, the Standard Soil Fertility Analysis shall include the following parameters: Acidity Exchangeable Sodium Percentage Phosphorus Base Saturation (by calculation) Magnesium Potassium Calcium Manganese Sodium Cation Exchange Capacity Percent Humic Matter Zinc Copper pH WQ0003396 Version ? 2 Shell Version 090806 Page 10 of 13 16. Noncompliance Notification: The Permittee shall report by telephone to the Raleigh Regional Office, telephone number (919) 791- 4200, 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 facility resulting in the treatment of significant amounts of wastes that is abnormal in quantity or characteristic, including the known passage of a hazardous substance. b. Any process unit failure (e.g., mechanical, electrical, etc.), due to known or unknown reasons, rendering the facility incapable of adequate wastewater treatment. c. Any facility failure resulting in a by-pass directly to receiving surface waters. d. Any time self -monitoring indicates the facility has gone out of compliance with its permit limitations. e. Ponding in or runoff from the irrigation sites. Any emergency requiring immediate reporting (e.g., discharges to surface waters, imminent failure of a storage structure, etc.) outside normal business hours shall be reported to the Division's Emergency Response personnel at telephone number (800) 662-7956, (800) 858-0368, or (919) 733-3300. Persons reporting such occurrences by telephone shall also file a written report in letter form within five days following first knowledge of the occurrence. This report shall outline the actions taken or proposed to be taken to ensure the problem does not recur. V. INSPECTIONS The Permittee shall provide adequate inspection and maintenance to ensure proper operation of the wastewater treatment and disposal, closed -loop recycle, and reclaimed water utilization facilities. 2. The Permittee or their designee shall inspect the wastewater treatment and disposal, closed -loop recycle, and reclaimed water utilization facilities to prevent malfunctions, facility deterioration and operator errors resulting in discharges, which may cause the release of wastes to the environment, a threat to human health or a public nuisance, The Permittee shall maintain an inspection log that includes, at a minimum, the date and time of inspection, observations made, and any maintenance, repairs, or corrective actions taken. The Permittee shall maintain this inspection log for. a period of five years from the date of the inspection, and this log shall be made available to the Dvision upon request. Any duly authorized Division representative may, upon presentation of credentials, enter and inspect any property, premises or place on or related to the wastewater treatment and disposal, closed -loop recycle, and reclaimed water utilization facilities facilities permitted herein at any reasonable time for the purpose of determining compliance with this permit; may inspect or copy any records required to be maintained under the terms and conditions of this permit, and may collect groundwater, surface water or leachate samples. VI. GENERAL CONDITIONS Failure to comply with the conditions and limitations contained herein may subject the Permittee to an enforcement action by the Division in accordance with North Carolina General Statutes 143- 215.6A to 143-215.6C. 2. This permit shall become voidable if the permitted facilities are not constructed in accordance with the conditions of this permit, the Division approved plans and specifications, and other supporting documentation. WQ0003396 Version 2.2 Shell Version 090806 Page 11 of 13 3. This permit is effective only with respect to the nature and volume of wastes described in the permit' application, Division approved plans and specifications, and other supporting documentation. No variances to applicable rules governing the construction or operation of the permitted facilities are granted, unless specifically requested and approved in this permit pursuant to 15A NCAC 02T .0105(n). 4. 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 jurisdictional government agencies (e.g., local, state, and federal). Of particular concern to the Division are applicable river buffer rules in 15A NCAC 02B .0200; erosion and sedimentation control requirements in 15A NCAC Chapter 4 and under the Division's General Permit NCG010000; any requirements pertaining to wetlands under 15A NCAC 02B .0200 and 02H .0500; and documentation of compliance with Article 21 Part 6 of Chapter 143 of the General Statutes. 5. In the event the permitted facilities change ownership or the Permittee changes their name, a formal permit modification request shall be submitted to the Division. This request shall be made on official Division forms, and shall include appropriate property ownership documentation and other supporting documentation as necessary. The Permittee of record shall remain fully responsible for maintaining and operating the facilities permitted herein until a permit is issued to the new owner, The Permittee shall retain a set of Division approved plans and specifications for the life of the facilities permitted herein. 7. The Permittee shall maintain this permit until all permitted facilities herein are properly closed or permitted under another permit issued by the appropriate permitting authority pursuant to 15A NCAC 02T .01050). 8. This permit is subject to revocation or unilateral modification upon 60 days notice from the Division Director, in whole or part for the requirements listed in 15A NCAC 02T .0110. 9. Unless the Division Director grants a variance, expansion of the permitted facilities contained herein shall not be granted if the Permittee exemplifies any of the criteria in 15A NCAC 02T .0120(b). 10. The Permittee shall pay the- annual fee within 30 days after being billed by the Division. Failure to pay the annual fee accordingly shall be cause for the Division to revoke this permit pursuant to 15A NCAC 02T A105(e)(3). Permit issued this the 18a' day of December, 2009 NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION r olee . Sullins, Director Division of Water Quality By Authority of the Environmental Management Commission Permit Number WQ0003396 WQ0003396 Version 2.2 Shell Version 090906 Page 12 of 13 Permit No. WQ0003396 Uniboard USA, LLC Uniboard USA, Moncure ❑ Partial ❑ Final Surface Irrigation, Closed -Loop Recycle, and Reclaimed Water Utilization December 18, 2009 Chatham Countv ENGINEERING CERTIFICATION In accordance with 1 SA NCAC 02T .0116, 1, as a duly registered Professional Engineer in the State of North Carolina, having the Permittee's authorization to ❑ periodically ❑ weekly ❑ fully observe the construction of the permlitted facility, hereby state to the best of my abilities that due care and diligence was used in the observation of the construction, such that the facility was built within substantial compliance and intent of this permit, the Division approved plans and specifications, and other supporting documentation. ❑ Any variation to this permit, the Division approved plans and specifications, and other supporting documentation has been documented in the attached as -built drawings, and shall serve as the Permittee's minor modification request to amend the hermit accordingly. Provide a brief narrative description of any variations: Professional Engineer's Name Engineering Firm Mailing Address City State Zip Telephone E-mail NC PE Seal. Signature Date THE COMPLETED ENGINEERING CERTIFICATION, INCLUDING ALL SUPPORTING INFORMATION AND MATERIALS, SHALL BE SENT TO THE FOLLOWING ADDRESS: NORTH CAROLINA DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES DIVISION OF WATER QUALITY AQUIFER PROTECTION SECTION LAND APPLICATION UNIT By U.S. Postal Service: By Courier/Special Delivery: 1636 MAIL SERVICE CENTER 2728 CAPITAL BOULEVARD RALEIGH, NORTH CAROLINA 27699-1636 RALEIGH, NORTH CAROLINA 27604 WQ0003396 Version 2.2 Shell Version 090806 Page 13 of 13 THIS PAGE BLANK ATTACHMENT A - LIMITATIONS AND MONITORING REQUIREMENTS PPI 001 — WWT)F' Effluent (Prior to Irrigation) Permit Number: WQ0003396 Version: 2.2 EFFLUENT CIIARACTERISTICS 3 EFFLUENT LIMITS MONITORING REQUIREMENTS Parameter Description - PCS Code Monthly Average Mean Monthly Geometric Daily MinimumMinimumDaily Riaximgm Measurement Frequency Sample Type Solids.'Fotal Suspended - 00530 Monthly Composite 130D, 5-Day (20 Deg. C) - 00310 Monthly Composite Nitrogen. Ammonia Total (as N) - 00610 Monthly Composite Nitrogen. Nitrate'Yotai (as N) - 00620 Monthly Composite Nitrogen, Kjeldahl, Dotal (as N) - 00625 Monthly Composile pit - 00400 Daily ( 5 X week) Grab Solids, Total Dissolved- I30 Deg.0 - 70300 3 X year' Composite Chloride (as C: i) - 00940 3 X `°ear' Composite Formaldeln=de - 71880 Annually 2 Composite Colif'orm, l7ecal NIT', Nl-l'C T3roth.44.5C. - 31616 Monthly Grab I. 3 x year sampling shall be conducted during March. July, and November. 2. Annual sampling shall be conducted in November. 3. I:tfluent sampling shall occur Tollowing final treatment and prior to irrigation. WQ0003396 Version 22 Attachment A Page 1 of 2 ATTACHMENT A - LIMITATIONS AND MONITORING REQUIREMENTS Permit Number: WQ0003396 Version: 2.2 PPI 002 — Influent flow to Side "D" of Lagoon #S (Process wastewater from PB mill and first flush of sand filter backwash front MDF mill) EFFLUENT CIIARACTERISTICS EFFLUENT LIMITS MONITORING REQUIREMENTS Parameter Description -PCS Code Monthly Average Mean Monthly Geometric Daily Minimum Daily Maximum Measurement Frequency Sample Type Flow, in conduit or thru treatment plant - 50050 56,000 (ii'1) Continuous Estimate PPI 003 — Reclaimed Water to PB Mill EFFLUENTCHARACTERISTICS EFFLUENT LIMITS MONITORING REQUIREMENTS Parameter Description -PCS Cade Monthly Average Mean Monthly Geometric Daily Minimum Daily Maximum Measurement Frequency Sample Type Flow, in conduit or thru treatment plant - 50050 Continuous Recorder Turbidity, I-ICII 'rurbidimeter - 00076 Continuous Recorder WQ0003. lersion 2.2 Attaclunent A ;e 2 of 2 ATTACHMENT B - APPROVED LAND APPLICATION SITES AND LIMITATIONS Uniboard USA, LLC --- Uniboard USA - Moncure Permit Ntimber: WQ0003396 Version: 2.2 IRRIGATION AREA INFORMATION APPLICATION LIMITATIONS Field Owner County Latitude Longitude Net Acreage Dominant Soil Series parameter hourly Rate Yearly Max Units 02 Unihoard USA, LLC Chathatn 35"36'16" 79'02'26" 3.64 01284 - Application Surface Irrigation 0.60 52 inches 03 Uniboard USA. LI.C. Chatham 359621" 79002'29" 2.27 01284 - Application Surface Irrigation 0.60 52 inches 04 Unihoard USA, LI,C Chatham 35°30'26" 79'02'35" 4.58 01284 - Application Surface Irrigation 0.20 12.74 inches 05 Unihoard USA, I.I,C Chatham 35036'32" 79002'35" 4.63 01284 - Application Surface Irrigation 0.20 12.74 inches 06 Unihoard USA, LLC Chatham 35036'37" 79002'37" 5.67 01284 - Application Surface Irrigation 0.35 52 inches 07 Unihoard USA. LLC Chatham 35036'39" 79002'43" 5.65 01284 - Application Surface Irrigation 0.60 52 inches 08 Unihoard I ISA, TAX Chatham 35036'18" 79002'45" 2.83 01284 - Application Surface Irrigation 0.60 52 inches 09 Unihoard USA.11C Chatham 35036'24" 79°02'47" 4.58 01284 - Application Surface Irrigation 0.60 52 inches i0 Enihoard USA.I,LC Chatham 35036'30" 79002'47" 5.64 01284 - Application Surface Irrigation 0.60 52 inches totals 39.49 W00003396 Version 2.2 Attachment B Page I of 2 THIS PAGE BLANK WQ0003_ ✓ersion 2.2 Attachment B 'age 2 of ATTACHMENT C — GROUNDWATER MONITORING AND LIMITATIONS Permit Number: WQ0003396 Version: 2.2 Monitoring wells: SMW-3, SMW-4, SMW-5, SMW-8, SMW -9, SMW-18R, SMW-19, SMW-20, SMW-21, and the surface water sampling station (SCMS) GROUNDWATERCHARACTERISTICS GROUNDWATER STANDARDS MONITORING REQE11RENIFNTS Parameter Description - Parameter Code Daily Maximum Frequency Measurement Sample Type Footnotes Water level. distance from measuring point - 82546 3 X year Calculated pil - 00400 6.5-8.5 s.u. 3 X year Grab Solids,'lotal Dissolved- 180 Deg.0 - 70300 500 mg/l 3 Xyear Grab Carbon. Tot Organic (TOC) - 00680 3 X year Grab Chloride (as Cl) - 00940 250 mg/I 3 X.ycar Grab Nitrogen, Ammonia "total (as N) - 00610 3 X year drab Nitrogen, Nitrate Totnl (as N) _ 00620 10 tngll 3 X.year Grab Phosphorous, in "total Orthophosphate - 70507 3 X year Grab Methanal (Formaldehyde) Whole Water.ug/L - 76995 Annually Grab Volatile Couapot€nds. (GCINiS) - 78732 .Annually Grab 1. 3 x Year tnonitoriitg shall be condtcted in Mttreit, 3u1y & November: Anneal monitoring shall be conducted every Noveinher. 2. The measurement ofwater levels shall be made prior to purging the wells. The depth to xialer in each well shall be measured rrom the surveyed point on the lop of the casing. The measurement of pi I shall tie made afler purging and prior to sampling I'm the remaining parameters. 3. The measuring prints (top of well casing) ofall monitoring wells shall be surveyed to provide the relative elevation of the treasuring point for each monitoring well. The measuring points (top of easing) ofall monitoring wells shall be surveyed relative to a common datum. 4. Volatile Organic Compounds (VOC) - In November only, analyze by one of the following methods, a. Standard Method 6230I), I'QL at 0.5 ltg/L or less h. Standard Method 62101). PQI, at 0.5 lT/L or less C. I:PA Method 8021. Low Concentration. PQI, at 0.5 leglL or less (I. EPA Method 8260, Low Concentration. PQL at 0.5 ltglL or less C. Another method with prior approval by the Aquifer Protection Section Chief Any method used must meet the follo%N ing quali€icatim€s: a. A laboratory must be DWQ certified to run any method used. b. The nie€hod used must. at a minimum, include all the constituents listed in Table Vill of -Standard Method 62301). c, "the melhod used must provide a PQI, of 0,5 fig/l, or less that must be supported by laboratory proficiency studies as required by the DWQ Laboratory Certification Unit. Any constituents detected above the MIA, but below the I'QL of 0.5 pgfl. €nest be qualified (estimated) and reported. 5. If' any volatile orgy€€ic compounds (VOC) are detected as a result of monitoring as provided in Attachment C. then the Raleigh Regional Office Aquifer Protection Supervisor, telephone number (919) 791-4200. must be contacted immediately for further instructions regarding any additional follow-up analyses required. If TOC concentrations greater than 10 tug/I are detected in any downgradient monitoring well, additional sampfing and analysis must be conducted to Identify the individual constituents comprising this TOC concentration. if the TOC concentration as measured in the background monitor well exceeds lit mg/l, this concentration will be taken to represent the naturally occurring TOC concentration. Any exceedances of this naturally occurring TOC concentration in the dowugradient wells s11a11 be subject to the additional sampling and analysis as described above. WQ0003396 Version 2.2 Attachment C Page i of 2 7. Monitoring wells shall be repo►ted consistent with the nomenclature and location information provided in Figure 3 and this attachment. WQ0003. Version 2.2 Attachment C Page 2 of �y .� pray - rY Tare'' Field5..,�xr• i� Mr�y � �`� �; i �+..., I I� � 1' � ty 5. .e.rf '� •r4� y1 �.t� 1 'I 1,4 I'l �`�"`� � �4 Y ��4 4 � E i ~max l ir'•sr✓^.' � l�� �( .� �•wy�....,..�.-.._.. - � ip � 'I w �:,��' .r ; w . SITE{ ram.,,• r 79 "�b'�.,` �� /r f .1 rf..��..�.� "�'—�.� �*� r�"•.� . _ I � colt Y' 1 1 Jw uIlk 3i + ✓ �'} ky l.ti.eo I E t I y4, 5 SCALE RQ p1 � c*.n1'I(*1 0.2 0.4 Miles Lat/Long: 35.6D13°N, 79.0439°W Source: 1998 Moncure, NO Quadrangle, 1:24.000 ENVIRONMENTAL Uniboard USA LLC, SITE TOPOGRAPHIC MAP 10/16/08 Figure RESOURCES 985 CORINTH 1 ERWI MANAGEMENT ROAD MONCURE, NORTH CAROLINA , r f Ed : i I 9�Sllit'&l:l = d"cSGI F81 YirrR iDiijlli... �.. I ♦ i oil { • r �'. 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Be RB/SCI LG%1 BPf - &,ra anlm �eauvr i ! t 11 [sFi �tf.a 1 : au Fawn res E�a s. ... ... .. - ` Tn WfRGc's I' :SPRAY:fIELf]2 I- CafSCed; s a a H nus BRxwuc x& MWIHOL PLAN MTEIG efYfl{)SM ta, IMS-W FBA HOF I _ l aI ols FUH: Y iMWH CApOW _ .. ----_ ei@F'1�7aG:t�s-}7vcRi<.[xfEsa.,- 4 :.. \ " - 6EiA ANo lYA'CAr mAE PRUIL p` s JOB N. {� Abandoned SMIf�-12� sec€ relocation for,Smw-18R sit r t r X i WATER 06 mt .ml �Ir�aRIR Uil PMrIR — t uumll cr v.rs is Irrll "TE k talc a �Bs Tart tp �rt►SC i pFS. J sv�-1s ,sz,o'r S EV w-9 All , MD ro c F li - A Rk Mw_8 k 5CN€S tA— is. k =o 174,"0 _ �- 9, SMW-20, W-21 ti k k ° k crrrw-r7 a � vw-? ue.Tsa y G ri.rao o ,6LDN }� Uniboard USA LLC ENVIRONMENTAL SPRAY IRRIGATION FIELD SITE MAP - 10/16/08 Figure RESOURCES 985 CORINTH ROAD 3 ERMI MANAGEMENT MONCURE, NORTH CAROLINA